Komatsu PC3400-11M0 Mining Excavator Shop Manual (SEN06694-06) (SN 36301-UP)
This Komatsu PC3400-11M0 Mining Excavator is a big mining shovel meant for heavy production work in pits and large quarries, not a small contractor machine. People who usually reach for the Komatsu PC3400-11M0 Mining Excavator Shop Manual (SEN06694-06) are field techs, mine-site mechanics, and rebuild shops trying to keep these units digging instead of parked. They’re usually chasing hard faults, planning major component swaps, or trying to avoid calling in the dealer for every issue. If that’s the kind of work you’re facing, this is the level of book you’re looking at.
What this manual helps you do
- Trace hydraulic faults through the circuits so you can confirm whether the problem is in a pump, valve bank, or actuator before ordering parts.
- Diagnose engine, electronic, and monitoring system issues using the kind of step-by-step checks most shops follow.
- Follow disassembly and reassembly sequences for major components like swing machinery, final drives, boom/stick cylinders, and structural groups.
- Check adjustment procedures for linkages, brakes, travel systems, and swing so the machine works the way it’s supposed to after repair.
- Verify test points and standard inspection steps during overhauls or pre-sale inspections to avoid missed damage and rework.
Who this is for
This is aimed at shop mechanics, dealer/field techs, and fleet maintenance leads who actually turn wrenches or supervise heavy repairs. Operators or managers just wanting basic daily checks or safety info will be happier with an Operation & Maintenance manual instead.
FAQ
Q: Is this a PDF I can search and print?
A: Yes, it’s a PDF you can search by keyword and print pages or sections as needed.
Q: Is it deep enough for full rebuild work?
A: This kind of shop manual usually covers workshop-level diagnostics, teardown, and assembly procedures for major systems and components.
Q: How do I know it matches my exact PC3400-11M0?
A: Check that your machine is a PC3400-11M0 and that your documentation cross-references SEN06694-06; for odd variants or special mine packages, you may need a supplemental manual.
Bottom line: If you’re repairing or rebuilding a PC3400-11M0 and want dealer-level guidance, this is what you want; if you just run the machine day to day, keep looking for the Operation & Maintenance book instead.
📘 Show Index
Komatsu PC3400-11M0 Mining Excavator Shop Manual (SEN06694-06) (SN 36301-UP) Index:
- 00 Foreword and Safety Instructions
- 1 FOREWORD
- 1.1 BEFORE READING THIS MANUAL
- 1.2 CONTENTS OF THIS BINDER
- 1.2.1 CONTACTING THE SERVICE
- 1.2.2 GUARANTEE
- 1.3 DIVISION OF THE BINDER
- 2 SAFETY
- 2.1 SAFETY INFORMATION
- 2.2 OVERVIEW
- 2.2.1 NORMAL OPERATIONS
- 2.2.2 REGULAR MAINTENANCE
- 2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR
- 2.2.4 ADDITIONAL SAFETY PRECAUTIONS
- 2.3 SOUND PRESSURE AND VIBRATION LEVELS INTHE OPERATOR’S CAB.
- 2.3.1 SOUND
- 2.3.2 VIBRATION
- 2.4 GENERAL PRECAUTIONS COMMON TO OPERATIONON THE EXCAVATOR
- 2.4.1 UNDERSTANDING THE EXCAVATOR
- 2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THEEXCAVATOR
- 2.4.3 PREPARATIONS FOR SAFE OPERATION
- 2.4.4 FIRE PREVENTION
- 2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR
- 2.4.6 BURN PREVENTION
- 2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS
- 2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
- 2.4.9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTEDDEBRIS
- 2.4.10 ELECTROMAGNETIC COMPATIBILITY (EMC)
- 2.4.11 PRECAUTIONS AT JOBSITE
- 2.4.12 STARTING MOTOR
- 2.4.13 OPERATION
- 2.5 PRECAUTION FOR MAINTENANCE
- 2.5.1 GENERAL PRECAUTIONS
- 2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE
- 2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID
- 2.6 ADDITIONAL SAFETY INFORMATIONFOR TROUBLESHOOTING AND ADJUSTMENTS
- 2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM
- 2.6.2 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNINGDURING ADJUSTMENTS
- 2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR
- 2.7 SPECIAL SAFETY EQUIPMENT
- 2.7.1 FRONT GUARD PROTECTIVE STRUCTURE ’FOPS’ FOROPERATOR’S CAB
- 2.7.2 OBJECT HANDLING
- 2.7.3 LIGHTING
- 2.7.4 WARNING BEACON
- 2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEANSTANDARD)
- 10 Structure & Function
- 1 Introduction
- 1.1 Foreword
- 1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining excavators
- 1.3 Explanation of abbreviations
- 1.4 Diagrams and illustrations in this manual
- 2 Specifications
- 2.1 Lifting Gears
- 2.2 Safety hints for sling accessory
- 2.3 Standard Tightening Torque Chart
- 2.4 Special Tightening Torques
- 2.5 Torque for flange Joints
- 2.6 Tightening Torque for hydraulic hose connecting nut
- 2.7 Conversion Table
- 2.8 Blind plugs
- 3 Main assembly groups
- 3.1 General overview
- 3.2 Superstructure
- 3.3 Machine house
- 3.4 Hydraulic oil tank
- 3.5 Hydraulic oil cooler
- 3.6 Fuel tank
- 3.7 Cab base
- 3.8 Operator’s cab
- 3.9 Air conditioning
- 3.10 Main control valves
- 3.11 Slew Gearbox
- 3.12 Undercarriage
- 3.13 Slew ring
- 3.14 attachment
- 3.14.1 Backhoe attachment (BHA)
- 3.14.2 Front shovel attachment (FSA)
- 3.15 Safety circuit
- 3.16 Counterweight
- 3.17 Lubrication system (SLS & CLS)
- 4 Drive
- 4.1 Prime drive assembly
- 4.2 Engine and PTO mounts
- 4.2.1 Engine Mounts
- 4.2.2 Torque Support
- 4.3 Flexible coupling
- 4.3.1 Information for maintenance
- 4.3.2 Coupling elements
- 4.3.3 Separation and assembly of the coupling inner and outer part
- 4.3.4 Operation troubles, causes, and rectification
- 4.4 Fan drive and radiator assembly
- 4.4.1 Fan motor & fan assembly
- 4.4.2 Radiator fan drive
- 4.4.3 Fan pump
- 4.4.4 Radiator fan drive speed measurement and fan reverse function
- 4.5 Pump distributor gearbox (PTO)
- 4.5.1 Pump spline lubrication
- 4.5.2 PTO lubrication and cooling
- 4.6 Hydraulic pumps – location, drive speed and flow rates
- 4.7 Air filter
- 5 Hydraulic oil tank
- 5.1 General layout
- 5.2 Hydraulic oil tank, location of the electric equipment
- 5.3 Suction oil tank with strainers
- 5.4 Bypass valve with strainer
- 5.5 Back pressure valve
- 5.6 Transfer pump
- 5.7 Return and leak oil filter
- 5.8 Breather filter
- 5.9 Hydraulic oil tank bleeding instruction
- 5.10 Return oil filter chamber sight gauge
- 6 Hydraulic oil cooling
- 6.1 Overall view of the hydraulic oil coolers
- 6.1.1 Fan motor & Fan assembly
