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Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08237 PDF

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08237 PDF

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Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08237 – PDF DOWNLOAD

SERIAL NUMBER 08237 and up

Category: komatsu Tags: Komatsu PC4000-11 T2, Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08237, Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08237 - PDF DOWNLOAD Vendor: Pneumatics Docs

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Description

Description

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08237 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08237 – PDF DOWNLOAD

Language : English
Pages : 2342
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08237 – PDF DOWNLOAD

SERIAL NUMBER 08237 and up

Shop Manual . 1
00 Foreword & Safety 3
1 Foreword 5
1.1 BEFORE READING THIS MANUAL 6
1.2 CONTENTS OF THIS BINDER . 7
1.2.1 Contacting the Service 7
1.2.2 Guarantee . 7
1.3 DIVISION OF THE BINDER 8
2 SAFETY 9
TOC . 10
2.1 SAFETY INFORMATION 11
2.2 OVERVIEW 12
2.2.1 NORMAL OPERATIONS . 12
2.2.2 REGULAR MAINTENANCE . 12
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR . 12
2.2.4 ADDITIONAL SAFETY PRECAUTIONS . 12
2.3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB . 13
2.3.1 SOUND . 13
2.3.2 VIBRATION . 13
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 14
2.4.1 UNDERSTANDING THE MACHINE . 14
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 14
2.4.2.1 ENSURING SAFE OPERATION . 14
2.4.3 PREPARATIONS FOR SAFE OPERATION . 14
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 14
2.4.3.2 INSPECTING THE MACHINE 14
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 15
2.4.3.4 KEEP MACHINE CLEAN 15
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT . 15
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT . 16
2.4.3.7 IF A PROBLEM IS FOUND . 16
2.4.4 FIRE PREVENTION . 16
2.4.4.1 PRECAUTIONS TO PREVENT FIRE . 16
2.4.4.2 ACTION IF FIRE OCCURS . 18
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB 18
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 19
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 19
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE 19
2.4.5.3 NO PEOPLE ON THE ATTACHMENT . 19
2.4.5.4 WORKING IN HIGH PLACES 19
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK . 20
2.4.5.6 LEAVING THE MACHINE . 20
2.4.6 BURN PREVENTION . 20
2.4.6.1 Hot coolant . 20
2.4.6.2 Hot oil . 21
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS . 21
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 21
2.4.9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS . 22
2.4.9.1 UNAUTHORIZED MODIFICATION . 22
2.4.9.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 22
2.4.10 ELECTROMAGNETIC COMPATIBILITY (EMC) 22
2.4.11 PRECAUTIONS AT JOBSITE . 23
2.4.11.1 VISIBILITY FROM OPERATOR’S SEAT 24
2.4.11.2 CAMERA SYSTEM WITH MONITORS 24
2.4.11.3 ENSURE GOOD VISIBILITY . 24
2.4.11.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS . 24
2.4.11.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS . 25
2.4.11.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES . 25
2.4.11.7 Lightning Strikes 26
2.4.11.8 WORKING ON LOOSE GROUND 26
2.4.11.9 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 27
2.4.11.10 VENTILATION OF ENCLOSED AREAS . 28
2.4.12 STARTING motor . 29
2.4.12.1 WARNING TAG 29
2.4.12.2 CHECKS BEFORE STARTING motor . 29
2.4.12.3 PRECAUTION WHEN STARTING motor . 29
2.4.12.4 PRECAUTION IN COLD AREAS . 30
2.4.13 OPERATION 30
2.4.13.1 CHECKS BEFORE OPERATION 30
2.4.13.2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE . 31
2.4.13.3 PRECAUTIONS WHEN traveling . 32
2.4.13.4 TRAVELING ON SLOPES 33
2.4.13.5 OPERATIONS ON SLOPES . 34
2.4.13.6 PROHIBITED OPERATIONS 34
2.4.13.7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES . 35
2.4.13.8 PARKING THE MACHINE 35
2.4.13.9 TRANSPORTATION . 35
2.5 PRECAUTION FOR MAINTENANCE 36
2.5.1 GENERAL PRECAUTIONS . 36
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES . 37
2.5.1.2 STOP motor FOR MAINTENANCE 38
2.5.1.3 WARNING TAG . 39
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY . 40
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS . 40
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING . 41
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS . 41
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT . 42
2.5.1.9 NOISE . 42
2.5.1.10 WHEN USING A HAMMER 42
2.5.1.11 PROPER TOOLS . 43
2.5.1.12 ACCUMULATOR 43
2.5.1.13 PERSONNEL 43
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 44
2.5.2.1 PRECAUTION WHEN WELDING . 44
2.5.2.2 BATTERY HANDLING 44
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID 45
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE . 46
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES 47
2.5.3.3 REPLACEMENT OF HOSE LINES . 47
2.5.3.4 INSPECTION OF HOSE LINES 47
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS . 48
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE 48
2.5.3.7 AIR CONDITIONING MAINTENANCE 48
2.5.3.8 COMPRESSED AIR 49
2.5.3.9 WASTE MATERIALS . 49
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS . 50
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM 50
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS . 50
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 50
2.7 SPECIAL SAFETY EQUIPMENT 51
2.7.1 FRONT GUARD PROTECTIVE STRUCTURe ’FOPS’ FOR OPERATOR’S CAB 52
2.7.2 OBJECT HANDLING . 52
2.7.3 LIGHTING 52
2.7.4 WARNING BEACON 52
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 52
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 52
2.7.5.2 INSTRUCTIONS FOR USE 54
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 56
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS . 56
2.7.5.5 INSTRUCTIONS FOR USE 58
01 Specification 59
Specification PC4000-11 . 61
10 Structure & Function . 85
TOC . 87
1 Introduction 97
1.1 Foreword 98
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 99
1.3 Explanation of abbreviations 100
1.4 Diagrams and illustrations in this manual . 101
2 Specifications 103
2.1 Lifting Gears . 104
2.2 Safety hints for sling accessory 106
2.3 Standard Tightening Torque Chart 107
2.4 Conversion Table 108
2.5 Blind plugs . 114
2.6 Classification of threads to the nominal width 116
2.7 Plugs and fittings according to ISO 8434-1 / DIN 2353 . 117
3 Main assembly groups 119
3.1 General layout 120
3.2 Superstructure 122
3.3 Machine house . 124
3.4 Hydraulic oil tank 126
3.5 Hydraulic oil cooler 128
3.6 Fuel tank . 130
3.7 Cab base 132
3.8 Operator’s cab 134
3.9 Control blocks 136
3.10 Slew gear 138
3.10.1 Slew gear of type 2063 . 138
3.10.2 Slew gear of type 632770 . 140
3.11 Undercarriage 142
3.12 Slew ring 144
3.13 Attachment . 146
3.13.1 Front Shovel Attachment (FSA) 146
3.13.2 Backhoe Attachment (BHA) . 148
3.14 Counterweight 150
3.15 Safety circuit (pilot control circuit) . 152
3.15.0.1 Safety Circuit → with redundant switches . 153
3.15.0.2 Wiring Diagram of the safety circuit . 154
4 Drive . 155
4.1 Prime drive assembly 156
4.2 Engine and PTO mounts . 158
4.2.1 Engine Mounts . 158
4.2.2 Torque Support 159
4.3 Flexible coupling . 160
4.3.1 Information for maintenance . 162
4.3.2 Coupling elements . 163
4.3.3 Separation and assembly of the coupling inner and outer part 164
4.3.4 Operation troubles, causes, and rectification . 165
4.4 Fan drive and radiator assembly . 166
4.4.1 Radiator fan drive 168
4.4.2 Fan pump 170
4.4.3 Radiator fan drive speed adjustment . 172
4.5 Pump distributor gearbox (PTO) 174
4.5.1 Pump spline lubrication . 176
4.5.1.1 Oil level in the main pump drive shaft housing 177
4.5.2 PTO lubrication and cooling . 178
4.5.2.1 Checks and adjustments 180
4.6 Hydraulic pumps – location, drive speed and flow rates 182
4.6.1 Pump data . 184
4.7 Air filter 186
5 Hydraulic oil tank 189
5.1 General layout 190
5.2 Hydraulic oil tank, location of the electric equipment 192
5.3 Suction oil tank with strainers . 194
5.4 Return oil collector pipe with strainer . 196
5.5 Back pressure valve . 198
5.6 Transfer pump . 200
5.7 Return and leak oil filter 202
5.8 Breather filter . 204
6 Hydraulic oil cooling . 207
6.1 Overall view of the hydraulic oil cooling . 208
6.2 Function of the hydraulic oil cooling circuit . 210
6.3 Adjustment of the back pressure valve . 212
6.4 Two stage cooler fan RPM control 214
6.4.1 Pressure relief valve . 216
6.4.2 Solenoid valves . 218
6.4.3 Fan pump 220
6.5 Checks and Adjustments of the cooler fan drive speeds . 222
6.5.1 Function Check of Fan Speed Control . 226
7 Controlling . 227
7.1 General layout 228
7.2 Control and filter panel 230
7.3 Valve cartridge block . 232
7.4 Pilot pressure supply and adjustments . 234
7.4.1 Pilot pressure control (PPC) circuit 234
7.4.2 Checks and adjustment of pilot pressure . 238
7.4.3 Remote control valves arrangement . 240
7.5 Function of the electro-hydraulic control system 242
7.5.1 Electronic hand lever (joystick) 246
7.5.1.1 Voltage supply of hand lever 20S020 . 247
7.5.1.2 Direction signal course from hand lever to controllers 248
7.5.1.3 Double ratiometric* output diagram 249
7.6 Foot pedal control 250
7.6.1 Voltage supply of Foot lever (20S021a) 252
7.6.2 Direction signal course from foot pedal to controllers 253
7.6.3 Double ratiometric* output diagram for 2 direction pedal 254
7.6.4 Single ratiometric* output diagram for 1 direction pedal 254
7.7 Hand lever & foot pedal monitoring 255
7.7.1 Lever monitoring screens (example) 256
7.7.2 Valve monitoring screen (example) . 258
7.8 Valve solenoid adjustment . 260
7.8.1 Overview sol min/max current & adjustment range . 261
7.9 ACCEL & DECEL time adjustment . 262
7.9.1 Accel & Decel times . 262
8 Components 265
8.1 Main control blocks and high pressure screens (FSA) . 266
8.2 Main control blocks and high pressure screens (BHA) . 268
8.3 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA) . 270
8.4 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA) . 272
8.5 Single control blocks (floating) for stick and boom (FSA) . 274
8.6 Restrictor block with secondary relief valve 276
8.7 Anti-cavitation valve (ACV) block . 278
8.8 Remote control valves . 280
8.9 4/3 Directional solenoid valves . 282
8.10 Proportional solenoid valves . 284
8.11 High-pressure screen . 286
8.12 Control blocks and valves 288
8.12.1 Spool types 294
8.12.2 MRV, SRV and ACV . 296
8.12.3 Load holding valve . 298
8.13 Travel brake valve . 302
8.14 Pressure reducing valve 304
8.15 4/2 Directional valves . 306
8.16 Pressure double stage valve 308
8.17 Hydraulic cylinder with NOK-3 sealing 310
8.17.1 Cylinder data markings . 313
9 Main hydraulic pumps and pump regulation 315