- 6.1.2 Overall view of the hydraulic oil cooler fan drive circuit
- 6.1.3 Bypass valve
- 6.1.4 Bypass valve connections
- 6.2 Fan pump
- 6.3 Overview of the oil cooler circuit
- 6.3.1 Hydraulic oil cooling fan drive speed Measurement and fan reverse function
- 6.3.2 Inspection of the cooler core vibration absorbers
- 7 Controlling
- 7.1 General layout PPC line
- 7.2 Valve cartridge block
- 7.3 Pilot pressure supply
- 7.3.1 X1 pilot pressure circuit outline
- 7.3.2 X2 pilot pressure circuit outline
- 7.3.3 Pilot pressure circuit at main control valve blocks
- 7.3.4 Checks and adjustment of pilot pressure
- 7.4 Main control valves designation
- 7.5 Function of the electronic pump & bleed control system
- 7.5.1 Controller setting for Lever Control and Attachment Type in the excavator Configuration
- 7.5.2 Electronic hand lever (joystick)
- 7.6 Foot pedal control
- 7.7 Hand lever & foot pedal monitoring
- 7.7.1 Lever monitoring screens (example)
- 7.7.2 PPC signal information screen (example)
- 7.7.3 Solenoid Valve monitoring PPC circuit
- 7.8 Valve solenoid adjustment
- 7.8.1 Overview sol min/max current & adjustment range
- 7.9 ACCEL & DECEL time adjustment
- 7.9.1 Accel & Decel times
- 8 Components
- 8.1 Main control valves overview (BHA)
- 8.2 Main control valves overview (FSA)
- 8.3 Main control valve designation (BHA)
- 8.3.1 Rear side
- 8.3.2 Front side
- 8.4 Main control valve designation (FSA)
- 8.4.1 Rear side
- 8.4.2 Front side
- 8.5 Main control valves designation
- 8.6 Main control valve
- 8.7 Main control valve 3
- 8.8 Boom operation sample MCV 2 (BHA)
- 8.8.1 Neutral position
- 8.8.2 Boom raise
- 8.8.3 Boom lower
- 8.9 Spool types
- 8.10 Main control valves spool functions (BHA)
- 8.10.1 Main control valve 1
- 8.10.2 Main control valve 2
- 8.10.3 Main control valve 3
- 8.11 Main control valves spool functions (FSA)
- 8.11.1 Main control valve 1
- 8.11.2 Main control valve 2
- 8.11.3 Main control valve 3
- 8.12 Slow return valve
- 8.13 4/3 Directional solenoid valves
- 8.14 Solenoid valves
- 8.14.1 Operation of solenoid valve and check valve
- 8.15 Solenoid valve
- 8.16 EPC solenoid valve
- 8.17 High-pressure screen
- 8.18 Main relief valve
- 8.19 Suction & safety relief valve (SSRV)
- 8.20 Suction valve (SV)
- 8.21 Load check valve
- 8.22 Variable back pressure valve
- 8.23 Boom regeneration valve
- 8.24 Hydraulic cylinder
- 8.24.1 BHA Bucket cylinder (Example)
- 8.24.2 Stick cylinder
- 8.24.3 Boom cylinder
- 8.24.4 Cylinder data markings
- 8.24.5 Floating valve for stick and boom (FSA)
- 9 Main hydraulic pumps and pump regulation
- 9.1 General
- 9.1.1 Main pump and auxiliary pump bleeding procedure
- 9.1.2 Pump locations and pump datas
- 9.2 Main pumps
- 9.2.1 Hydraulic pump type HPV375+375
- 9.2.2 Servo valve
- 9.3 Electronic pump regulation system
- 9.3.1 Cut-off function
- 9.3.2 Temperature control
- 9.4 Valve controller (14K303 – 14K305)
- 9.5 Monitoring, error indication, adjustment
- 9.5.1 Monitoring items of the three Valve controllers
- 9.5.2 Error indication of the Three valve controllers
- 9.5.3 Adjustable parameters of the Three valve controllers
- 9.6 Checks and adjustments
- 9.6.1 Engine power check
- 9.6.2 Pump calibration
- 9.7 Engine speed sensor (pick-up)
- 9.7.1 General
- 9.7.2 Engine speed sensor (pick-up) adjustment
- 10 Operating hydraulics
- 10.1 General
- 10.1.1 3-circuit hydraulic system
- 10.1.2 Floating system (FSA only)
- 10.2 Hydraulics for the attachment cyLinders
- 10.2.1 Electric / hydraulic flowchart "boom up" (BHA)
- 10.2.2 Electric / hydraulic flowchart "boom up" (FSA)
- 10.2.3 Electric / hydraulic flowchart "Boom down" (BHA)
- 10.2.4 Electric / hydraulic flowchart "Boom down" (FSA)
- 10.2.5 Electric / hydraulic flowchart "Stick out" (BHA)
- 10.2.6 Electric / hydraulic flowchart "Stick out" (FSA)
- 10.2.7 Electric / hydraulic flowchart "Stick in" (BHA)
- 10.2.8 Electric / hydraulic flowchart "Stick in" (FSA)
- 10.2.9 Electric / hydraulic flowchart "Bucket fill" (BHA)
- 10.2.10 Electric / hydraulic flowchart "Bucket fill" (FSA)
- 10.2.11 Electric / hydraulic flowchart "Bucket dump" (BHA)
- 10.2.12 Electric / hydraulic flowchart "Bucket dump" (FSA)
- 10.2.13 Electric / hydraulic flowchart "Clam open" (FSA)
- 10.2.14 Electric / hydraulic flowchart "Clam close" (FSA)
- 10.2.15 Checks & adjustments of the main relief valve (MRV)
- 10.2.16 Checks and adjustments of the lowering speed
- 10.2.17 Cushion function
- 10.3 Hydraulics for the slew circuit
- 10.3.1 Slew circuit
- 10.3.2 Slew motor
- 10.3.3 Slew gearbox
- 10.3.4 Slew parking brake
- 10.3.5 Slew brake valve
- 10.3.6 Double stage valve (DSV)
- 10.3.7 Electric / hydraulic flowchart "Slew left"
- 10.3.8 Electric / hydraulic flowchart "Slew right"
- 10.3.9 Checks for the slew circuit
- 10.3.10 Slew parking brake release function check
- 10.4 Hydraulics for the travel system
- 10.4.1 Travel circuit
- 10.4.2 Travel motor
- 10.4.3 Rotary joint
- 10.4.4 Travel gearbox
- 10.4.5 Travel parking brake
- 10.5 Travel brake valve
- 10.5.1 Electric / hydraulic flowchart "travel forward"
- 10.5.2 Electric / hydraulic flowchart "travel backwards"
- 10.5.3 Checks and adjustments
- 11 Hydraulic track tensioning system
- 11.1 General
- 11.2 Functional description
- 11.2.1 Valve cartridge block
- 11.2.2 Rotary joint
- 11.2.3 Track tensioning Valve block
- 11.2.4 Accumulator second stage
- 11.2.5 Accumulator first stage
- 11.2.6 Track tensioning cylinder
- 11.3 Tensioning cylinder
- 11.4 Double stage valve
- 11.5 Checks / Adjustments
- 12 Access stairway, hydraulically operated
- 12.1 General
- 12.2 Function of the hydraulically operated access stairway
- 12.3 Hydraulic schematic stairway movement
- 13 Central refilling system (Service arm)
- 13.1 General
- 13.2 Service arm connections
- 13.3 Refilling system layout
- 13.4 Grease refill and Auto Stop function
- 13.5 Function
- 14 Symbol explanation of hydraulic diagram
- 14.1 Reference code of the hydraulic components
- 14.1.1 Area code
- 14.1.2 Component identifying letter
- 14.2 Hydraulic symbols
- 14.2.1 Lines, unions
- 14.2.2 Components, valves
- 14.2.3 Sensors
- 14.2.4 Valves, valve components
- 14.2.5 Pump, motor, cylinder
- 14.3 Hydraulic circuit diagram
- 14.3.1 HYDRAULIC CIRCUIT DIAGRAM (BHA) (1/1)
- 14.3.2 HYDRAULIC CIRCUIT DIAGRAM (FSA) (1/2)
- 14.3.3 HYDRAULIC CIRCUIT DIAGRAM (FSA) (2/2)
- 15 Symbol explanation electric wiring diagram
- 15.1 Reference code of the electrical components