9.1 General . 316
9.1.1 Pump locations and pump data 318
9.2 Main pumps 320
9.2.1 Hydraulic pump type HPV375+375 320
9.2.1.1 Main pump sectional drawings 322
9.2.2 Servo valve . 324
9.2.2.1 VC valve  servo piston . 325
9.2.2.2 EPC valve . 330
9.3 Electronic pump regulation system . 332
9.3.1 Cut-off function 334
9.3.2 Slew control 335
9.3.2.1 Function of slew speed switch 20S154 335
9.3.3 Temperature control . 336
9.3.3.1 Hydraulic oil temperature charts 336
9.3.4 Energy efficiency (economy mode) 337
9.4 Pump controller (14K305) 338
9.5 Monitoring, error indication, adjustment 340
9.5.1 Monitoring items of the pump controller . 340
9.5.2 Error indication of the pump controller . 343
9.5.3 Adjustable parameters of the pump controller 344
9.5.3.1 Description of the Primary P-Factor . 346
9.5.4 Pump sol ’min’ current values according to pump type plate 347
9.5.5 Pump sol ’max’ current values according to pump type plate 348
9.6 Checks and adjustments 350
9.6.1 Engine power check 350
9.6.2 Cut-off function check 352
9.6.2.1 Cut-off for clam close (FSA only) . 353
9.7 Engine speed sensor (pick-up) . 354
9.7.1 General . 355
9.7.2 Engine speed sensor (pick-up) adjustment 355
9.7.3 In case of problems – when correct speed sensor adjustment is guaranteed 356
10 Operating hydraulics . 357
10.1 General 358
10.1.1 Floating system (FSA only) . 360
10.2 Hydraulics for the attachment cylinders 364
10.2.1 Electric / hydraulic flowchart “Boom UP” (FSA) . 364
10.2.2 Electric / hydraulic flowchart “boom up” (BHA) . 366
10.2.3 Electric / hydraulic flowchart “boom down” (FSA) . 368
10.2.4 Electric / hydraulic flowchart “Boom down” (BHA) . 370
10.2.5 Electric / hydraulic flowchart “Stick out” (FSA) . 372
10.2.6 Electric / hydraulic flowchart “Stick out” (BHA) . 374
10.2.7 Electric / hydraulic flowchart “Stick in” (FSA) 376
10.2.8 Electric / hydraulic flowchart “Stick in” (BHA) 378
10.2.9 Electric / hydraulic flowchart “Bucket fill” (FSA) . 380
10.2.10 Electric / hydraulic flowchart “Bucket fill” (BHA) 382
10.2.11 Electric / hydraulic flowchart “Bucket dump” (FSA) 384
10.2.12 Electric / hydraulic flowchart “Bucket dump” (BHA) 386
10.2.13 Electric / hydraulic flowchart “Clam open” (FSA) 388
10.2.14 Electric / hydraulic flowchart “Clam close” (FSA) . 390
10.2.15 Checks & adjustments of the main relief valve (MRV) . 392
10.2.16 Checks and adjustments of the secondary relief valves (SRV) . 394
10.2.16.1 Boom cylinders, piston side (BHA & FSA), boom up 394
10.2.16.2 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down . 398
10.2.16.3 Stick cylinders, piston side (FSA), stick out . 402
10.2.16.4 Stick cylinders, piston side (BHA), stick in 406
10.2.16.5 Stick cylinders, piston rod side (FSA), stick in 410
10.2.16.6 Stick cylinders, piston rod side (BHA), stick out . 414
10.2.16.7 Bucket cylinders, piston side (FSA), bucket fill 418
10.2.16.8 Bucket cylinders, piston side (BHA), bucket fill 422
10.2.16.9 Bucket cylinders, piston rod side (FSA), bucket dump 426
10.2.16.10 Bucket cylinders, piston rod side (BHA), bucket dump . 430
10.2.16.11 Clam cylinders, piston rod side (FSA), clam open . 434
10.2.16.12 Clam cylinders, piston side (FSA), clam close 438
10.2.17 Checks and adjustments of the lowering speed 442
10.2.17.1 Checks and adjustments of the lowering speed – boom (FSA) . 442
10.2.17.2 Checks and adjustments of the lowering speed – boom (BHA) . 448
10.2.17.3 Checks and adjustments of the lowering speed – stick (FSA) 450
10.2.17.4 Checks and adjustments of the lowering speed – stick (BHA) 456
10.2.17.5 Checks and adjustments of the lowering speed – bucket (FSA) . 458
10.2.17.6 Checks and adjustments of the lowering speed – bucket (BHA) . 460
10.2.17.7 Checks and adjustments of the lowering speed – clam (FSA) . 464
10.3 Hydraulics for the slew circuit 466
10.3.1 Slew circuit . 466
10.3.2 Slew motor . 470
10.3.3 Slew gearbox of type 2063 472
10.3.4 Slew gearbox of type 632770 474
10.3.5 Slew parking brake of type 2063 476
10.3.6 Slew parking brake of type 632770 478
10.3.7 Slew brake valve . 480
10.3.8 Electric / hydraulic flowchart “Slew left” . 484
10.3.9 Electric / hydraulic flowchart “Slew right” 486
10.3.10 Checks and adjustments for the slew circuit . 488
10.3.10.1 Checks & adjustments, slew speed 488
10.3.10.2 Checks & adjustments, double stage valve 490
10.3.10.3 Checks of the brake pilot pressure 493
10.3.11 Function check for hydraulic slew brake . 494
10.3.12 Slew parking brake release function check . 496
10.4 Hydraulics for the travel system . 498
10.4.1 Travel circuit . 498
10.4.2 Travel motor . 500
10.4.3 Rotary joint . 502
10.4.4 Travel gearbox . 504
10.4.4.1 Travel gearbox of type 2063 504
10.4.4.2 Travel gearbox of type 631053 506
10.4.5 Travel parking brake . 508
10.4.5.1 Travel parking brake of type 631053 508
10.4.5.2 Travel parking brake of type 2063 509
10.5 Travel brake valve . 510
10.5.1 Electric / hydraulic flowchart “travel forward” 512
10.5.2 Electric / hydraulic flowchart “travel backwards” 514
10.5.3 Checks and adjustments . 516
10.5.3.1 Checks and adjustments for the travel circuit 516
10.5.3.2 Function check for the travel parking brake 520
11 Hydraulic track tensioning system 523
11.1 General 524
11.2 Functional description . 526
11.3 Double stage valve . 528
11.4 Tensioning cylinder 530
11.5 Adjustments / checks . 532
12 Access stairway, hydraulically operated 535
12.1 General 536
12.2 Function of the hydraulically operated access stairway . 538
12.3 Adjustments / checks . 544
13 Central refilling system (Service arm) . 547
13.1 General 548
13.2 Function . 550
14 Hints for reading the Hydraulic Diagram 553
14.1 General 554
14.2 Hydraulic symbols 556
14.2.1 Lines, unions 557
14.2.2 Components, valves . 559
14.2.3 Sensors 559
14.2.4 Valves, valve components . 560
14.2.5 Pump, motor, cylinder 564
15 Hints for reading the electric Wiring Diagram 569
15.1 General 570
15.2 Reference code of the electrical components 571
15.2.1 Area code 571
15.2.2 Component identifying letter . 572
15.3 Graphical symbols 573
15.4 Concept of the Wiring Diagram 578
15.4.1 Cover page of the Komatsu W/D 578
15.4.2 Example 1 from the schematics in the W/D . 580
15.4.3 Example 2 from the schematics in the W/D . 582
15.4.4 Table of contents in the W/D (page 1 of 2) . 584
15.4.5 Location list 586
15.4.6 Cross reference list for electr. components in the W/D . 588
15.4.7 Cross reference list for terminals in the W/D 590
15.4.8 Cross reference list for connectors in the W/D . 592
15.4.9 Cross reference list for terminal boards in the W/D 594
15.4.10 Connection table 596
15.5 Cable and connector marking 598
15.6 Cable color identification . 600
16 Monitoring & Control System 601
16.1 General 602
16.1.1 Monitoring & control system – overview . 602
16.1.2 Global layout PC4000-11 T2 . 603
16.1.3 Controller system overview PC4000-11 T2 604
16.1.4 Interface connection . 606
16.1.5 General description 607
16.2 Machine monitor – Operator level . 608
16.2.1 Main gauge screens . 610
16.2.2 Operator menus & icons & functions of keys F1 .F6 . 614
16.2.2.1 Operator menu: ECO Guidance – Operation Records 616
16.2.2.2 Operator menu: ECO Guidance – Average Fuel Consumption Logs 618
16.2.2.3 Operator menu: Machine Setting . 620
16.2.2.4 Operator menu: Maintenance . 622
16.2.2.5 Reset of ’remaining time’ till next maintenance interval . 624
16.2.2.6 Usage limitation . 625
16.2.2.7 Operator menu: Monitor Setting – Screen Adjustment . 627
16.2.2.8 Operator menu: Monitor Setting – Clock Adjustment – Calender . 628
16.2.2.9 Operator menu: Monitor Setting – Clock Adjustment – Time . 629
16.2.2.10 Operator menu: Monitor Setting – Clock Adjustment – 12h/24h Mode 630
16.2.2.11 Operator menu: Monitor Setting – Clock Adjustment – Daylight Saving Time 631
16.2.2.12 Operator menu: Monitor Setting – Language . 632
16.3 Error and status indication on the operator level 633
16.3.1 Prompts (status indications) . 633
16.3.2 Cautions . 634
16.3.3 Emergency shutdown screen 635
16.3.4 Fault levels for error messages 637
16.3.5 Action code level L01 638
16.3.6 Action code level L02 639
16.3.7 Action code level L03 640
16.3.8 Action code level L04 641
16.3.9 Error list . 642
16.4 Table of failure codes . 644
16.4.1 Failure codes without monitor indication . 656
16.4.2 Additional text information for action codes . 656
16.5 Table of C-codes – Diesel engine Tier2 . 657
16.6 Flow charts of machine monitor screens . 668
16.6.1 Flow chart Operator Level 668
16.6.2 Flow chart Service Level . 669
16.7 Machine monitor – Service level 670
16.7.1 Entering the Service Level . 670
16.7.2 Key symbols (F1 .F6) on the Service Level . 672
16.7.3 Service Menu selection screens . 673
16.8 Service Menu – item 01 Monitoring / Custom . 674
16.8.1 Monitoring list for: ENG controller 674
16.8.2 Monitoring list for: PUMP controller . 676
16.8.3 Monitoring list for: VALVE0 controller . 679
16.8.4 Monitoring list for: VALVE1 controller . 682
16.8.5 Monitoring list for: VALVE2 controller . 686
16.8.6 Monitoring list for: MON (monitor) . 688
16.8.7 Monitoring list for: KOM PLS (K+ controller) . 690
16.8.8 How to perform the monitoring function . 692
16.9 Service Menu – item 02 PM Clinic . 694
16.9.1 PM Clinic (General) 694
16.9.2 PM Clinic (Power Check) 695
16.9.3 Functions of PM CLINIC (POWER CHECK) . 696
16.10 Service Menu – item 03 Memory Clear . 697
16.11 Service Menu – item 04 Abnormality record . 698
16.11.1 Reset error messages 699
16.12 Service Menu – item 05 Maintenance record . 700
16.13 Service Menu – item 06 Maintenance Mode Setting . 701
16.14 Service Menu – item 07 Snap Shot 702
16.15 Service Menu – item 08 Phone Number Entry . 703
16.16 Service Menu – item 09 Default 704
16.17 Service Menu – item 10 Unit . 706
16.18 Service Menu – item 11 Adjustment . 708
16.18.1 Adjustments for: PUMP controller 708
16.18.2 Pump sol ’min’ current values according to pump type plate 711
16.18.3 Pump sol ’max’ current values according to pump type plate 712
16.18.4 Adjustments for: VALVE0 controller 713
16.18.5 Accel & Decel times . 720
16.18.6 Adjustments for: VALVE2 controller 721
16.18.7 Adjustments for: MON (Monitor) 722
16.18.7.1 Using the Idling Stop Timer . 723
16.19 Service Menu – item 12 Machine Configuration 724
16.19.1 Details of Machine Configuration for PC4000-11 T2 . 725
16.19.2 Changing lever control from EURO to KMG . 726
16.19.2.1 Changing lever control from KMG to EURO . 726
16.19.3 Changing attachment type from FSA to BHA 728
16.19.3.1 Changing attachment type from BHA to FSA 728
16.19.4 In case of problems during changing procedure for lever control or attachment type 729
16.19.5 Hydraulic Oil & PTO Gear Oil Definition Tables 730
16.19.5.1 Hydraulic oil temperature charts 730