- 15.1.1 Area code
- 15.1.2 Component identifying letter
- 15.2 Cable and connector marking
- 15.3 Cable color identification
- 15.4 ELECTRICAL CIRCUIT DIAGRAM
- 15.4.1 ELECTRICAL CIRCUIT DIAGRAM (1/35)
- 15.4.2 ELECTRICAL CIRCUIT DIAGRAM (2/35)
- 15.4.3 ELECTRICAL CIRCUIT DIAGRAM (3/35)
- 15.4.4 ELECTRICAL CIRCUIT DIAGRAM (4/35)
- 15.4.5 ELECTRICAL CIRCUIT DIAGRAM (5/35)
- 15.4.6 ELECTRICAL CIRCUIT DIAGRAM (6/35)
- 15.4.7 ELECTRICAL CIRCUIT DIAGRAM (7/35)
- 15.4.8 ELECTRICAL CIRCUIT DIAGRAM (8/35)
- 15.4.9 ELECTRICAL CIRCUIT DIAGRAM (9/35)
- 15.4.10 ELECTRICAL CIRCUIT DIAGRAM (10/35)
- 15.4.11 ELECTRICAL CIRCUIT DIAGRAM (11/35)
- 15.4.12 ELECTRICAL CIRCUIT DIAGRAM (12/35)
- 15.4.13 ELECTRICAL CIRCUIT DIAGRAM (13/35)
- 15.4.14 ELECTRICAL CIRCUIT DIAGRAM (14/35)
- 15.4.15 ELECTRICAL CIRCUIT DIAGRAM (15/35)
- 15.4.16 ELECTRICAL CIRCUIT DIAGRAM (16/35)
- 15.4.17 ELECTRICAL CIRCUIT DIAGRAM (17/35)
- 15.4.18 ELECTRICAL CIRCUIT DIAGRAM (18/35)
- 15.4.19 ELECTRICAL CIRCUIT DIAGRAM (19/35)
- 15.4.20 ELECTRICAL CIRCUIT DIAGRAM (20/35)
- 15.4.21 ELECTRICAL CIRCUIT DIAGRAM (21/35)
- 15.4.22 ELECTRICAL CIRCUIT DIAGRAM (22/35)
- 15.4.23 ELECTRICAL CIRCUIT DIAGRAM (23/35)
- 15.4.24 ELECTRICAL CIRCUIT DIAGRAM (24/35)
- 15.4.25 ELECTRICAL CIRCUIT DIAGRAM (25/35)
- 15.4.26 ELECTRICAL CIRCUIT DIAGRAM (26/35)
- 15.4.27 ELECTRICAL CIRCUIT DIAGRAM (27/35)
- 15.4.28 ELECTRICAL CIRCUIT DIAGRAM (28/35)
- 15.4.29 ELECTRICAL CIRCUIT DIAGRAM (29/35)
- 15.4.30 ELECTRICAL CIRCUIT DIAGRAM (30/35)
- 15.4.31 ELECTRICAL CIRCUIT DIAGRAM (31/35)
- 15.4.32 ELECTRICAL CIRCUIT DIAGRAM (32/35)
- 15.4.33 ELECTRICAL CIRCUIT DIAGRAM (33/35)
- 15.4.34 ELECTRICAL CIRCUIT DIAGRAM (34/35)
- 15.4.35 ELECTRICAL CIRCUIT DIAGRAM (35/35)
- 15.4.36 INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (1/6)
- 15.4.37 INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (2/6)
- 15.4.38 INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (3/6)
- 15.4.39 INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (4/6)
- 15.4.40 INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (5/6)
- 15.4.41 INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (6/6)
- 16 Monitoring & Control System
- 16.1 General
- 16.1.1 Monitoring & control system – overview
- 16.1.2 Controller system overview PC3400-11M0
- 16.1.3 Interface connection
- 16.1.4 General description
- 16.2 Machine monitor – Operator level
- 16.2.1 Main gauge screens
- 16.2.2 Operator menus / Tabs / functions of keys F1…F6
- 16.3 Error and status indication on the operator level
- 16.3.1 Prompts (status indications)
- 16.3.2 Lock lever locked automatically
- 16.3.3 Cautions
- 16.3.4 Emergency shutdown screen
- 16.3.5 Fault levels for error messages
- 16.3.6 Action code level L01
- 16.3.7 Action code level L02
- 16.3.8 Action code level L03
- 16.3.9 Action code level L04
- 16.3.10 Error list
- 16.3.11 Failure codes without monitor indication
- 16.3.12 Additional text information for action codes
- 16.4 Table of failure codes
- 16.5 Table of C-codes – Diesel engine Tier2
- 16.6 Flow charts of machine monitor screens
- 16.6.1 Flow chart Operator Level
- 16.6.2 Flow chart Service Level
- 16.7 Machine monitor
- 16.7.1 Entering the Service Level
- 16.7.2 Softkey symbols (F1…F6) on the Service Level
- 16.7.3 Service Menu selection screens
- 16.8 Service Menu – item 01 Monitoring / Custom
- 16.8.1 Monitoring list for: ENG controller
- 16.8.2 Monitoring list for: VALVE M controller
- 16.8.3 Monitoring list for: VALVE 1 controller
- 16.8.4 Monitoring list for: VALVE 2 controller
- 16.8.5 Monitoring list for: VALVE 3 controller
- 16.8.6 Monitoring list for: MON (monitor)
- 16.8.7 Monitoring list for: KOM PLS (K+ controller)
- 16.8.8 How to perform the monitoring function
- 16.9 Service Menu – item 02 PM Clinic
- 16.9.1 PM Clinic (General)
- 16.9.2 PM Clinic (Power Check)
- 16.9.3 Functions of PM CLINIC (POWER CHECK)
- 16.10 Service Menu – item 03 Abnormality record
- 16.10.1 Reset error messages
- 16.11 Service Menu – item 04 Maintenance record
- 16.12 Service Menu – item 05 Maintenance Mode Setting
- 16.13 Service Menu – item 06 Snap Shot
- 16.14 Service Menu – item 07 Phone Number Entry
- 16.15 Service Menu – item 08 Default
- 16.16 Service Menu – item 09 Unit
- 16.17 Service Menu – item 10 Adjustment
- 16.17.1 Adjustments for: VALVE M controller
- 16.17.2 Accel & Decel times
- 16.17.3 Adjustments for: VALVE 1 controller
- 16.17.4 Adjustments for: VALVE 2 controller
- 16.17.5 Adjustments for: VALVE 3 controller
- 16.17.6 Adjustments for: MON (Monitor)
- 16.18 Service Menu – item 11 Machine Configuration
- 16.18.1 Details of Excavator Configuration for PC3400-11M0
- 16.18.2 Changing lever control from EURO to KG
- 16.18.3 Changing attachment type from FSA to BHA
- 16.18.4 In case of problems during changing procedure for lever control or attachment type
- 16.18.5 Hydraulic Oil & PTO Gear Oil Definition Tables
- 16.19 Service menu: item 12 Fan reverse mode
- 16.20 Service menu: Item 13 Cylinder Cushion control calibration
- 16.21 Service menu: Item 14 Pump calibration
- 16.21.1 All pump swash plate Sensor calibration
- 16.21.2 Pump I-q automatic calibration
- 16.21.3 In case of problems
- 16.22 Automatic engine speed control
- 16.22.1 Auto-Deceleration mode
- 16.22.2 Auto Low Idle mode
- 16.23 KOMTRAX Plus controller (UM600)
- 16.24 CR730 controller
- 16.24.1 Location of CR730 controllers
- 16.25 Controller replacement procedure
- 16.25.1 Sequence of the controller replacement procedure
- 16.25.2 After controller replacement
- 16.25.3 Controller location
- 17 Lubrication system
- 17.1 Lubrication system (SLS & CLS)
- 17.1.1 General description
- 17.2 Basic function of the lubrication systems
- 17.3 Grease refill and Auto Stop function
- 17.4 Lubrication System (CLS & SLS)
- 17.4.1 Lubrication pump station
- 17.4.2 Additional information on the SLS
- 17.4.3 Manual lube activation
- 17.5 Lubrication cycle
- 17.5.1 Operation and control
- 17.5.2 Lubrication cycle – processing
- 17.5.3 Time segments & switch points of a lubrication cycle
- 17.5.4 KOMTRAX PLUS pause time settings
- 17.6 Hydraulically driven lube pump
- 17.7 Lubricant injectors
- 17.7.1 Tightening torques for fittings at grease injectors
- 17.7.2 Description
- 17.7.3 Adjustment of the lubricant output
- 17.7.4 Operation principle of lubricant injectors
- 17.7.5 Connection of one or more SL-V injectors
- 17.8 Vent valve
- 17.8.1 Vent valve description