16.19.5.2 PTO gear oil temperature charts . 730
16.20 Automatic engine speed control 731
16.20.1 Auto-Deceleration mode 731
16.20.2 Auto Low Idle mode 731
16.20.3 Idling Stop Timer . 731
16.21 KOMTRAX Plus controller (UM600) . 732
16.22 CR720 controller 736
16.22.1 Location of CR720 controllers . 736
16.23 Controller replacement procedure 738
16.23.1 Sequence of the controller replacement procedure 738
16.23.2 After controller replacement 739
16.23.3 Controller location . 740
17 Lubrication system . 741
17.1 General overview (SLS & CLS ) 742
17.1.1 General description 743
17.2 Basic function of the lubrication systems 744
17.3 Lubrication systems (CLS 1 & SLS) 746
17.3.1 Lubrication pump station . 746
17.3.2 General Information on CLS 1 . 748
17.3.3 General information on the SLS . 748
17.3.4 Manual lube activation . 748
17.4 Lubrication cycle 749
17.4.1 Operation and control 749
17.4.2 Lubrication cycle – processing . 750
17.4.3 Time segments & switch points of a lubrication cycle . 751
17.4.4 Lubrication modes 752
17.4.4.1 Automatic lubrication mode . 752
17.4.4.2 Manual lubrication mode 752
17.4.4.3 REDUCED PAUSE TIME FOR SERVICE . 752
17.5 Hydraulically driven lube pump . 754
17.5.1 Adjustment of lube pump speed 756
17.5.1.1 Stroke speed adjustment 757
17.5.1.2 Working pressure . 757
17.6 Lubricant injectors 758
17.6.1 Tightening torques for fittings at grease injectors 759
17.6.2 Description 759
17.6.3 Adjustment of the lubricant output . 760
17.6.4 Operation principle of lubricant injectors . 762
17.6.4.1 Function description . 763
17.6.5 Connection of one or more injectors 764
17.7 Vent Valve and grease outlet filter 766
17.7.1 Vent valve description . 767
17.8 End-line switch 768
17.8.1 Description 769
17.8.2 CLS 1 end-line switch adjustment . 770
17.8.3 SLS end-line switch adjustment . 772
17.9 Lubricant level sensors 774
17.9.1 Description 775
17.9.1.1 Checks . 775
17.10 Commissioning . 776
17.10.1 Commissioning of the CLS 1 lubrication system . 776
17.10.2 Fine adjustment . 777
17.10.3 Commissioning of the SLS lubrication system . 778
18 Deep temperature equipment (option) 781
18.1 General information 782
18.1.1 Introduction . 782
18.1.2 Deep temperature components overview . 782
18.1.3 Power supply preconditions for preheating 783
18.1.4 Power requirements for preheating systems 784
18.2 Preheating procedure . 785
18.2.1 Global flow chart of the preheating procedure 785
18.2.2 Starting the preheating procedure 786
18.2.3 Preheating of operator’s cab and Diesel engine [coolant system] 787
18.2.4 Preheating of lubricants and superstructure (Diesel) [electric system] . 788
18.3 Constant heating of travel motors (TTT-equipment below-40°C only) 789
18.4 Component location . 790
18.4.1 Electric heating elements for hydraulic & batteries [electric machine] . 790
18.4.2 Electric heating elements for hydraulics [Diesel machine] 792
18.4.3 Electric heating elements for engines & batteries [Diesel machine] . 794
18.5 Components of TT equipment . 796
18.5.1 Preheating components on a Diesel machine 796
18.5.2 Preheating components on an electric machine . 797
18.5.3 Wiring Diagrams for preheating systems (examples) 798
18.5.3.1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3 . 798
18.5.3.2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3 . 799
18.5.3.3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3 . 800
18.5.3.4 Wiring diagram “Suction Oil Manifold Preheating” . 801
18.5.3.5 Wiring diagram “PTO Preheating” 802
18.5.3.6 Wiring diagram “Battery heater pads” . 803
40 Troubleshooting 805
TOC . 807
1 Introduction 833
1.1 Overview 834
1.1.1 General advice when using troubleshooting charts 834
1.2 General Precautions . 835
2 General Information for Troubleshooting . 837
2.1 Preparations For Work . 838
2.2 Precautions During Work . 838
2.3 Precautions When Carrying Out Any Operation . 839
2.3.1 Precautions when carrying out removal work 839
2.3.2 Precautions when carrying out installation work . 839
2.3.3 Precautions when completing the operation . 840
2.4 Fundamental Requirements for Trouble shooting . 841
2.4.1 Technical documentation . 841
2.4.2 Tools . 841
2.4.2.1 Reference Guide for Deutsch Removal Tools . 844
2.4.3 Personnel . 845
2.5 Points To Remember When Trouble- shooting . 845
2.6 Sequence Of Events In Troubleshooting . 847
2.7 Checks Before Troubleshooting . 848
2.8 Handling Of Electric Equipment And Hydraulic Components . 849
2.8.1 Points to remember when handling electric equipment . 849
2.8.2 Points To Remember When Handling Hydraulic Equipment 851
2.9 General working procedures 854
2.9.1 Air Bleeding of Various Hydraulic Parts . 854
2.9.2 Air bleeding from the hydraulic pumps . 854
2.9.3 Air bleeding from hydraulic cylinders . 854
2.10 Cylinder bypass test . 855
2.11 Basics about “How to crimp” (with strain relief) . 856
2.11.1 Crimp tool & repair kit 856
2.11.2 General 857
2.11.3 Select the required connector components . 857
2.11.4 Stripping a wire . 858
2.11.5 Crimping . 859
2.11.6 Connector assembly after crimping 860
2.12 Cable Shielding 861
3 Mounting Locations and Connector Types 863
3.1 View onto the superstructure 864
3.2 Location of engine electrical parts . 866
3.2.1 Location of engine remote oil tank sensors 868
3.3 Location of hydraulic components (1) 870
3.3.1 Location of hydraulic components (2) 872
3.3.2 Location of hydraulic components (3) 874
3.4 View onto the SLS or CLS grease barrel and the lubrication cycle components . 876
3.5 Hydraulic oil tank & suction oil tank – Location of electrical components . 878
3.6 Hydraulically operated access stairway 880
3.7 Service arm . 882
3.8 Connector Types Overview 884
4 Standard Value Table for Electrical Components 889
5 Tables for Testing and Troubleshooting 903
5.1 Test Value Tables for Transducers . 904
5.1.1 Pump press. transducers . 904
5.1.2 Hydraulic oil pressure transducers 905
5.1.3 Miscellaneous Pressure Transducers 906
5.1.4 Temperature Transducers . 907
5.2 Hydraulic oil temperature charts 908
5.3 PTO gear oil temperature charts . 908
5.4 Table of failure codes 909
5.5 Table of C-codes – Diesel engine Tier2 921
5.6 Tables of Symptom Codes . 931
5.6.1 Symptoms of the engine and Related electrical systems . 931
5.6.2 Symptoms of the Hydraulic System 931
5.6.3 Symptoms of the Mechanical System . 932
5.6.4 SYMPTOMS OF ADDITIONAL SYSTEMS 932
5.7 Cable colour identification . 933
6 Troubleshooting by Trouble Code . 935
B@HANS – Hyd Oil Overheat . 936
Hydraulic diagram and location of 57K506a-1 / 57K506b-1 for message B@HANS 938
6A1BMA – Trouble Shut-Off (gate) valve not open error . 940
View onto the gap of proximity switch 40B031 941
Wiring Diagram (40B031) for message 6A1BMA 942
AA10NX – Air Cleaner1 Clogging 944
View onto the engine air cleaner (AA10NX) . 945
AB00KE – Charge Voltage Low . 946
Wiring Diagram (batteries) for message AB00KE . 947
K@3A00 – Fire In System . 948
Configuration information for Fire Suppression System Machinery House . 949
Monitoring information for Fire Suppression System Machinery House 949
Wiring Diagram (20K351) for message K@3A00 950
Wiring Diagram (controller input of fire suppression system MH) for K@3A00 951
B@F0MA – CLS1 Lubrication System Error 952
B@CPMA – SLS Lubrication System Error . 953
B@F0N9 – CLS1 pressure increase time too long . 954
B@CPN9 – SLS pressure increase time too long 954
Allocation of vent valves and end-of-line switches 955
Vent valve (62Q507a & 62Q509a) 956
Wiring Diagram – lube pump solenoid & vent valve (CLS1 & SLS) . 957
B@F0N0 – CLS1 pressure decrease time too long . 958
B@CPN0 – SLS pressure decrease time too long 958
Vent valve (62Q507a & 62Q509a) 959
B@F0ZK – CLS1 grease level too low 960
B@CPZK – SLS grease level too low . 960
Wiring Diagram – grease level sensors (CLS1) 962
Wiring Diagram – grease level sensors (SLS) . 963
B@HAZK – Hydraulic oil level too low 964
Hydraulic oil level in defined machine position . 965
Wiring Diagram – hydraulic oil level sensor 40B004 966
B@CBNS – PTO1 Gear Oil Temp High 967
View onto the universal pump distributor gearbox (PTO) 969
B@CBZG – PTO1 Gear Lubrication Error 970
Monitoring PTO lube oil pressure 971
Shutdown adjustment for PTO lube oil pressure . 971
B@H2NX – Breather Filter Clogging . 972
Location of 40B024 and hydraulic oil level definitions 973
B@M9NX – PTO1 Gear Oil Filter Clogging 974
View onto the PTO1 gear oil filter with pressure sensor 57B027-1 975
B@HBNX – Return Oil Filter Clogging . 976
B@L4NX – Leak Oil Filter Clogging . 977
B@L5N9 – Pilot Press X2 Too Low . 978
Valve cartridge block, location of components . 979
B@L5N0 – Pilot Press X2 Too High 980
Valve cartridge block, location of components . 981
B@BKPQ – Eng Remote Oil Tank1 Empty . 982
B@HANX – Screen At Hyd Cooler Entry Clogging 983
Hydraulic oil tank & return oil collector pipe with strainer – location of components . 984
AB30MA – Starter Circuit Abnormality 986
Wiring Diagram for AB30MA . 987
989HMA – Emergency stop line abnormality 988
Wiring Diagram – emergency line for 989HMA 989
Monitoring screens for message 989HMA . 990
DGT3MA – PTO1 oil temperature sensor abnormality 992
Wiring Diagram and location of 57B049-1 . 993
DGH2MA – Hydraulic oil temp sensor abnormality 994
Wiring Diagram and monitoring selection for 59B015 995
DHQ7MA – PTO1 lube pressure sensor abnormality 996
Wiring Diagram and monitoring selection for 57B017-1 997
D1E7KB – Starter cut relay short circuit 998
Wiring Diagram – Starter cut relay for message D1E7KB . 999
D1E7KY – Starter cut relay hot short circuit 1000
Wiring Diagram – Starter cut relay for message D1E7KY .1001
DHPEMA – Pump-1/2 pressure sensor abnormality .1002
DHPGMA – Pump-3/4 pressure sensor abnormality .1002
DHPJMA – Pump-5/6 pressure sensor abnormality .1002
DHPLMA – Pump-7/8 pressure sensor abnormality .1002
Wiring Diagram – PWR and GND supply for pump pressure transducers .1004
DLE2MA – Engine speed sensor abnormality 1006
Wiring Diagram – 52B064 for message DLE2MA 1007
DA27KP – 24V sensor power abnormality .1008
Wiring Diagram – 24V sensor power supply for DA27KP .1009
DA26KP – 5V sensor2 power abnormality .1010
Wiring Diagram – 5V sensor power supply for DA26KP 1011
DA22KK – Solenoid Power Low Error(Pump Con) .1012
DA22MA – Solenoid Power Circuit Abnormality .1013
Wiring Diagram 1 – emergency stop line for DA22MA .1014
Wiring Diagram 2 for DA22MA .1015
DXAAKA – Pump1 Solenoid open circuit 1016
DXABKA – Pump2 Solenoid open circuit 1016
DXACKA – Pump3 Solenoid open circuit 1016
DXADKA – Pump4 Solenoid open circuit 1016
DXAEKA – Pump5 Solenoid open circuit 1016
DXAFKA – Pump6 Solenoid open circuit 1016
DXAGKA – Pump7 Solenoid open circuit 1016
DXAHKA – Pump8 Solenoid open circuit 1016
Wiring Diagram – EPC valve control 1018