- 17.9 Lubricant level sensors
- 17.10 Commissioning
- 17.10.1 Commissioning of the CLS lubrication system
- 17.10.2 Fine adjustment
- 17.10.3 Commissioning of the SLS lubrication system
- 18 Deep temperature equipment (option)
- 18.1 General information
- 18.1.1 Introduction
- 18.1.2 Deep temperature components overview
- 18.1.3 Power supply preconditions for preheating
- 18.1.4 Power requirements for preheating systems
- 18.2 Preheating procedure
- 18.2.1 Global flow chart of the preheating procedure
- 18.2.2 Starting the preheating procedure
- 18.2.3 Preheating of operator's can and diesel engine [coolant system]
- 18.2.4 Preheating of lubricants and superstructure (diesel) [electric system]
- 18.3 Electric heating elements
- 18.3.1 Electric heating elements for hydraulics [diesel machine]
- 18.3.2 Electric heating elements for engines & batteries [diesel machine]
- 18.4 Components of TT equipment
- 18.4.1 Wiring diagrams for preheating systems
- 40 Troubleshooting
- 1 Introduction
- Precautions before work
- 1.1 Overview
- 1.1.1 General advice when using troubleshooting charts
- 1.2 General precautions
- 1.2.1 Excavator park position during maintenance & repair
- 2 General information for troubleshooting
- 2.1 Preparations for work
- 2.2 Precautions during work
- 2.3 Precautions when carrying out any operation
- 2.3.1 Precautions when carrying out removal work
- 2.3.2 Precautions when carrying out installation work
- 2.3.3 Precautions when completing the operation
- 2.4 Fundamental requirements for trouble shooting
- 2.4.1 Technical documentation
- 2.4.2 Tools
- 2.4.3 Personnel
- 2.5 Points to remember when troubleshooting
- 2.6 Sequence of events In troubleshooting
- 2.7 Checks before troubleshooting
- 2.8 Handling of electric equipment and hydraulic components
- 2.8.1 Points to remember when handling electric equipment
- 2.8.2 Points to remember when handling hydraulic equipment
- 2.9 General working procedures
- 2.9.1 Air bleeding of various hydraulic parts
- 2.9.2 Air bleeding from the hydraulic pumps (static)
- 2.9.3 Air bleeding from hydraulic cylinders (dynamic)
- 2.9.4 Cylinder bypass test
- 2.10 Basics about "How to crimp" (with strain relief)
- 2.10.1 Crimp tool & repair kit
- 2.10.2 General
- 2.10.3 Select the required connector components
- 2.10.4 Stripping a wire
- 2.10.5 Crimping
- 2.10.6 Connector assembly after crimping
- 2.11 Cable shielding
- 3 Mounting locations and connector types
- 3.1 Location of emergency shut off – , stairway and service arm lowering devices
- 3.2 Location of battery box and emergency stop switches
- 3.3 Location of service safety switch
- 3.4 Location of engine related electrical components
- 3.5 Location of fuel supply, PTO and hydraulic pumps electrical components
- 3.6 Location of valve cartridge block electrical components
- 3.7 Location of main blocks electrical components
- 3.8 Location of SLS and CLS electrical components
- 3.9 Location of SLS pressure sensor
- 3.10 Location of CLS pressure sensor
- 3.11 Location of fuel tank electrical components
- 3.12 Location of hydraulic oil cooler electrical components
- 3.13 Location of cab base electrical components (location 14)
- 3.14 Location of cab base electrical components (location 11)
- 3.15 Location of hydraulic oil tank & suction oil tank electrical components
- 3.16 Location of bypass valve electrical components
- 3.17 Location of electrical components on hydraulically operated access stairway
- 3.18 Location of service arm electrical components
- 3.19 Location of electrical components on cushion function
- 3.19.1 Location of electrical components on cushion function (BHA)
- 3.19.2 Location of electrical components on cushion function (FSA)
- 3.20 Location of electrical components on boom recirculation valve
- 3.21 Location of electrical components on distributor manifold
- 3.21.1 Location of electrical components on distributor manifold (BHA)
- 3.21.2 Location of electrical components on distributor manifold (FSA)
- 3.22 Location of electrical components for slew left/right circuit
- 3.23 Location of electrical components for travel circuit
- 3.24 Connector types overview
- 4 Standard value table for electrical components
- 5 Tables for testing and troubleshooting
- 5.1 Test value tables for pressure sensors
- 5.1.1 Pressure sensors
- 5.1.2 Hydraulic oil pressure Sensors
- 5.1.3 Miscellaneous Pressure Transducers
- 5.1.4 Temperature Sensors
- 5.2 Hydraulic oil temperature charts
- 5.3 PTO gear oil temperature charts
- 5.4 Table of failure codes
- 5.5 Table of C-codes – Diesel engine Tier2
- 5.6 Tables of symptom codes
- 5.6.1 Symptoms of the engine and related electrical systems
- 5.6.2 Symptoms of the hydraulic system
- 5.6.3 Symptoms of the mechanical system
- 5.6.4 Symptoms of additional systems
- 5.7 Cable color identification
- 6 Troubleshooting by trouble code
- B@HANS – Hyd Oil Overheat
- 6A1BMA – Trouble Shut-Off (gate) valve not open error
- AA10NX – Air Cleaner1 Clogging
- AB00KE – Charge Voltage Low
- B@F0MA – CLS Lubrication System Error
- B@CPMA – SLS Lubrication System Error
- B@F0N9 – CLS pressure increase time too long
- B@CPN9 – SLS pressure increase time too long
- B@F0N0 – CLS pressure decrease time too long
- B@CPN0 – SLS pressure decrease time too long
- B@F0ZK – CLS grease level too low
- B@CPZK – SLS grease level too low
- B@HAZK – Hydraulic oil level too low
- B@CBNS – PTO Gear Oil Temp High
- B@CBZG – PTO Gear Lubrication Error
- B@M9NX – PTO Gear Oil Filter Clogging
- B@HBNX – Return Oil Filter Clogging
- B@L4NX – Leak Oil Filter Clogging
- B@L5N9 – Pilot Press X2 Too Low
- B@L5N0 – Pilot Press X2 Too High
- B@BKPQ – Eng Remote Oil Tank1 Empty
- B@HANX – Screen At Hyd Cooler Entry Clogging
- AB30MA – Starter circuit abnormality
- 989HMA – Emergency stop line abnormality
- DGT3MA – PTO1 oil temperature sensor abnormality
- DGH2MA – Hydraulic oil temp sensor abnormality
- DHQ7MA – PTO1 lube pressure sensor abnormality
- DHPTMA – Radiator fan pump pressure sensor abnormality
- DHPUMA – Oil cooler fan pump pressure sensor abnormality
- D1E7KB – Starter cut relay short circuit
- DHPEMA – Pump-1 pressure sensor abnormality
- DHPGMA – Pump-2 pressure sensor abnormality
- DHPJMA – Pump-3 pressure sensor abnormality
- DBY7KP – 24 V sensor power abnormality VALVE 2
- DBW7KP – 24 V sensor power abnormality VALVE M
- DBW6KP- 5 V sensor2 power abnormality
- DBX6KP- 5 V sensor2 power abnormality