DXAAKB – Pump1 Solenoid short circuit .1019
DXABKB – Pump2 Solenoid short circuit .1019
DXACKB – Pump3 Solenoid short circuit .1019
DXADKB – Pump4 Solenoid short circuit .1019
DXAEKB – Pump5 Solenoid short circuit .1019
DXAFKB – Pump6 Solenoid short circuit .1019
DXAGKB – Pump7 Solenoid short circuit .1019
DXAHKB – Pump8 Solenoid short circuit .1019
Wiring Diagram – EPC valve control 1021
DWA5KA – CLS pump solenoid open circuit .1022
DWA8KA – SLS pump solenoid open circuit .1022
Wiring Diagram – CLS/SLS pump solenoid control 1023
DWA5KB – CLS pump solenoid short circuit 1024
DWA8KB – SLS pump solenoid short circuit 1024
Wiring Diagram – CLS/SLS pump solenoid control 1025
DWA5KY – CLS pump solenoid hot short circuit 1026
DWA8KY – SLS pump solenoid hot short circuit 1026
Wiring Diagram – CLS/SLS pump solenoid / hot short circuit 1027
DWA7KA – CLS line release solenoid open circuit .1028
DWA9KA – SLS lube line release sol. open circuit 1028
Wiring Diagram – CLS/SLS lube line release solenoid control .1029
DWA7KB – CLS line release solenoid short circuit 1030
DWA9KB – SLS lube line release solenoid short circuit .1030
Wiring Diagram – CLS/SLS lube line release solenoid control .1031
DWA7KY – CLS line release sol. hot short circuit 1032
DWA9KY – SLS lube line release sol hot short circuit 1032
Wiring Diagram – CLS/SLS lube line release solenoid / hot short circuit .1033
DWAAKA – PTO lube preload solenoid open circuit .1034
Wiring Diagram and monitoring screen for message DWAAKA .1035
DWAAKB – PTO lube preload solenoid short circuit 1036
Wiring Diagram and monitoring screen for message DWAAKB .1037
DWAAKY – PTO lube preload sol. hot short circuit 1038
Wiring Diagram for message DWAAKY .1039
D166KB – Oil cooler fan sol(Min)relay short circuit .1040
Wiring Diagram – relay 11K068 for 57K506a (D166KB) 1041
D167KB – Oil cooler fan sol(Mid)relay short circuit .1042
Wiring Diagram – relay 11K069 for 57K506b (D167KB) 1043
D168KB – Oil cooler preload sol relay short circuit .1044
Wiring Diagram – relay 11K070 (D168KB) 1045
D1E9KB – Wiper fast relay short circuit .1046
D1ETKB – Wiper slow relay short circuit .1046
D1EBKB – Wiper stop relay short circuit .1046
Wiring Diagram – Wiper motor control 1047
D162KB – Horn relay short circuit .1048
Wiring Diagram – signal horn control 1049
D1F0KB – Engine1/motor1 shutdown relay short circuit 1050
Wiring Diagram 1 – engine1 shutdown relay 11K064-1 1051
D1F0KY – Engine1/motor1 shutdown relay hot short 1052
Wiring Diagram for D1F0KY .1053
D110KA – Battery relay open circuit .1054
Wiring Diagram – battery relay 11Q044d 1055
D110KB – Battery relay short circuit 1056
Wiring Diagram – battery relay 11Q044d 1057
DA29KQ – Model Selection Abnormality 1058
Monitoring screen for machine selection .1058
Wiring Diagram – model selection abnormality (DA29KQ) .1059
DA2YKQ – Motor/Engine Selection Abnormality .1060
Monitoring screen for motor/engine selection 1060
Wiring Diagram – motor/engine selection abnormality (DA2YKQ) 1061
DA20KQ – Pump Con Selection Abnormality .1062
Monitoring screen for pump controller selection .1062
DDABMC – Lock lever switch abnormality 1064
Wiring Diagram – lock lever switch 20S105 (DDABMC) 1065
DKURMA – R lever right-left potentio abnormality 1066
Wiring Diagram – right lever right-left potentiometer input (DKURMA) 1067
DKUSMA – R lever right-left redu pot abnorm(VALVE/M) 1068
Wiring Diagram – right lever redundant right-left potentiometer input (DKUSMA) 1069
DKUQL8 – R lever right-left potentio error 1070
Wiring Diagram – right lever main + redundant right-left signal voltage (DKUQL8) 1071
DKUQL4 – R lever right-left sig. mismatch(VALVE/M) 1072
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1 .1074
DKUNMA – R lever front-back potentio abnormality 1076
Wiring Diagram – right lever front-back potentiometer input (DKUNMA) 1077
DKUPMA – R lever front-back redu pot abnorm(VALVE/M) 1078
Wiring Diagram – right lever redundant front-back potentiometer input (DKUPMA) 1079
DKUML8 – R lever front-back potentio error 1080
Wiring Diagram – R lever main + redundant front-back signal voltage (DKUML8) 1081
DKUML4 – R lever front-back sig. mismatch(VALVE/M) 1082
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1 .1084
DKUXMA – Left lever right-left potentio abnormality .1086
Wiring Diagram – left lever right-left potentiometer input (DKUXMA) .1087
DKUYMA – L lever right-left redu pot abnorm(VALVE/M) 1088
Wiring Diagram – left lever redundant right-left potentiometer input (DKUYMA) .1089
DKUWL8 – L lever right-left potentio error 1090
Wiring Diagram – left lever main + redundant right-left signal voltage (DKUWL8) .1091
DKUWL4 – L lever right-left sig. mismatch(VALVE/M) 1092
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1 .1094
DKUUMA – L lever front-back potentio abnormality 1096
Wiring Diagram – left lever front-back potentiometer input (DKUUMA) .1097
DKUVMA – L lever front-back redu pot abnorm(VALVE/M) 1098
Wiring Diagram – L lever front-back redu pot abnorm(VALVE/M) for DKUVMA .1099
DKUTL8 – L lever front-back potentio error 1100
Wiring Diagram – L lever front-back potentio error (DKUTL8) .1101
DKUTL4 – L lever front-back sig. mismatch(VALVE/M) 1102
Wiring Diagram – L lever front-back sig. mismatch(VALVE/M) for DKUTL4 .1104
DKW1MA – R pedal potentio abnormality .1106
Wiring Diagram – R pedal potentio abnormality (DKW1MA) 1107
DKW2MA – R pedal redundant pot abnormality(VALVE/M) .1108
Wiring Diagram – R pedal redundant pot abnormality(VALVE/M) for DKW2MA 1109
DKW0L8 – R pedal potentio error .1110
Wiring Diagram – R pedal potentio error (DKW0L8) 1111
DKW0L4 – R pedal signal mismatch (VALVE/M Con) 1112
Wiring Diagram – R pedal signal mismatch (VALVE/M Con) for DKW0L4 .1114
DKW4MA – L pedal potentio abnormality .1116
Wiring Diagram – L pedal potentio abnormality (DKW4MA) 1117
DKW5MA – L pedal redundant pot abnormality (VALVE/M) 1118
Wiring Diagram – L pedal redundant pot abnormality (VALVE/M) for DKW5MA .1119
DKW3L8 – L pedal potentio error .1120
Wiring Diagram – L pedal potentio error (DKW3L8) 1121
DKW3L4 – L pedal signal mismatch (VALVE/M Con) 1122
Wiring Diagram – L pedal signal mismatch (VALVE/M Con) for DKW3L4 .1124
DKW7MA – Clam open potentio abnormality .1126
Wiring Diagram – Clam open potentio abnormality (DKW7MA) 1127
DKW8MA – Clam open redu pot abnormality (VALVE/M) .1128
Wiring Diagram – Clam open redu pot abnormality (VALVE/M) for DKW8MA 1129
DKW6L8 – Clam open potentio error .1130
Wiring Diagram – Clam open potentio error (DKW6L8) 1131
DKW6L4 – Clam open signal mismatch (VALVE/M Con) 1132
Wiring Diagram – Clam open signal mismatch (VALVE/M Con) for DKW6L4 .1134
DKWAMA – Clam close potentio abnormality 1136
Wiring Diagram – Clam close potentio abnormality (DKWAMA) .1137
DKWBMA – Clam close redundant pot abnorm (VALVE/M) 1138
Wiring Diagram – Clam close redundant pot abnorm (VALVE/M) for DKWBMA .1139
DKW9L8 – Clam close potentio error 1140
Wiring Diagram – Clam close potentio error (DKW9L8) .1141
DKW9L4 – Clam close signal mismatch (VALVE/M Con) .1142
Wiring Diagram – Clam close signal mismatch (VALVE/M Con) for DKW9L4 1144
DKWDMA – Hydraulic slew brake potentio abnormality 1146
Wiring Diagram – Hydraulic slew brake potentio abnormality (DKWDMA) .1147
DKWEMA – Hyd. slew brake redu pot abnorm (VALVE/M) 1148
Wiring Diagram – Hyd. slew brake redu pot abnorm (VALVE/M) for DKWEMA .1149
DKWCL8 – Hydraulic slew brake potentio error 1150
Wiring Diagram – Hydraulic slew brake potentio error (DKWCL8) .1151
DKWCL4 – Hyd. slew brake sig. mismatch (VALVE/M) 1152
Wiring Diagram – Hyd. slew brake sig. mismatch (VALVE/M) for DKWCL4 .1154
DWNPKA – Service arm up solenoid open circuit .1156
Wiring Diagram and monitoring screen for message DWNPKA .1157
DWNPKB – Service arm up solenoid short circuit 1158
Wiring Diagram and monitoring screen for message DWNPKB .1159
DWNPKY – Service arm up solenoid hot short circuit 1160
Wiring Diagram and monitoring screen for message DWNPKY .1161
DWNQKA – Service arm down solenoid open circuit .1162
Wiring Diagram and monitoring screen for message DWNQKA .1163
DWNQKB – Service arm down solenoid short circuit 1164
Wiring Diagram and monitoring screen for message DWNQKB .1165
DWNQKY – Service arm down solenoid hot short circuit 1166
Wiring Diagram and monitoring screen for message DWNQKY .1167
DW4BKA – Travel parking brake solenoid open circuit .1168
Wiring Diagram and monitoring screen for message DW4BKA .1169
DW4BKB – Travel parking brake sol. short circuit 1170
Wiring Diagram and monitoring screen for message DW4BKB .1171
DW4BKY – Travel parking brake sol. hot short circuit 1172
Wiring Diagram and monitoring screen for message DW4BKY .1173
DW45KA – Slew parking brake solenoid open circuit .1174
Wiring Diagram and monitoring screen for message DW45KA .1175
DW45KB – Slew parking brake solenoid short circuit 1176
Wiring Diagram and monitoring screen for message DW45KB .1177
DW45KY – Slew parking brake sol. hot short circuit 1178
Wiring Diagram and monitoring screen for message DW45KY .1179
DXN0KA – Slew1 epc solenoid open circuit 1180
DXN1KA – Bucket/Boom1 epc solenoid open circuit (FSA) .1180
DXN2KA – Boom1 epc solenoid open circuit (BHA) 1180
DXN3KA – Stick1 epc solenoid open circuit .1180
DXN4KA – Boom2 epc solenoid open circuit 1180
DXN5KA – Clam2 epc solenoid open circuit (FSA) 1180
DXN6KA – Stick2 epc solenoid open circuit (BHA) .1180
DXN7KA – Stick/Bucket2 epc solenoid open circuit (FSA) 1180
DXN8KA – Bucket2 epc solenoid open circuit (BHA) 1180
DXN9KA – Travel2 left epc solenoid open circuit .1180
DXNAKA – Slew3 epc solenoid open circuit 1180
DXNBKA – Bucket3 epc solenoid open circuit 1180
DXNCKA – Boom3 epc solenoid open circuit 1180
DXNDKA – Boom4 epc solenoid open circuit 1180
DXNEKA – Bucket4 epc solenoid open circuit 1180
DXNFKA – Stick4 epc solenoid open circuit .1180
DXNGKA – Travel4 right epc solenoid open circuit 1180
Details of the above 6-digit failure codes (FSA & BHA) 1181
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 .1182
Wiring Diagram for EPC 61K624 – 61K625 1183
Wiring Diagram for EPC 61K626 – 61K627 1184
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 .1185
Wiring Diagram for EPC 61K632 – 61K633 1186
Wiring Diagram for EPC 61K634 – 61K635 1187
Monitoring screens as an example 1188
DXN0KB – Slew1 epc solenoid short circuit .1190
DXN1KB – Bucket/Boom1 epc solenoid short circuit (FSA) 1190
DXN2KB – Boom1 epc solenoid short circuit (BHA) .1190
DXN3KB – Stick1 epc solenoid short circuit 1190
DXN4KB – Boom2 epc solenoid short circuit .1190
DXN5KB – Clam2 epc solenoid short circuit FSA) 1190
DXN6KB – Stick2 epc solenoid short circuit (BHA) 1190
DXN7KB – Stick/Bucket2 epc solenoid short circuit (FSA) .1190
DXN8KB – Bucket2 epc solenoid short circuit (BHA) .1190
DXN9KB – Travel2 left epc solenoid short circuit 1190
DXNAKB – Slew3 epc solenoid short circuit .1190
DXNBKB – Bucket3 epc solenoid short circuit .1190
DXNCKB – Boom3 epc solenoid short circuit .1190
DXNDKB – Boom4 epc solenoid short circuit .1190
DXNEKB – Bucket4 epc solenoid short circuit .1190
DXNFKB – Stick4 epc solenoid short circuit 1190
DXNGKB – Travel4 right epc solenoid short circuit .1190
Details of the above 6-digit failure codes (FSA & BHA) 1191
DXN0KY – Slew1 epc solenoid hot short circuit .1192
DXN1KY – Bucket/Boom1 epc sol. hot short circuit (FSA) 1192
DXN2KY – Boom1 epc solenoid hot short circuit (BHA) .1192
DXN3KY – Stick1 epc solenoid hot short circuit 1192
DXN4KY – Boom2 epc solenoid hot short circuit .1192
DXN5KY – Clam2 epc solenoid hot short circuit (FSA) .1192
DXN6KY – Stick2 epc solenoid hot short circuit (BHA) 1192
DXN7KY – Stick/Bucket2 epc sol. hot short circuit (FSA) .1192
DXN8KY – Bucket2 epc solenoid hot short circuit (BHA) .1192
DXN9KY – Travel2 left epc sol. hot short circuit 1192
DXNAKY – Slew3 epc solenoid hot short circuit .1192
DXNBKY – Bucket3 epc solenoid hot short circuit .1192
DXNCKY – Boom3 epc solenoid hot short circuit .1192
DXNDKY – Boom4 epc solenoid hot short circuit .1192
DXNEKY – Bucket4 epc solenoid hot short circuit .1192
DXNFKY – Stick4 epc solenoid hot short circuit 1192
DXNGKY – Travel4 right epc sol. hot short circuit .1192
Details of the above 6-digit failure codes (FSA & BHA) 1193
Wiring Diagram for EPC 61K620 – 61K621 – 61K622 .1194
Wiring Diagram for EPC 61K624 – 61K625 1195
Wiring Diagram for EPC 61K626 – 61K627 1196
Wiring Diagram for EPC 61K628 – 61K629 – 61K630 .1197
Wiring Diagram for EPC 61K632 – 61K633 1198
Wiring Diagram for EPC 61K634 – 61K635 1199
DWACKA – Service arm check valve sol. open circuit 1200
Wiring Diagram and monitoring screen for message DWACKA .1201
DWACKB – Service arm check valve sol. short circuit .1202
Wiring Diagram and monitoring screen for message DWACKB .1203
DWACKY – Service arm check valveSol hotShortCircuit .1204
Wiring Diagram and monitoring screen for message DWACKY .1205
DWADKA – Ladder speed control solenoid open circuit .1206
Wiring Diagram and monitoring screen for message DWADKA .1207
DWADKB – Ladder speed control sol. short circuit 1208
Wiring Diagram and monitoring screen for message DWADKB .1209
DWADKY – Ladder speed control sol. hot short circuit 1210
Wiring Diagram – Ladder speed control sol. hot short circuit (DWADKY) .1211
DBW5MA – 5V sensor1 power abnormality .1212
DBW6MA – 5V sensor2 power abnormality .1212
Wiring Diagram – 5V power supply and GND output at VALVE0 .1216
DBW9KQ – Model Selection Abnormality 1218
Monitoring screen for machine selection .1218
Wiring Diagram – model selection abnormality (DBW9KQ) .1219
DBWZKQ – Lever control selection abnormality 1220
Monitoring screen & Wiring Diagram – Lever control selection abnormality (DBWZKQ) .1221
DBWYKQ – Attachment selection abnormality .1222
Monitoring screen & Wiring Diagram – Attachment selection abnormality (DBWYKQ) 1223
DBW2KK – Solenoid Power Low Error (VALVE/M Con) .1224
Wiring Diagram 1 for message DBW2KK .1226
Wiring Diagram 2 for message DBW2KK .1227
DBW0KQ – VALVE/M Con Selection Abnormality 1228
Monitoring screen & Wiring Diagram for message DBW0KQ .1229
DDDWMC – Ladder operation switch abnormality 1230
Wiring Diagram and monitoring screen for message DDDWMC .1231
DKWHMA – R lever right-left redu pot abnorm (VLV/S1) 1232
Wiring Diagram – right lever redundant right-left potentiometer input (DKWHMA) 1233
DKWFL4 – R lever right-left sig. mismatch (VALVE/S1) 1234
Wiring Diagram – R lever right-left signal input at VALVE0 and VALVE1 .1236
DKWLMA – R lever front-back redu pot abnorm (VLV/S1) 1238
Wiring Diagram – right lever redundant front-back potentiometer input (DKWLMA) 1239
DKWJL4 – R lever front-back sig. mismatch (VALVE/S1) 1240
Wiring Diagram – R lever front-back signal input at VALVE0 and VALVE1 .1242
DKWPMA – L lever right-left redu pot abnorm (VLV/S1) 1244
Wiring Diagram – left lever redundant right-left potentiometer input (DKWPMA) .1245
DKWML4 – L lever right-left sig. mismatch (VALVE/S1) 1246
Wiring Diagram – L lever right-left signal input at VALVE0 and VALVE1 .1248
DKWSMA – L lever front-back redu pot abnorm (VLV/S1) 1250
Wiring Diagram – L lever front-back redu pot abnorm (VLV/S1) for DKWSMA .1251
DKWQL4 – L lever front-back sig. mismatch (VALVE/S1) 1252
Wiring Diagram – L lever front-back sig. mismatch (VALVE/S1) for DKWQL4 .1254
DKWVMA – R pedal red pot abnormality (VALVE/S1) .1256
Wiring Diagram – R pedal red pot abnormality (VALVE/S1) for DKWVMA 1257
DKWTL4 – R pedal signal mismatch (VALVE/S1 Con) .1258
Wiring Diagram – R pedal signal mismatch (VALVE/S1 Con) for DKWTL4 1260
DKWYMA – L pedal red pot abnormality (VALVE/S1) .1262
Wiring Diagram – L pedal red pot abnormality (VALVE/S1) for DKWYMA 1263
DKWWL4 – L pedal signal mismatch (VALVE/S1 Con) .1264
Wiring Diagram – L pedal signal mismatch (VALVE/S1 Con) for DKWWL4 1266
DKX2MA – Clam open redu pot abnormality (VALVE/S1) 1268
Wiring Diagram – Clam open redu pot abnormality (VALVE/S1)) for DKX2MA 1269
DKX0L4 – Clam open signal mismatch (VALVE/S1 Con) .1270
Wiring Diagram – Clam open signal mismatch (VALVE/S1 Con) for DKX0L4 1272
DKX5MA – Clam close redu pot abnormality (VALVE/S1) .1274
Wiring Diagram – Clam close redu pot abnormality (VALVE/S1) for DKX5MA 1275
DKX3L4 – Clam close signal mismatch (VALVE/S1 Con) 1276
Wiring Diagram – Clam close signal mismatch (VALVE/S1 Con) for DKX3L4 .1278
DKX8MA – Hyd. slew brake redu pot abnorm (VALVE/S1) .1280
Wiring Diagram – Hyd. slew brake redu pot abnorm (VALVE/S1) for DKX8MA 1281
DKX6L4 – Hyd. slew brake signal mismatch (VALVE/S1) .1282
Wiring Diagram – Hyd. slew brake signal mismatch (VALVE/S1) for DKX6L4 1284
DWNRKA – Ladder up solenoid open circuit 1286
Wiring Diagram and monitoring screen for message DWNRKA .1287
DWNRKB – Ladder up solenoid short circuit .1288
Wiring Diagram and monitoring screen for message DWNRKB .1289
DWNRKY – Ladder up solenoid hot short circuit .1290
Wiring Diagram – Ladder up solenoid hot short circuit (DWNRKY) 1291
DW7RKA – Hydraulic slew brake solenoid open circuit .1292
Wiring Diagram and monitoring screen for message DW7RKA .1293
DW7RKB – Hydraulic slew brake sol. short circuit 1294
Wiring Diagram and monitoring screen for message DW7RKB .1295
DW7RKY – Hyd. slew brake sol. hot short circuit .1296
Wiring Diagram – Hyd. slew brake sol. hot short circuit (DW7RKY) 1297
DWANKA – Slew1 right solenoid open circuit 1298
Wiring Diagram and monitoring screen for message DWANKA .1299
DWANKB – Slew1 right solenoid short circuit .1300
Wiring Diagram and monitoring screen for message DWANKB .1301
DWANKY – Slew1 right solenoid hot short circuit .1302
Wiring Diagram and monitoring screen for message DWANKY .1303
DWAJKA – Slew1 left solenoid open circuit .1304
Wiring Diagram and monitoring screen for message DWAJKA .1305
DWAJKB – Slew1 left solenoid short circuit 1306
Wiring Diagram and monitoring screen for message DWAJKB .1307
DWAJKY – Slew1 left solenoid hot short circuit 1308
Wiring Diagram and monitoring screen for message DWAJKY .1309
DWASKA – Bucket1 fill solenoid open circuit .1310
Wiring Diagram and monitoring screen for message DWASKA .1311
DWASKB – Bucket1 fill solenoid short circuit 1312
Wiring Diagram and monitoring screen for message DWASKB .1313
DWASKY – Bucket1 fill solenoid hot short circuit 1314
Wiring Diagram and monitoring screen for message DWASKY .1315
DWBEKA – Boom1 down solenoid open circuit .1316
Wiring Diagram and monitoring screen for message DWBEKA .1317
DWBEKB – Boom1 down solenoid short circuit 1318
Wiring Diagram and monitoring screen for message DWBEKB .1319
DWBEKY – Boom1 down solenoid hot short circuit 1320
Wiring Diagram and monitoring screen for message DWBEKY .1321
DWBAKA – Boom1 up solenoid open circuit .1322
Wiring Diagram and monitoring screen for message DWBAKA .1323
DWBAKB – Boom1 up solenoid short circuit 1324
Wiring Diagram and monitoring screen for message DWBAKB .1325
DWBAKY – Boom1 up solenoid hot short circuit 1326
Wiring Diagram and monitoring screen for message DWBAKY .1327
DWBJKA – Stick1 out solenoid open circuit .1328
Wiring Diagram and monitoring screen for message DWBJKA .1329
DWBJKB – Stick1 out solenoid short circuit 1330
Wiring Diagram and monitoring screen for message DWBJKB .1331
DWBJKY – Stick1 out solenoid hot short circuit 1332
Wiring Diagram and monitoring screen for message DWBJKY .1333
DWBNKA – Stick1 in solenoid open circuit 1334
Wiring Diagram and monitoring screen for message DWBNKA .1335
DWBNKB – Stick1 in solenoid short circuit .1336
Wiring Diagram and monitoring screen for message DWBNKB .1337
DWBNKY – Stick1 in solenoid hot short circuit .1338
Wiring Diagram and monitoring screen for message DWBNKY .1339
DWBBKA – Boom2 up solenoid open circuit .1340
Wiring Diagram and monitoring screen for message DWBBKA .1341
DWBBKB – Boom2 up solenoid short circuit 1342
Wiring Diagram and monitoring screen for message DWBBKB .1343
DWBBKY – Boom2 up solenoid hot short circuit 1344
Wiring Diagram and monitoring screen for message DWBBKY .1345
DWBFKA – Boom2 down solenoid open circuit .1346
Wiring Diagram and monitoring screen for message DWBFKA .1347
DWBFKB – Boom2 down solenoid short circuit 1348
Wiring Diagram and monitoring screen for message DWBFKB .1349
DWBFKY – Boom2 down solenoid hot short circuit 1350
Wiring Diagram and monitoring screen for message DWBFKY .1351
DWBXKA – Clam2 close solenoid open circuit 1352
Wiring Diagram and monitoring screen for message DWBXKA .1353
DWBXKB – Clam2 close solenoid short circuit .1354
Wiring Diagram and monitoring screen for message DWBXKB .1355
DWBXKY – Clam2 close solenoid hot short circuit .1356
Wiring Diagram and monitoring screen for message DWBXKY .1357
DWBKKA – Stick2 out solenoid open circuit .1358
Wiring Diagram and monitoring screen for message DWBKKA (FSA only) 1359
DWBKKB – Stick2 out solenoid short circuit 1360
Wiring Diagram and monitoring screen for message DWBKKB .1361
DWBKKY – Stick2 out solenoid hot short circuit 1362
Wiring Diagram and monitoring screen for message DWBKKY .1363
DWBTKA – Clam2 open solenoid open circuit .1364
Wiring Diagram and monitoring screen for message DWBTKA .1365
DWBTKB – Clam2 open solenoid short circuit 1366
Wiring Diagram and monitoring screen for message DWBTKB .1367
DWBTKY – Clam2 open solenoid hot short circuit 1368
Wiring Diagram and monitoring screen for message DWBTKY .1369
DWBPKA – Stick2 in solenoid open circuit 1370
Wiring Diagram and monitoring screen for message DWBPKA .1371
DWBPKB – Stick2 in solenoid short circuit .1372
Wiring Diagram and monitoring screen for message DWBPKB .1373