- DBY6KP- 5 V sensor2 power abnormality
- F816KP- 5 V sensor2 power abnormality
- DBW2KK- Solenoid power low error (VALVE M Con)
- DBX2KK- Solenoid power low error (VALVE 1 Con)
- DBY2KK- Solenoid power low error (VALVE 2 Con)
- F812KK- Solenoid power low error (VALVE 3 Con)
- DW4BMA – Travel parking brake solenoid circuit abnormality
- DXAAKA – Pump1F Solenoid open circuit
- DXABKA – Pump1R Solenoid open circuit
- DXACKA – Pump2F Solenoid open circuit
- DXADKA – Pump2R Solenoid open circuit
- DXAEKA – Pump3F Solenoid open circuit
- DXAFKA – Pump3R Solenoid open circuit
- DXAAKB – Pump1F Solenoid short circuit
- DXABKB – Pump1R Solenoid short circuit
- DXACKB – Pump2F Solenoid short circuit
- DXADKB – Pump2R Solenoid short circuit
- DXAEKB – Pump3F Solenoid short circuit
- DXAFKB – Pump3R Solenoid short circuit
- DWA5KA – CLS pump solenoid open circuit
- DWA8KA – SLS pump solenoid open circuit
- DWA7KA – CLS line release solenoid open circuit
- DWA9KA – SLS lube line release sol. open circuit
- DWA5KB – CLS pump solenoid short circuit
- DWA8KB – SLS pump solenoid short circuit
- DWA7KB – CLS line release solenoid short circuit
- DWA9KB – SLS lube line release solenoid short circuit
- DWA5KY – CLS pump solenoid hot short circuit
- DWA8KY – SLS pump solenoid hot short circuit
- DWA7KY – CLS line release sol. hot short circuit
- DWA9KY – SLS lube line release sol hot short circuit
- DWAAKA – PTO lube pre-load solenoid open circuit
- DWAAKB – PTO lube pre-load solenoid short circuit
- DWAAKY – PTO lube pre-load sol. hot short circuit
- D1E9KB – Lower wiper move relay short circuit
- D1EBKB – Lower wiper brake relay short circuit
- D1EAKB – Upper wiper move relay short
- D1ECKB – Upper wiper brake relay short
- D162KB – Horn relay short circuit
- D1F0KA – Engine1/motor1 shutdown relay open circuit
- D1F0KB – Engine1/motor1 shutdown relay short circuit
- D1F0KY – Engine1/motor1 shutdown relay hot short circuit
- D1FBKA – Solenoid power self-holding relay open circuit
- D1FBKB – Solenoid power self-holding relay short circuit
- D110KA – Battery relay open circuit
- D110KB – Battery relay short circuit
- DBWWKQ – Motor/Engine selection abnormality
- DBXWKQ – Motor/Engine selection abnormality
- DBYWKQ – Motor/Engine selection abnormality
- F81WKQ- Motor/Engine selection abnormality
- DBWXKQ – Motor1 frequency select abnormality
- DBW0KQ – VALVE M Con selection abnormality
- DBX0KQ – VALVE 1 Con selection abnormality
- DBY0KQ – VALVE 2 Con selection abnormality
- F810KQ – VALVE 3 Con selection abnormality
- DDABL4 – Lock lever switch mismatch
- DKURMA – R lever right-left potentio abnormality
- DKUSMA – R lever right-left redundant pot. abnormality (VALVE M)
- DKUQL8 – R lever right-left potentio error
- DKUQL4 – R lever right-left signal mismatch (VALVE M)
- DKUNMA – R lever front-back potentio abnormality
- DKUPMA – R lever front-back redu pot abnorm (VALVE M)
- DKUML8 – R lever front-back potentio error
- DKUML4 – R lever front-back sig. mismatch (VALVE M)
- DKUXMA – Left lever right-left potentio abnormality
- DKUYMA – L lever right-left redu pot abnorm (VALVE M)
- DKUWL8 – L lever right-left potentio error
- DKUWL4 – L lever right-left sig. mismatch (VALVE M)
- DKUUMA – L lever front-back potentio abnormality
- DKUVMA – L lever front-back redu pot abnorm (VALVE M)
- DKUTL8 – L lever front-back potentio error
- DKUTL4 – L lever front-back sig. mismatch (VALVE M)
- DKW1MA – R pedal potentio abnormality
- DKW2MA – R pedal redundant pot abnormality (VALVE M)
- DKW0L8 – R pedal potentio error
- DKW0L4 – R pedal signal mismatch (VALVE M Con)
- DKW4MA – L pedal potentio abnormality
- DKW5MA – L pedal redundant pot abnormality (VALVE M)
- DKW3L8 – L pedal potentio error
- DKW3L4 – L pedal signal mismatch (VALVE M Con)
- DKW7MA – Clam open potentio abnormality
- DKW8MA – Clam open redu pot abnormality(VALVE/M)
- DKW6L8 – Clam open potentio error
- DKW6L4 – Clam open signal mismatch(VALVE/M Con)
- DKWAMA – Clam close potentio abnormality
- DKWBMA – Clam close redundant pot abnorm(VALVE/M)
- DKW9L8 – Clam close potentio error
- DKW9L4 – Clam close signal mismatch(VALVE/M Con)
- DKWDMA – Hydraulic slew brake potentio abnormality
- DKWEMA – Hyd. slew brake redu pot abnorm (VALVE M)
- DKWCL8 – Hydraulic slew brake potentio error
- DKWCL4 – Hyd. slew brake sig. mismatch (VALVE M)
- DLM3KA – Radiator fan 1 speed sensor open circuit
- DLM9KA – Radiator fan 2 speed sensor open circuit
- DLM8KA – Oil cooler fan 1 speed sensor open circuit
- DLMAKA – Oil cooler fan 2 speed sensor open circuit
- DLM3KB – Radiator fan 1 speed sensor short circuit
- DLM9KB – Radiator fan 2 speed sensor short circuit
- DLM8KA – Oil cooler fan 1 speed sensor short circuit
- DLMAKB – Oil cooler fan 2 speed sensor short circuit
- DLM3MB – Radiator fan speed sensor drift
- DLM8MB – Oil cooler fan speed sensor drift
- DWM2KA – VALVE 1 W/E PPC pressure shut off valve solenoid open circuit
- DWM3KA – VALVE 2 W/E PPC pressure shut off valve solenoid open circuit
- DWM4KA – VALVE 3 W/E PPC pressure shut off valve solenoid open circuit
- DWM2KB – VALVE 1 W/E PPC pressure shut off valve solenoid short circuit
- DWM3KB – VALVE 2 W/E PPC pressure shut off valve solenoid short circuit
- DWM4KB – VALVE 3 W/E PPC pressure shut off valve solenoid short circuit
- DWM2KY – VALVE 1 W/E PPC press. shut off valve solenoid hot short circuit
- DWM3KY – VALVE 2 W/E PPC press. shut off valve solenoid hot short circuit
- DWM4KY – VALVE 3 W/E PPC press. shut off valve solenoid hot short circuit
- DWM5KA – Travel left PPC pressure shut off valve solenoid open circuit
- DWM7KA – Travel right PPC pressure shut off valve solenoid open circuit
- DWM6KA – Slew PPC pressure shut off valve solenoid open circuit
- DWM5KB – Travel left PPC pressure shut off valve solenoid short circuit
- DWM7KB – Travel right PPC pressure shut off valve solenoid short circuit
- DWM5KY – Travel left PPC pressure shut off valve solenoid hot short circuit
- DWM7KY – Travel right PPC pressure shut off valve solenoid hot short circuit
- DWM6KB – Slew PPC pressure shut off valve solenoid short circuit
- DWM6KY – Slew PPC pressure shut off valve solenoid hot short circuit
- DWM8KA – Boom recirculation valve PPC pressure shut off valve 1 solenoid open circuit
- DWMEKA – Boom recirculation valve PPC pressure shut off valve 2 solenoid open circuit
- DWM8KB – Boom recirculation valve PPC pressure shut off valve 1 solenoid short circuit