DWBPKY – Stick2 in solenoid hot short circuit .1374
Wiring Diagram and monitoring screen for message DWBPKY .1375
DWATKA – Bucket2 fill solenoid open circuit .1376
Wiring Diagram and monitoring screen for message DWATKA .1377
DWATKB – Bucket2 fill solenoid short circuit 1378
Wiring Diagram and monitoring screen for message DWATKB .1379
DWATKY – Bucket2 fill solenoid hot short circuit 1380
Wiring Diagram and monitoring screen for message DWATKY .1381
DWAXKA – Bucket2 dump solenoid open circuit .1382
Wiring Diagram and monitoring screen for message DWAXKA .1383
DWAXKB – Bucket2 dump solenoid short circuit 1384
Wiring Diagram and monitoring screen for message DWAXKB .1385
DWAXKY – Bucket2 dump solenoid hot short circuit 1386
Wiring Diagram and monitoring screen for message DWAXKY .1387
DWKFKA – Travel2 left backward sol. open circuit 1388
Wiring Diagram and monitoring screen for message DWKFKA .1389
DWKFKB – Travel2 left backward sol. short circuit .1390
Wiring Diagram and monitoring screen for message DWKFKB .1391
DWKFKY – Travel2 left backward sol. hot short circuit .1392
Wiring Diagram and monitoring screen for message DWKFKY .1393
DWKBKA – Travel2 left forward sol. open circuit .1394
Wiring Diagram and monitoring screen for message DWKBKA .1395
DWKBKB – Travel2 left forward sol. short circuit 1396
Wiring Diagram and monitoring screen for message DWKBKB .1397
DWKBKY – Travel2 left forward sol. hot short 1398
Wiring Diagram and monitoring screen for message DWKBKY .1399
D5ZWKB – Travel hour meter short circuit 1400
Wiring Diagram and monitoring screen for message D5ZWKB .1401
D1EUKB – Travel alarm relay short circuit .1402
Wiring Diagram and monitoring screen for message D1EUKB .1403
DBX9KQ – Model Selection Abnormality 1404
Wiring Diagram and monitoring screen for message DBX9KQ .1405
DBXZKQ – Lever Control Selection Abnormality 1406
Wiring Diagram and monitoring screen for message DBXZKQ .1407
DBXYKQ – Attachment selection abnormality .1408
Wiring Diagram – Attachment selection abnormality (DBXYKQ) 1409
D561MA – Lock lever sol. power cut abnorm(VALVE/S1) .1410
Monitoring screens and Wiring Diagram 1 for message D561MA 1411
Wiring Diagram 2 for message D561MA .1412
D563MA – Ladder up sensor sol cut abnorm(VLV/S1) 1413
Monitoring screens and Wiring Diagram 1 for message D563MA 1414
Wiring Diagram 2 for message D563MA .1415
D565MA – Service arm (up) sensor sol cut abnorm(VLV/S1) .1416
Wiring Diagram 1 and monitoring screens for message D565MA 1417
Wiring Diagram 2 for message D565MA .1418
DBX2KK – Solenoid Power Low Error(VALVE/S1 Con) .1419
Monitoring screen and Wiring Diagram 1 for message DBX2KK .1420
Wiring Diagram 2 for message DBX2KK – Safety circuit 1421
DBX0KQ – VALVE/S1 Con Selection Abnormality .1422
Wiring Diagram and monitoring screen for message DBX0KQ .1423
DWAQKA – Slew3 right solenoid open circuit 1424
Wiring Diagram and monitoring screen for message DWAQKA .1425
DWAQKB – Slew3 right solenoid short circuit .1426
Wiring Diagram and monitoring screen for message DWAQKB .1427
DWAQKY – Slew3 right solenoid hot short circuit .1428
Wiring Diagram and monitoring screen for message DWAQKY .1429
DWALKA – Slew3 left solenoid open circuit .1430
Wiring Diagram and monitoring screen for message DWALKA .1431
DWALKB – Slew3 left solenoid short circuit 1432
Wiring Diagram and monitoring screen for message DWALKB .1433
DWALKY – Slew3 left solenoid hot short circuit 1434
Wiring Diagram and monitoring screen for message DWALKY .1435
DWAUKA – Bucket3 fill solenoid open circuit .1436
Wiring Diagram and monitoring screen for message DWAUKA .1437
DWAUKB – Bucket3 fill solenoid short circuit 1438
Wiring Diagram and monitoring screen for message DWAUKB .1439
DWAUKY – Bucket3 fill solenoid hot short circuit 1440
Wiring Diagram and monitoring screen for message DWAUKY .1441
DWAYKA – Bucket3 dump solenoid open circuit .1442
Wiring Diagram and monitoring screen for message DWAYKA .1443
DWAYKB – Bucket3 dump solenoid short circuit 1444
Wiring Diagram and monitoring screen for message DWAYKB .1445
DWAYKY – Bucket3 dump solenoid hot short circuit 1446
Wiring Diagram and monitoring screen for message DWAYKY .1447
DWBGKA – Boom3 down solenoid open circuit .1448
Wiring Diagram and monitoring screen for message DWBGKA .1449
DWBGKB – Boom3 down solenoid short circuit 1450
Wiring Diagram and monitoring screen for message DWBGKB .1451
DWBGKY – Boom3 down solenoid hot short circuit 1452
Wiring Diagram and monitoring screen for message DWBGKY .1453
DWBDKA – Boom4 up solenoid open circuit .1454
Wiring Diagram and monitoring screen for message DWBDKA .1455
DWBDKB – Boom4 up solenoid short circuit 1456
Wiring Diagram and monitoring screen for message DWBDKB .1457
DWBDKY – Boom4 up solenoid hot short circuit 1458
Wiring Diagram and monitoring screen for message DWBDKY .1459
DWBHKA – Boom4 down solenoid open circuit .1460
Wiring Diagram and monitoring screen for message DWBHKA .1461
DWBHKB – Boom4 down solenoid short circuit 1462
Wiring Diagram and monitoring screen for message DWBHKB .1463
DWBHKY – Boom4 down solenoid hot short circuit 1464
Wiring Diagram and monitoring screen for message DWBHKY .1465
DWAVKA – Bucket4 fill solenoid open circuit .1466
Wiring Diagram and monitoring screen for message DWAVKA .1467
DWAVKB – Bucket4 fill solenoid short circuit 1468
Wiring Diagram and monitoring screen for message DWAVKB .1469
DWAVKY – Bucket4 fill solenoid hot short circuit 1470
Wiring Diagram and monitoring screen for message DWAVKY .1471
DWAZKA – Bucket4 dump solenoid open circuit .1472
Wiring Diagram and monitoring screen for message DWAZKA .1473
DWAZKB – Bucket4 dump solenoid short circuit 1474
Wiring Diagram and monitoring screen for message DWAZKB .1475
DWAZKY – Bucket4 dump solenoid hot short circuit 1476
Wiring Diagram and monitoring screen for message DWAZKY .1477
DWBMKA – Stick4 out solenoid open circuit .1478
Wiring Diagram and monitoring screen for message DWBMKA .1479
DWBMKB – Stick4 out solenoid short circuit 1480
Wiring Diagram and monitoring screen for message DWBMKB .1481
DWBMKY – Stick4 out solenoid hot short circuit 1482
Wiring Diagram and monitoring screen for message DWBMKY .1483
DWBRKA – Stick4 in solenoid open circuit 1484
Wiring Diagram and monitoring screen for message DWBRKA .1485
DWBRKB – Stick4 in solenoid short circuit .1486
Wiring Diagram and monitoring screen for message DWBRKB .1487
DWBRKY – Stick4 in solenoid hot short circuit .1488
Wiring Diagram and monitoring screen for message DWBRKY .1489
DWKRKA – Travel4 right backward sol. open circuit .1490
Wiring Diagram and monitoring screen for message DWKRKA .1491
DWKRKB – Travel4 right backward sol. short circuit 1492
Wiring Diagram and monitoring screen for message DWKRKB .1493
DWKRKY – Travel4 right backward sol. hot short 1494
Wiring Diagram and monitoring screen for message DWKRKY .1495
DWKMKA – Travel4 right forward sol. open circuit 1496
Wiring Diagram and monitoring screen for message DWKMKA .1497
DWKMKB – Travel4 right forward sol. short circuit .1498
Wiring Diagram and monitoring screen for message DWKMKB .1499
DWKMKY – Travel4 right forward sol. hot short .1500
Wiring Diagram and monitoring screen for message DWKMKY .1501
DXEDKA – Hydraulic slew brake epc sol. open circuit .1502
Wiring Diagram and monitoring screen for message DXEDKA .1503
DXEDKB – Hyd. slew brake epc sol. short circuit .1504
Wiring Diagram and monitoring screen for message DXEDKB .1505
DXEDKY – Hyd. slew brake epc sol. hot short circuit .1506
Wiring Diagram and monitoring screen for message DXEDKY .1507
DWKVKA – Boom4 float solenoid open circuit 1508
Wiring Diagram and monitoring screen for message DWKVKA .1509
DWKVKB – Boom4 float solenoid short circuit .1510
Wiring Diagram and monitoring screen for message DWKVKB .1511
DWKVKY – Boom4 float solenoid hot short circuit .1512
Wiring Diagram and monitoring screen for message DWKVKY .1513
DWKWKA – Stick1 float solenoid open circuit .1514
Wiring Diagram and monitoring screen for message DWKWKA .1515
DWKWKB – Stick1 float solenoid short circuit 1516
Wiring Diagram and monitoring screen for message DWKWKB .1517
DWKWKY – Stick1 float solenoid hot short circuit 1518
Wiring Diagram and monitoring screen for message DWKWKY .1519
DWKZKA – Stick4 float solenoid open circuit .1520
Wiring Diagram and monitoring screen for message DWKZKA .1521
DWKZKB – Stick4 float solenoid short circuit 1522
Wiring Diagram and monitoring screen for message DWKZKB .1523
DWKZKY – Stick4 float solenoid hot short circuit 1524
Wiring Diagram and monitoring screen for message DWKZKY .1525
DBY9KQ – Model Selection Abnormality 1526
Wiring Diagram and monitoring screen for message DBY9KQ .1527
DBYZKQ – Lever Control Selection Abnormality 1528
Wiring Diagram and monitoring screen for message DBYZKQ .1529
DBYYKQ – Attachment selection abnormality .1530
Wiring Diagram – Attachment selection abnormality (DBYYKQ) 1531
D562MA – Lock lever sol power cut abnorm(VALVE/S2) 1532
Wiring Diagram 1 and monitoring screen for message D562MA .1533
Wiring Diagram 2 for message D562MA .1534
D564MA – Ladder up sensor sol cut abnorm(VLV/S2) 1535
Monitoring screens and Wiring Diagram 1 for message D564MA 1536
Wiring Diagram 2 for message D564MA .1537
D566MA – Service arm sensor sol cut abnorm(VALV/S2) .1538
Wiring Diagram 1 and monitoring screens for message D566MA 1539
Wiring Diagram 2 for message D566MA .1540
DBY2KK – Solenoid Power Low Error(VALVE/S2 Con) .1541
Monitoring screen and Wiring Diagram 1 for message DBY2KK .1542
Wiring Diagram 2 for message DBY2KK – Safety circuit 1543
DBY0KQ – VALVE/S2 Con Selection Abnormality .1544
Wiring Diagram and monitoring screen for message DBY0KQ .1545
DJH2KX – Hydraulic oil level sensor abnormality .1546
Wiring Diagram and monitoring screen for message DJH2KX .1547
DJE3KX – Remote engine oil level1 sens. abnormality .1548
Wiring Diagram and monitoring screen for message DJE3KX .1549
DH2GKX – Suction tank pressure sensor abnormality .1550
Wiring Diagram and monitoring screen for message DH2GKX .1551
DH2HKX – Oil cooler pressure sensor abnormality .1552
Wiring Diagram and monitoring screen for message DH2HKX .1553
DH2JKX – Preload valve return oil press abnormality .1554
Wiring Diagram and monitoring screen for message DH2JKX .1555
DHSUKX – X2 pressure sensor abnormality .1556
Wiring Diagram and monitoring screen for message DHSUKX .1557
DJF1KX – Fuel level sensor abnormality 1558
Wiring Diagram and monitoring screen for message DJF1KX .1559
DGE5MA – Ambient air temp sensor abnormality 1560
Wiring Diagram and monitoring screen for message DGE5MA .1561
DH2KKX – Return oil chamber press. sensor abnormal 1562
Wiring Diagram and monitoring screen for message DH2KKX .1563
DH2LKX – Leak oil chamber press. sensor abnormality .1564
Wiring Diagram and monitoring screen for message DH2LKX .1565
DJE5L4 – SLS sensor system abnormality 1566
Wiring Diagram and monitoring screen for message DJE5L4 .1567
DJE6L4 – CLS sensor system abnormality 1568
Wiring Diagram and monitoring screen for message DJE6L4 .1569
DBVLKA – Operating Lamp Open Circuit(KOMTRAX) .1570
Wiring Diagram for message DJE6L4 .1571
DBVLKB – Operating Lamp Short Circuit (KOMTRAX) .1572
Wiring Diagram for message DBVLKB .1573
DBV1KK – KOMTRAX Plus source voltage Error 1574
Wiring Diagram for message DBV1KK .1575
DBV5KB – 5V sensor1 power abnormality .1576
Wiring Diagram 1 and monitoring screens for message DBV5KB 1577
Wiring Diagram 2 for message DBV5KB .1578
DBV6KB – 24V Sensor Power Abnormality .1580
Wiring Diagram 1 and monitoring screens for message DBV6KB 1581
Wiring Diagram 2 for message DBV6KB .1582
DAFGMC – GPS Module Error .1584
Wiring Diagram for message DAFGMC .1585
D862KA – GPS Antenna Open Circuit .1586
DBVVKR – Ethernet 1 Disconnection .1587
DBVWKR – Ethernet 2 Disconnection .1588
DA2RKR – CAN1 Discon (Pump Con) .1590
CAN1 overview for message DA2RKR 1591
DBWRKR – CAN1 Discon (Valve/M Con) 1592
CAN1 overview for message DBWRKR 1593
DBXRKR – CAN1 Discon (Valve/S1 Con) .1594
CAN1 overview for message DBXRKR 1595
DBYRKR – CAN1 Discon (Valve/S2 Con) .1596
CAN1 overview for message DBYRKR 1597
DB2QKR – CAN2 Discon (Engine Con) .1598
CAN2 overview for message DB2QKR 1599
DA2QKR – CAN2 Discon (Pump Con) .1600
CAN2 overview for message DA2QKR 1601
DBWQKR – CAN2 Discon (Valve/M Con) 1602
CAN2 overview for message DBWQKR 1603
DBXQKR – CAN2 Discon (Valve/S1 Con) .1604
CAN2 overview for message DBXQKR 1605
DBYQKR – CAN2 Discon (Valve/S2 Con) .1606
CAN2 overview for message DBYQKR 1607
DBVQKR – CAN2 Discon (KOMTRAX Plus) .1608
CAN2 overview for message DBVQKR 1609
D19YKB – Emergency Lighting Ladder Relay Short Circuit 1610
Wiring Diagram and monitoring screen for message D19YKB .1611
DV00KB – Shutdown Buzzer Short Circuit 1612
Wiring Diagram and monitoring screen for message DV00KB .1613
7 Troubleshooting by Symptoms .1615
7.1 Symptoms of the engine and related electrical system 1616
SEL001 – Engine does not start (engine does not rotate) .1616
Wiring Diagram 1 (batteries) for symptom code SEL001 1618
Wiring Diagram 2 (20S030 & 20S105) for symptom code SEL001 1619
Wiring Diagram 3 (engine enable) for symptom code SEL001 1620
Wiring Diagram 4 (starter motors) for symptom code SEL001 .1621
SEL001a – Engine does not start (Pre-lube does not stop) 1622
SEL002 – Engine stops while in operation 1624
View onto the fuel system water separator (SEL002) 1625
SEL003 – Engine speed is hunting during boom-up movement 1626
SEL004 – Engine does not stop .1628
SEL005 – Engine lacks output (no power) .1630
Judgment Table for SEL005 .1631
SEL006 – Exhaust smoke is black .1632
Judgment Table for SEL006 .1633
SEL007 – Oil consumption is excessive .1634
Judgment Table for SEL007 .1635
SEL008 – Oil becomes contaminated quickly .1636
Judgment Table for SEL008 .1637
SEL009 – Fuel consumption is excessive 1638
Judgment Table for SEL009 .1639
SEL010 – Oil is in engine coolant .1640
Judgment Table for SEL010 .1641
SEL011 – Oil level rises 1642
Judgment Table for SEL011 .1643
SEL012 – Coolant temperature becomes too high (overheating) .1644
Judgment Table for SEL012 .1645
7.2 Symptoms of the Hydraulic System 1646
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function) 1646
SHY002 – Engine speed sharply drops or engine stalls too much .1648
SHY003 – No work equipment, travel or slew movement .1649
SHY004 – Work equipment has too much hydraulic drift 1650
SHY005 – Work equipment has big time lag 1651
SHY006 – Machine deviates during travel movement 1652
SHY007 – Hydraulic system has lack of power .1653
SHY008 – Machine does not slew 1654
Slew brake block (SHY008) .1655
SHY009 – Slew acceleration is poor 1656
SHY010 – Excessive overrun when stopping slew movement 1658
SHY011 – Floating system without function (FSA only) 1660
SHY012 – Abnormal noise coming from SRV or MRV 1661
SHY013 – Track tensioning system without function .1662
Track tensioning – overview (SHY013) 1663
SHY014 – Ladder does not move, or slow movement .1664
SHY015 – Refilling arm does not move, or slow movement 1666
SHY016 – The hydr. driven grease pump does not move .1668
SHY017 – Abnormal track chain movement during digging .1670
SHY018 – Slew parking brake without function 1671
SHY019 – Travel parking brake without function 1672
7.3 Symptoms of the Mechanical System .1674
SME001 – Abnormal noise is made .1674
Judgment Table for SME001 .1675
SME002 – Abnormal noise around the PTO / hydraulic pumps 1676
SME003 – Vibration is excessive (engine mountings) 1678
Judgment Table for SME003 .1679
SME004 – Vibration is excessive (engine torsion) 1680
SME005 – There is a big shock when stopping slew movement .1681
SME006 – There is a big abnormal noise when moving/stopping slew movement .1682
SME007 – Fan blades make abnormal noise .1684
SME008 – Abnormal noise coming from a travel gearbox 1686
SME009 – Abnormal noise coming from the work equipment (lack of grease) .1688
SME010 – Abnormal idler movement 1690
SME011 – Leak at the PTO shaft seal .1692
7.4 Symptoms of Additional Systems 1694
SAD001 – Air conditioner for the cabin does not work 1694
View onto the A/C unit (SAD001) .1695
SAD002 – Air conditioner compressor clutch is burnt .1696
View onto the A/C compressor and its mounting (SAD002) 1697
SAD003 – Air conditioning system defective (pipes and hoses full of moisture) .1698
View onto the A/C filling and service station .1699
50 Disassembly & Assembly .1701
TOC .1703
1 Introduction 1711
1.1 Foreword 1712
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 1713
1.3 Diagrams and illustrations in this manual .1713
1.4 Procedures for disassembling and assembling in this manual 1714
2 Safety 1715
2.1 Overview 1717
2.1.1 Method of using this manual .1717
2.2 General precautions .1719
2.2.1 General .1719
2.2.2 Personal protective clothing 1719
2.2.3 When using a hammer .1720
2.2.4 Proper tools 1720
2.2.5 Personnel .1720
2.2.6 Fire prevention .1721
2.2.7 Unauthorized modification .1721
2.3 Precautions for maintenance and repair 1722
2.3.1 General precautions .1722
2.3.2 Keep work place clean and tidy 1722
2.3.3 Precautions when welding 1723
2.3.4 Precaution with high pressure fluids 1723
2.3.4.1 Handling high pressure hoses and pipes 1723
2.3.5 Compressed air 1723
2.3.6 Waste materials .1724
3 Superstructure 1725
3.1 Superstructure 1726
3.2 Machine house .1728
3.2.1 Disconnection plate at the machine house 1730
3.2.1.1 Machine house hose ports – port allocations .1730
3.2.2 Machine house roof 1732
3.2.2.1 Disassembling of the machine house roof cover plates 1735
3.2.2.2 Assembling of the machine house roof cover plates .1740
3.2.3 Exhaust System 1744
3.2.3.1 Disassembling of the Exhaust System .1744
3.2.3.2 Assembling of the exhaust system 1747
3.2.4 air intake system .1750
3.2.4.1 Disassembling of the Air intake System 1750
3.2.4.2 Assembling of the air intake system .1753
3.2.5 Air duct 1756
3.2.5.1 Disassembling of the air duct system (if equipped) 1756
3.2.5.2 Assembling of the Air Duct (If equipped) 1757
3.2.6 Diesel engine .1758
3.2.6.1 DISASSEMBLING AND ASSEMBLING OF THE ALTERNATOR 1758
3.2.6.2 DISASSEMBLING AND ASSEMBLING OF THE STARTER MOTORS 1758
3.2.6.3 Disassembling of the Diesel engine 1759
3.2.6.4 Assembling of the Diesel engine .1767
3.2.7 Batteries .1774
3.2.7.1 Disassembling of the batteries 1774
3.2.7.2 Assembling of the batteries .1776
3.2.8 Flexible coupling .1777
3.2.8.1 Disassembling of the CentaFlex coupling assembly 1777
3.2.8.2 Assembling of the CentaFlex coupling assembly .1780
3.2.8.3 Replacing the rubber rollers of the CentaFlex coupling 1782
3.2.9 Radiator fan and fan drive assembly .1784
3.2.9.1 Disassembling of the radiator fan .1786
3.2.9.2 Assembling of the radiator fan 1788
3.2.9.3 Disassembling of the radiator fan motor .1790
3.2.9.4 Assembling of the radiator fan motor 1792
3.2.9.5 Disassembling of the Radiator assembly 1794
3.2.9.6 Assembling of the radiator assembly .1799
3.2.10 Main pump assemblies .1804
3.2.10.1 Disassembling and assembling of the auxiliary pumps 1805
3.2.10.2 Disassembling of the main pump assemblies 1806
3.2.10.3 Assembling of the main pump assemblies .1810
3.2.11 Universal PTO 1814
3.2.11.1 Disassembling of the universal PTO .1814
3.2.11.2 Assembling of the universal PTO 1817
3.3 Hydraulic System 1820
3.3.1 Hydraulic oil cooler assembly .1820
3.3.1.1 Disassembling of hydraulic cooler fan and motor .1821
3.3.1.2 Assembling of hydraulic cooler fan and motor 1824
3.3.1.3 Disassembling of the hydraulic oil radiators 1827
3.3.1.4 Assembling of the hydraulic oil coolers .1831
3.3.1.5 Disassembling of the hydraulic oil cooler assembly 1834
3.3.1.6 Assembling of the hydraulic oil cooler assembly .1839
3.3.2 Hydraulic oil tank 1844
3.3.2.1 Disassembling of the main shut-off valve 1846
3.3.2.2 Assembling of the main shut-off valve .1848
3.3.2.3 Disassembling of the hydraulic oil tank .1850
3.3.2.4 Assembling of the hydraulic oil tank 1855
3.3.3 Main control valve blocks .1862
3.3.3.1 Disassembling of the main control valve blocks 1862
3.3.3.2 Assembling of the main control valve blocks .1865
3.3.3.3 Disassembling of the MRV at the main control valve blocks .1868
3.3.3.4 Assembling of the MRV at the main control valve blocks 1869
3.3.3.5 Disassembling of SRV on main control valve block 1870
3.3.3.6 Assembling of SRV on main control valve blocks 1871
3.3.3.7 Disassembling of ACV-/SRV-block on main control valve blocks 1872
3.3.3.8 Assembling of ACV-/SRV-block on main control valve blocks .1874
3.3.4 Distributor Manifold 1876
3.3.4.1 Disassembling of SRV-valve blocks / restrictor blocks at the distributor manifold .1877
3.3.4.2 Assembling of SRV-valve blocks / restrictor blocks at the distributor manifold 1879
3.3.4.3 Disassembling of anti cavitation valves at the distributor manifold .1881
3.3.4.4 Assembling of anti cavitation valves at the distributor manifold 1883
3.3.4.5 Disassembling of the Diffuser block at the manifold (FSA) .1885
3.3.4.6 Assembling of the Diffuser block at the manifold 1887
3.3.4.7 Disassembling of the distributor manifold .1888
3.3.4.8 Assembling of the distributor manifold 1891
3.4 Slew system .1894
3.4.1 Slew gears 1894
3.4.1.1 Disassembling of the slew gear 1895
3.4.1.2 Assembling of the slew gear .1898
3.4.2 Slew motor 1902
3.4.2.1 Disassembling of the slew motor .1903
3.4.2.2 Assembling of the slew motor 1906
3.4.3 Slew parking brake 1908
3.4.3.1 Disassembling of the slew parking brake of type 2063 1909
3.4.3.2 Assembling of the slew parking brake of type 2063 .1912