- DWMEKB – Boom recirculation valve PPC pressure shut off valve 2 solenoid short circuit
- DWM8KY – Boom recirculation valve PPC pressure shut off valve 1 solenoid hot short circuit
- DWMEKY – Boom recirculation valve PPC pressure shut off valve 2 solenoid hot short circuit
- DWNCKA – Oil cooler fan pump solenoid open circuit
- DWN5KA – Radiator fan pump solenoid open circuit
- DWNCKB – Oil cooler fan pump solenoid short circuit
- DWN5KB – Radiator fan pump solenoid short circuit
- DXQ0KA – Control pump solenoid open circuit
- DXQ0KB – Control pump solenoid short circuit
- DW7BKA – Radiator fan 1 reverse solenoid open circuit
- DW7XKA – Radiator fan 2 reverse solenoid open circuit
- DW7BKB – Radiator fan 1 reverse solenoid short circuit
- DW7BKY – Radiator fan 1 reverse solenoid hot short circuit
- DW7HKA – Oil cooler fan 1 reverse solenoid open circuit
- DW7HKB – Oil cooler fan 1 reverse solenoid short circuit
- DW7YKB – Oil cooler fan 2 reverse solenoid short circuit
- DW7HKY – Oil cooler fan 1 reverse solenoid hot short circuit
- DW7YKY – Oil cooler fan 2 reverse solenoid hot short circuit
- DWNPKA – Service arm up solenoid open circuit
- DWNPKB – Service arm up solenoid short circuit
- DWNPKY – Service arm up solenoid hot short circuit
- DWNQKA – Service arm down solenoid open circuit
- DWNQKB – Service arm down solenoid short circuit
- DWNQKY – Service arm down solenoid hot short circuit
- DW4BKA – Travel parking brake solenoid open circuit
- DW4BKB – Travel parking brake sol. short circuit
- DW4BKY – Travel parking brake sol. hot short circuit
- DW45KA – Slew parking brake solenoid open circuit
- DW45KB – Slew parking brake solenoid short circuit
- DW45KY – Slew parking brake sol. hot short circuit
- DW45MA – Slew parking brake solenoid circuit abnormality
- DXR0KA – Bleed valve1 solenoid open circuit
- DXR1KA – Bleed valve2 solenoid open circuit
- DXR2KA – Bleed valve3 solenoid open circuit
- DXR0KB – Bleed valve1 solenoid short circuit
- DXR1KB – Bleed valve2 solenoid short circuit
- DXR2KB – Bleed valve3 solenoid short circuit
- DXR0KY – Bleed valve1 solenoid hot short circuit
- DXR1KY – Bleed valve2 solenoid hot short circuit
- DXR2KY – Bleed valve3 solenoid hot short circuit
- DKY4MA – Bleed valve1 stroke main sensor abnormality
- DKY5MA – Bleed valve2 stroke main sensor abnormality
- DKY6MA – Bleed valve3 stroke main sensor abnormality
- DKY7MA – Bleed valve1 stroke sub sensor abnormality
- DKY8MA – Bleed valve2 stroke sub sensor abnormality
- DKY9MA – Bleed valve3 stroke sub sensor abnormality
- DKV0MA – Boom valve1 stroke main sensor abnormality
- DKV1MA – Stick valve1 stroke main sensor abnormality
- DKYEMA – Bucket valve1 stroke main sensor abnormality
- DKYAMA – Boom valve2 stroke main sensor abnormality
- DKYCMA – Stick valve2 stroke main sensor abnormality
- DKYFMA – Bucket valve2 stroke main sensor abnormality
- DKYBMA – Boom valve3 stroke main sensor abnormality
- DKYDMA – Stick valve3 stroke main sensor abnormality
- DKYGMA – Bucket valve3 stroke main sensor abnormality
- DKYKMA – Slew valve3 stroke main sensor abnormality
- DHF1MA – Slew left pressure sensor abnormality
- DHF2MA – Slew right pressure sensor abnormality
- DHF3MA – Travel left forward pressure sensor abnormality
- DHF4MA – Travel left backward pressure sensor abnormality
- DHF5MA- Travel right forward pressure sensor abnormality
- DHF6MA – Travel right backward pressure sensor abnormality
- DKTKMA – Boom bottom pressure sensor abnormality
- DKTLMA – Boom head pressure sensor abnormality
- DKTMMA – Stick bottom pressure sensor abnormality
- DKTNMA – Stick head pressure sensor abnormality
- DKTPMA – Bucket bottom pressure sensor abnormality
- DKTQMA – Bucket head pressure sensor abnormality
- DKR0MA – Pump1F swash plate angle sensor abnormality
- DKR1MA – Pump1R swash plate angle sensor abnormality
- DKR5MA – Pump2F swash plate angle sensor abnormality
- DKR6MA – Pump2R swash plate angle sensor abnormality
- DKR7MA – Pump3F swash plate angle sensor abnormality
- DKR8MA – Pump3R swash plate angle sensor abnormality
- DXR3KA – Boom down valve1 solenoid open circuit
- DXR6KA – Boom up valve1 solenoid open circuit
- DXR9KA – Stick out valve1 solenoid open circuit
- DXRCKA – Stick in valve1 solenoid open circuit
- DXRFKA – Bucket dump valve1 solenoid open circuit
- DXRJKA – Bucket fill valve1 solenoid open circuit
- DXRMKA -Travel left forward valve1 solenoid open circuit
- DXRQKA -Travel left backward valve1 solenoid open circuit
- DXR4KA – Boom down valve2 solenoid open circuit
- DXR7KA – Boom up valve2 solenoid open circuit
- DXRAKA – Stick out valve2 solenoid open circuit
- DXRDKA – Stick in valve2 solenoid open circuit
- DXRGKA – Bucket dump valve2 solenoid open circuit
- DXRKKA – Bucket fill valve2 solenoid open circuit
- DXRNKA -Travel right forward valve2 solenoid open circuit
- DXRRKA -Travel right backward valve2 solenoid open circuit
- DXR5KA – Boom down valve3 solenoid open circuit
- DXR8KA – Boom up valve3 solenoid open circuit
- DXRBKA – Stick out valve3 solenoid open circuit
- DXREKA – Stick in valve3 solenoid open circuit
- DXRHKA – Bucket dump valve3 solenoid open circuit
- DXRLKA – Bucket fill valve3 solenoid open circuit
- DXRPKA – Slew left valve3 solenoid open circuit
- DXRSKA – Slew right valve3 solenoid open circuit
- DXR3KB – Boom down valve1 solenoid short circuit
- DXR6KB – Boom up valve1 solenoid short circuit
- DXR9KB – Stick out valve1 solenoid short circuit
- DXRCKB – Stick in valve1 solenoid short circuit
- DXRFKB – Bucket dump valve1 solenoid short circuit
- DXRJKB – Bucket fill valve1 solenoid short circuit
- DXRMKB – Travel left forward valve1 solenoid short circuit
- DXRQKB – Travel left backward valve1 solenoid short circuit
- DXR4KB – Boom down valve2 solenoid short circuit
- DXR7KB – Boom up valve2 solenoid short circuit
- DXRAKB – Stick out valve2 solenoid short circuit
- DXRDKB – Stick in valve2 solenoid short circuit
- DXRGKB – Bucket dump valve2 solenoid short circuit
- DXRKKB – Bucket fill valve2 solenoid short circuit
- DXRNKB – Travel right forward valve2 solenoid short circuit
- DXRRKB – Travel right backward valve2 solenoid short circuit
- DXR5KB – Boom down valve3 solenoid short circuit
- DXR8KB – Boom up valve3 solenoid short circuit
- DXRBKB – Stick out valve3 solenoid short circuit
- DXREKB – Stick in valve3 solenoid short circuit
- DXRHKB – Bucket dump valve3 solenoid short circuit
- DXRLKB – Bucket fill valve3 solenoid short circuit
- DXRPKB – Slew left valve3 solenoid short circuit
- DXRSKB – Slew right valve3 solenoid short circuit
- DXR3KY – Boom down valve1 solenoid hot short circuit
- DXR6KY – Boom up valve1 solenoid hot short circuit
- DXR9KY – Stick out valve1 solenoid hot short circuit
- DXRCKY – Stick in valve1 solenoid hot short circuit
- DXRFKY – Bucket dump valve1 solenoid hot short circuit
- DXRJKY – Bucket fill valve1 solenoid hot short circuit
- DXRMKY -Travel left forward valve1 solenoid hot short circuit
- DXRQKY -Travel left backward valve1 solenoid hot short circuit
- DXR4KY – Boom down valve2 solenoid hot short circuit
- DXR7KY – Boom up valve2 solenoid hot short circuit
- DXRAKY – Stick out valve2 solenoid hot short circuit
- DXRDKY – Stick in valve2 solenoid hot short circuit
- DXRGKY – Bucket dump valve2 solenoid hot short circuit
- DXRKKY – Bucket fill valve2 solenoid hot short circuit
- DXRNKY -Travel right forward valve2 solenoid hot short circuit
- DXRRKY -Travel right backward valve2 solenoid hot short circuit
- DXR5KY – Boom down valve3 solenoid hot short circuit
- DXR8KY – Boom up valve3 solenoid hot short circuit
- DXRBKY – Stick out valve3 solenoid hot short circuit
- DXREKY – Stick in valve3 solenoid hot short circuit
- DXRHKY – Bucket dump valve3 solenoid hot short circuit
- DXRLKY – Bucket fill valve3 solenoid hot short circuit
- DXRPKY – Slew left valve3 solenoid hot short circuit
- DXRSKY – Slew right valve3 solenoid hot short circuit
- DWACKA – Service arm check valve sol. open circuit
- DWACKB – Service arm check valve sol. short circuit
- DWACKY – Service arm check valve sol. hot short circuit
- DWADKA – Stairway speed control solenoid open circuit
- DWADKB – Stairway speed control sol. short circuit
- DWADKY – Stairway speed control sol. hot short circuit
- DBWZKQ – Lever control selection abnormality
- DBWYKQ – Attachment selection abnormality
- DBW2KK – Solenoid Power Low Error (VALVE M Con)
- DBW0KQ – VALVE M Con selection abnormality
- DDDWMC – Stairway operation switch abnormality
- DKWHMA – R lever right-left redu pot. abnorm (VALVE 1)
- DKWFL4 – R lever right-left sig. mismatch (VALVE 1)
- DKWLMA – R lever front-back redu. pot. abnormality (VALVE 1)
- DKWJL4 – R lever front-back sig. mismatch (VALVE 1)
- DKWPMA – Left lever right-left redu pot abnormality (VALVE 1)
- DKWML4 – L lever right-left sig. mismatch (VALVE 1)
- DKWSMA – L lever front-back redu pot abnormality (VALVE 1)
- DKWQL4 – L lever front-back sig. mismatch (VALVE 1)
- DKWVMA – R pedal red potentio abnormality (VALVE 1)
- DKWTL4 – R pedal signal mismatch (VALVE 1)
- DKWYMA – L pedal red potentio abnormality (VALVE 1)
- DKWWL4 – L pedal signal mismatch (VALVE 1)
- DKX8MA – Hydraulic slew brake redu pot abnorm (VALVE 1)
- DKX6L4 – Hyd. slew brake signal mismatch (VALVE 1)
- DY2CKA – Washer relay open circuit
- DY2CKB – Washer relay short circuit
- DY20MA – Lower wiper motion abnormality
- DY2FMA – Upper wiper motion abnormality
- DWNRMA – Stairway up solenoid circuit abnormality
- DWNRKB – Stairway up solenoid short circuit
- DWNRKY – Stairway up solenoid hot short circuit
- DKY0MA- Boom recirculation valve stroke main sensor abnormality
- DJKY1MA – Boom recirculation valve stroke sub sensor abnormality
- DHPSMA – CLS pressure sensor abnormality
- DHPZMA – SLS pressure sensor abnormality
- DXRTKA – Boom recirculation valve solenoid open circuit
- DXRTKB – Boom recirculation valve solenoid short circuit
- DXRTKY – Boom recirculation valve solenoid hot short circuit
- DW7RKA – Hydraulic slew brake solenoid open circuit
- DW7RKB – Hydraulic slew brake sol. short circuit
- DW7RKY – Hyd. slew brake sol. hot short circuit
- DW4CMA – PPC lock solenoid abnormality
- DKULMA – Lock lever PPC lock relay abnormality
- DKVRMA – Stairway up position PPC lock relay abnormality
- DKVSMA – Service arm position PPC lock relay abnormality
- D5ZWKB – Travel hour meter short circuit
- DBXZKQ – Lever Control Selection abnormality
- DBXYKQ – Attachment selection abnormality
- DDXAL4 – Stairway upper position proximity switch mismatch
- DDXBL4 – Service arm upper position proximity switch mismatch
- D5ZYKB – Engine oil present signal short circuit
- DKA0MA – Boom angle potentio abnormality
- DKC0MA- Stick angle potentio abnormality
- DXEDKA – Hydraulic slew brake EPC sol. open circuit
- DXEDKB – Hyd. slew brake EPC sol. short circuit
- DXEDKY – Hyd. slew brake EPC sol. hot short circuit
- DAF0KM – Inconsistency of KomVision setting
- DBYZKQ – Lever control selection abnormality
- F81ZKQ – Lever control selection abnormality
- DBYYKQ – Attachment selection abnormality
- F81YKQ – Attachment selection abnormality
- DWK2KA – Variable back pressure solenoid open circuit
- DWK2KB – Variable back pressure solenoid short circuit
- DWK2KY – Variable back pressure solenoid hot short circuit
- DH2GKX – Suction tank pressure sensor abnormality
- DH2HKX – Oil cooler pressure sensor abnormality
- DH2JKX – Pre-load valve return oil press abnormality
- DHSUKX – X2 pressure sensor abnormality
- DGE5MA – Ambient air temp sensor abnormality
- DH2KKX – Return oil chamber pressure sensor abnormality
- DH2LKX – Leak oil chamber press. sensor abnormality
- DH2PKX – Pump drain pressure3 sensor abnormality
- DH2NKX – Pump drain pressure2 sensor abnormality
- DH2MKX – Pump drain pressure1 sensor abnormality
- DKVAKX – X1 pressure sensor abnormality
- DH2QKX – Oil cooler pressure sensor2 abnormality
- DH2RKX- Hydraulic tank inner pressure sensor abnormality
- DJE5L4 – SLS sensor system abnormality
- DJE6L4 – CLS sensor system abnormality
- DBVLKA – Operating Lamp Open Circuit (KOMTRAX)
- DBPLKA – Operating Lamp Open Circuit (KomVision)
- DAFLKA – Operating Lamp Open Circuit (Monitor)
- F81LKA – Operating Lamp Open Circuit (VALVE 3 Con)
- DBYLKA – Operating Lamp Open Circuit (VALVE 2 Con)
- DBXLKA – Operating Lamp Open Circuit (VALVE 1 Con)
- DBWLKA – Operating Lamp Open Circuit (Valve M Con)
- DBVLKB – Operating Lamp Short Circuit (KOMTRAX)
- DBPLKB – Operating Lamp Short Circuit (KomVision)
- DAFLKB – Operating Lamp Short Circuit (Monitor)
- F81LKB – Operating Lamp Short Circuit (VALVE 3 Con)
- DBYLKB – Operating Lamp Short Circuit (VALVE 2 Con)
- DBXLKB – Operating Lamp Short Circuit (VALVE 1 Con)
- DBWLKB – Operating Lamp Short Circuit (Valve M Con)
- DBV1KK – KOMTRAX Plus source voltage Error