3.4.3.3 Disassembling of the slew parking brake of type 632770 1915
3.4.3.4 Assembling of the slew parking brake of type 632770 .1918
3.4.4 slew service brake valve 1921
3.4.4.1 Disassembling of the slew service brake valve .1921
3.4.4.2 Assembling of the of the slew service brake valve .1923
3.4.5 Slew circle .1925
3.4.5.1 Disassembling of the slew circle 1925
3.4.5.2 Assembling of the slew circle .1929
3.4.6 Slew circle lubrication pinion (dummy wheel) 1934
3.4.6.1 Disassembling of the lubrication pinion assembly 1934
3.4.6.2 Assembling of the lubrication pinion assembly .1935
3.5 Lubrication pumps .1936
3.5.1 Disassembling of the lubrication pump .1936
3.5.2 Assembling of the lubricating pump 1937
3.6 Operator’s cab 1938
3.6.1 Disassembling of the operator’s cab .1939
3.6.2 Assembling of the operator’s cab 1943
3.6.3 Disassembling of the operator’s cab together with the cab support frame .1946
3.6.4 Assembling of the operator’s cab together with the cab support frame 1950
3.6.5 Cab-mounts 1954
3.6.5.1 Disassembling of the cab-mounts .1954
3.6.5.2 Assembling of the cab-mounts 1956
3.6.6 Front window 1958
3.6.6.1 Disassembling of the front window .1958
3.6.6.2 Assembling of the front window 1959
3.6.7 Operator’s seat .1960
3.6.7.1 Disassembling of the operator’s seat 1960
3.6.7.2 Assembling of the operator’s seat .1961
3.7 Cab base 1962
3.7.1 Disassembling of the cab support frame 1963
3.7.2 Assembling of the cab support frame .1965
3.7.3 Disassembling of the cab base .1967
3.7.4 Assembling of the cab base 1969
3.8 stairways and platforms .1971
3.8.1 Hydraulic access stairway .1971
3.8.1.1 Disassembling of the hydraulic access stairway 1971
3.8.1.2 Assembling of the hydraulic access stairway .1973
3.8.2 Disassembling of the access stairway cylinder .1975
3.8.3 Assembling of the access stairway cylinder 1977
3.8.4 Fuel tank step 1978
3.8.4.1 Disassembling of the fuel tank step .1978
3.8.4.2 Assembling of the fuel tank step 1980
3.8.5 step platforms 1981
3.8.5.1 Disassembling of the upper step platform at fuel tank .1981
3.8.5.2 Assembling of the upper step platform at fuel tank 1983
3.8.5.3 Disassembling of the lower step platform at machine house .1984
3.8.5.4 Assembling of the lower step platform at machine house 1985
3.8.6 Emergency escape ladders 1986
3.8.6.1 Disassembling of the emergency escape ladder assembly at the cab base .1986
3.8.6.2 Assembling of the emergency escape ladder assembly at the cab base 1988
3.8.6.3 Disassembling of the emergency escape ladder assembly at the machine house 1989
3.8.6.4 Assembling of the emergency escape ladder assembly at the machine house .1991
3.9 Counterweight .1992
3.9.1 Disassembling of the counterweight 1993
3.9.2 Assembling of the counterweight .1995
3.10 Fuel tank 1998
3.10.1 Disassembling of the fuel tank .1998
3.10.2 Assembling of the fuel tank 2002
3.11 Superstructure Lifting .2006
3.11.1 Disassemble the superstructure from the undercarriage 2006
3.11.2 Install the superstructure onto the undercarriage 2009
4 Undercarriage .2013
4.1 Undercarriage overview 2014
4.2 Travel system .2016
4.2.1 Crawler track .2016
4.2.1.1 Changing of the crawler track .2016
4.2.2 Sprocket 2023
4.2.2.1 Disassembling of the sprocket assembly 2023
4.2.2.2 Assembling of the sprocket assembly .2028
4.2.3 Guide wheel assembly 2031
4.2.3.1 Disassembling of the guide wheel assembly .2031
4.2.3.2 Assembling of the guide wheel assembly 2033
4.2.4 Track tensioning accumulators .2036
4.2.4.1 Disassembling of the low pressure accumulators 2036
4.2.4.2 Assembling of the low pressure accumulators .2038
4.2.4.3 Disassembling of the high pressure accumulators .2040
4.2.4.4 Assembling of the high pressure accumulators 2041
4.2.5 Track tension valve block .2042
4.2.5.1 Disassembling of the track tensioning valve block .2042
4.2.5.2 Assembling of the track tensioning valve block 2043
4.2.6 Track tensioning cylinders 2044
4.2.6.1 Disassembling of the track tensioning cylinders .2044
4.2.6.2 Assembling of the track tensioning cylinders 2046
4.2.7 Hydraulic hoses of the track tensioning system 2049
4.2.7.1 Precursory work .2049
4.2.7.2 Replace the hydraulic hoses inside the center body 2051
4.2.7.3 Replace the hydraulic hoses between center body and crawler frame .2051
4.2.7.4 Replace the hydraulic hoses inside the crawler frame 2053
4.2.7.5 Subsequent work .2053
4.2.8 Travel brake valve block (overspeed valve) 2054
4.2.8.1 Disassembling of the travel brake valve block .2054
4.2.8.2 Assembling of the travel brake valve block 2056
4.2.9 Travel motors .2058
4.2.9.1 Disassembling of the travel motors 2058
4.2.9.2 Assembling of the travel motors .2060
4.2.10 Travel parking brake .2062
4.2.10.1 Travel parking brake overview 2062
4.2.10.2 Disassembling of the travel parking brake of type 2063 .2067
4.2.10.3 Assembling of the travel parking brake of type 2063 2070
4.2.10.4 Disassembling of the travel parking brake of type 631053 .2073
4.2.10.5 Assembling of the travel parking brake of type 631053 2076
4.2.11 Travel gear box 2080
4.2.11.1 Disassembling of the travel gear box .2081
4.2.11.2 Assembling of the travel gear box 2083
4.2.12 Carrier roller .2086
4.2.12.1 Disassembling of the carrier roller assembly .2086
4.2.12.2 Assembling of the carrier roller assembly 2088
4.2.13 Track roller .2090
4.2.13.1 Disassembling of the track roller assembly .2090
4.2.13.2 Assembling of the track roller assembly 2092
4.3 Undercarriage center body .2094
4.3.1 Disassembling of the undercarriage center body and the crawler carriers .2094
4.3.2 Assembling of the undercarriage center body and the crawler carriers 2099
4.3.2.1 Install crawler carrier mounting bolts 2105
4.3.3 Rotary joint 2106
4.3.3.1 Disassembling of the rotary joint .2106
4.3.3.2 Assembling of the rotary joint 2110
5 Attachment 2115
5.1 Repair procedures .2116
5.1.1 Replacement of bushings at the attachment .2116
5.1.1.1 Disassembling of the bushings .2116
5.1.1.2 Installation of the bushings 2117
5.1.2 General installation instructions for attachment pins .2118
5.2 Backhoe Attachment (BHA) 2120
5.2.1 Overview 2120
5.2.2 Pin Sealing bucket – Steering Rod – bucket link rod .2122
5.2.3 Boom assembly .2124
5.2.3.1 Disassembling of the Boom .2124
5.2.3.2 Assembling of the boom 2126
5.2.3.3 Disassembling of the boom cylinders .2129
5.2.3.4 Assembling of the boom cylinders 2134
5.2.4 Stick assembly 2139
5.2.4.1 Disassembling of the Stick 2139
5.2.4.2 Assembling of the Stick .2144
5.2.4.3 Disassembling of the Stick Cylinders 2148
5.2.4.4 Assembling of the Stick cylinders .2152
5.2.5 Bucket and steering .2157
5.2.5.1 Disassembling of the bucket .2157
5.2.5.2 Assembling of the bucket 2161
5.2.5.3 Disassembling of the Bucket Cylinders .2164
5.2.5.4 Assembling of the Bucket Cylinders 2171
5.2.5.5 Disassembling of the bucket link rod 2178
5.2.5.6 Assembling of the bucket link rod .2181
5.2.5.7 Disassembling of the steering rods 2184
5.2.5.8 Assembling of the steering rods .2190
5.2.6 Hydraulic hoses at the backhoe attachment .2195
5.2.6.1 Replacing of the boom arc hoses .2195
5.2.6.2 Replacing of the lubrication hoses 2198
5.2.6.3 Replacing of the boom cylinder hoses 2199
5.2.6.4 Replacing of the stick cylinder hoses .2202
5.2.6.5 Replacing of the bucket cylinder hoses 2205
5.3 Front Shovel Attachment (FSA) .2208
5.3.1 Overview 2208
5.3.2 Using the Cylinder Mounting Device for Front shovel attachments (PN 967 000 40) .2210
5.3.2.1 Designated usage 2211
5.3.2.2 Non-designated usage 2211
5.3.3 Boom assembly .2212
5.3.3.1 Disassembling of the boom .2212
5.3.3.2 Assembling of the boom 2215
5.3.3.3 Disassembling of the boom cylinders .2218
5.3.3.4 Assembling of the boom cylinders 2223
5.3.4 Stick assembly 2228
5.3.4.1 Disassembling of the stick 2228
5.3.4.2 Assembling of the stick .2233
5.3.4.3 Disassembling of the stick cylinders 2238
5.3.4.4 Assembling of the stick cylinders .2242
5.3.5 Bull Clam bucket 2246
5.3.5.1 Disassembling of the bull clam bucket .2246
5.3.5.2 Assembling of the bull clam bucket 2250
5.3.5.3 Disassembling of the bucket cylinders .2254
5.3.5.4 Assembling of the bucket cylinders 2260
5.3.5.5 Disassembling of the clam cylinders .2266
5.3.5.6 Assembling of the clam cylinders 2271
5.3.6 Hydraulic hoses at the Faceshovel attachment 2277
5.3.6.1 Replacing of the boom arc hoses .2277
5.3.6.2 Replacing of the lubrication hoses 2280
5.3.6.3 Replacing of the boom cylinder hoses 2281
5.3.6.4 Replacing of the stick arc hoses 2284
5.3.6.5 Replacing of the stick cylinder hoses .2287
5.3.6.6 Replacing of the bucket cylinder hoses 2290
5.3.6.7 Replacing of the clam cylinder hoses 2292
5.4 Metering valves (grease injectors) at the attachment 2298
5.4.1 Disassembling of the metering valves (grease injectors) .2298
5.4.2 Assembling of the metering valves (grease injectors) 2300
5.5 Ground engaging tools (GET) .2301
5.5.1 Disassembling and assembling of the GET .2301
5.6 Cylinder bypass test 2303
6 Service Information .2305
6.1 Fluids and lubricants .2306
6.2 Lifting Gears .2306
6.3 Safety hints for sling accessory 2308
6.4 Weight tables .2309
6.4.1 Superstructure 2309
6.4.2 Undercarriage .2311
6.4.3 Backhoe attachment (BHA) 2312
6.4.4 Face shovel attachment (FSA) 2313
6.5 Torque charts according to KOMATSU company standard .2314
6.5.1 Metric standard thread 2314
6.5.2 Metric fine thread 2315
6.5.3 Cummins motor torques – metric 2316
6.5.4 Cummins motor torques – U.S. customary 2316
6.5.5 SAE-flange connections 2317
6.6 Blind plugs .2318
6.6.1 Dummy plates for SAE–flanges 2318
6.6.2 Classification of threads to the nominal width 2320
6.6.3 Plugs and fittings according to DIN 2353 2321
6.7 Conversion table 2322
6.7.1 Method of using the conversation table 2322
6.7.2 Millimeter – inch & kilogram – pound 2323
6.7.3 Liter – U.S. gallon & liter – U.K. gallon .2324
6.7.4 Nm- ft.lb .2325
6.7.5 Bar – PSI – kPa – MPa .2326
6.7.6 Temperature .2327
6.8 Tools .2328
6.8.1 Standard tool case 2328
6.8.2 Used special tools (Overview) .2330
6.9 Work instructions .2333
6.9.1 Bleeding the track tensioning system 2333
6.9.2 Hints for hydraulic hose installation .2335
6.9.3 Remove / install the crawler carrier 2338
6.9.4 Repair procedure for the radiator assembly 2339
7 Parts & Service News 2341
7.1 List of relevant PARTS AND SERVICE NEWS .2342

DESCRIPTION:

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08237 – PDF DOWNLOAD

SERIAL NUMBER 08237 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

G.B 30/12/24

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08237 PDF

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08237 – PDF DOWNLOAD

Description

Komatsu PC4000-11 T2 Hydraulic Mining Shovel Shop Manual 08237 – PDF DOWNLOAD

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