- DBV8KB – 5 V sensor0 power abnormality
- DBV5KB – 5 V sensor1 power abnormality
- DBW5KP – 5 V sensor1 power abnormality
- DBX5KP – 5 V sensor1 power abnormality
- DBY5KP – 5 V sensor1 power abnormality
- F815KP- 5 V sensor1 power abnormality
- DBV6KB – 24 V Sensor Power Abnormality
- DAFGMC – GPS Module Error
- D862KA – GPS Antenna Open Circuit
- DBVVKR – Ethernet 1 Disconnection
- DBVWKR – Ethernet 2 Disconnection
- DBWRKR – CAN 1 Discon (Valve M Con)
- DBXRKR – CAN 1 Discon (Valve 1 Con)
- DBYRKR – CAN 1 Discon (Valve 2 Con)
- F81RKR – CAN 1 Discon (Valve 3 Con)
- DB2QKR – CAN 2 Discon (Engine Con)
- DBWQKR – CAN 2 Discon (Valve M Con)
- DBXQKR – CAN 2 Discon (Valve 1 Con)
- DBYQKR – CAN 2 Discon (Valve 2 Con)
- F81QKR- CAN 2 Discon (Valve 3 Con)
- DBVRKR – CAN 1 Discon (KOMTRAX Plus)
- DBVQKR – CAN 2 Discon (KOMTRAX Plus)
- DBPRKR – CAN 1 Discon (KomVision)
- DBPQKR – CAN 2 Discon (KomVision)
- D19YKB – Step light relay short circuit
- DV00KB – Shutdown Buzzer Short Circuit
- DBP5KP – Camera power output low
- DBP0KM – KomVision Controller Setting Error
- DBP0MC – KomVision Controller run time error
- DBP0NR – KomVision controller high temperature error
- DBP0KT – KomVision Controller Internal Error
- DR10KA – Disconnection of Camera 1 NTSC Input
- DR20KA – Disconnection of Camera 2 NTSC Input
- DR30KA – Disconnection of Camera 3 NTSC Input
- DR40KA – Disconnection of Camera 4 NTSC Input
- DR50KA – Disconnection of Camera 5 NTSC Input
- DR60KA – Disconnection of Camera 6 NTSC Input
- DR90KA – Disconnection of Camera 7 NTSC Input
- 7 Troubleshooting by symptoms
- 7.1 Symptoms of the engine and related electrical system
- SEL001 – Engine does not start (engine does not rotate)
- SEL002 – Engine stops while in operation
- SEL003 – Engine speed is hunting during boom-up movement
- SEL004 – Engine does not stop
- SEL005 – Engine lacks output (no power)
- SEL006 – Engine does not start (pre-lube does not stop)
- SEL007 – Oil consumption is excessive
- SEL008 – Oil becomes contaminated quickly
- SEL009 – Fuel consumption is excessive
- SEL010 – Oil is in engine coolant
- SEL011 – Oil level rises
- SEL012 – Coolant temperature becomes too high (overheating)
- 7.2 Symptoms of the hydraulic system
- SHY001 – All the work equipment shows lack of power or slow movement (especially the "boom up" function)
- SHY002 – Engine speed sharply drops or engine stalls too much
- SHY003 – No work equipment, travel or slew movement
- SHY004 – Work equipment has too much hydraulic drift
- SHY005 – Work equipment has time lag
- SHY006 – Excavator deviates during travel movement
- SHY007 – Hydraulic system has lack of power
- SHY008 – Excavator does not slew
- SHY009 – Slew acceleration is poor
- SHY010 – Excessive overrun when stopping slew movement
- SHY011 – Abnormal noise coming from SSRV or MRV
- SHY012 – Floating system without function (FSA only)
- SHY013 – Track tensioning system without function
- SHY014 – Stairway does not move or slow movement
- SHY015 – Refilling arm does not move or slow movement
- SHY016 – Hydraulic driven grease pump does not move
- SHY017 – Abnormal track chain movement during digging
- SHY018 – Slew parking brake without function
- SHY019 – Travel parking brake without function
- 7.3 Symptoms of the mechanical system
- SME001 – Abnormal noise is made
- SME002 – Abnormal noise around the PTO / hydraulic pumps
- SME003 – Vibration is excessive (engine mountings)
- SME004 – Vibration is excessive (engine torsion)
- SME005 – There is a big shock when stopping slew movement
- SME006 – There is a big abnormal noise when moving / stopping slew movement
- SME007 – Fan blades make abnormal noise
- SME008 – Abnormal noise coming from a travel gearbox
- SME009 – Abnormal noise coming from the work equipment (lack of grease)
- SME010 – Abnormal idler movement
- SME011 – Leak at the PTO shaft seal
- 7.4 Symptoms of additional systems
- E-63 Air conditioner control panel does not turn on
- E-64 Wind does not com out from the air conditioner
- E-65 Air conditioner is weak in cold (electric capacitor does not move or only hi rotation moves)
- E-66 Air conditioner does not get cold (compressor does not move)
- PM-CLINIC
- 50 Disassembly & Assembly
- 1 Introduction
- Precautions before work
- 1.1 Foreword
- 1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels
- 1.3 Diagrams and illustrations in this manual
- 1.4 Procedures for disassembling and assembling in this manual
- 2 Safety
- 2.1 Overview
- 2.1.1 Method of using this manual
- 2.2 General precautions
- 2.2.1 General
- 2.2.2 Personal protective clothing
- 2.2.3 When using a hammer
- 2.2.4 Proper tools
- 2.2.5 Personnel
- 2.2.6 Fire prevention
- 2.2.7 Unauthorized modification
- 2.3 Precautions for maintenance and repair
- 2.3.1 General precautions
- 2.3.2 Keep work place clean and tidy
- 2.3.3 Precautions when welding
- 2.3.4 Precaution with high pressure fluids
- 2.3.4.1 Handling high pressure hoses and pipes
- 2.3.5 Compressed air
- 2.3.6 Waste materials
- 3 Superstructure
- 3.1 Superstructure overview
- 3.2 Machinery house
- 3.2.1 Machinery house roof
- 3.2.1.1 Disassembling of the machinery house roof cover plates
- 3.2.1.2 Assembling of the machinery house roof cover plates
- 3.2.2 Air intake system
- 3.2.2.1 Disassembling of the air intake system
- 3.2.2.2 Assembling of the air intake system
- 3.2.3 Exhaust system (SERIAL NO. FROM 36301 TO 36304)
- 3.2.3.1 Disassembling of the exhaust system
- 3.2.3.2 Assembling of the exhaust system
- 3.2.4 Exhaust system (SERIAL NO. 36305 AND UP)
- 3.2.4.1 Disassembling of the exhaust system
- 3.2.4.2 Assembling of the exhaust system
- 3.2.5 Diesel engine
- 3.2.5.1 Disassembling of the alternator
- 3.2.5.2 Assembling of the alternator
- 3.2.5.3 Disassembling of the starter motor
- 3.2.5.4 Assembling of the starter motor.
- 3.2.5.5 Disassembling of the Diesel engine
- 3.2.5.6 Assembling of the Diesel engine
- 3.2.6 Batteries
- 3.2.6.1 Disassembling of the batteries
- 3.2.6.2 Assembling of the batteries
- 3.2.7 Flexible coupling
- 3.2.7.1 Disassembling of the centaflex coupling assembly
- 3.2.7.2 Assembling of the centaflex coupling assembly
- 3.2.7.3 Replacing the rubber rollers of the centaflex coupling
- 3.2.8 Radiator fan and fan drive assembly.
- 3.2.8.1 Disassembling of the radiator fan assembly
- 3.2.8.2 Assembling of the radiator fan assembly
- 3.2.8.3 Disassembling of the radiator fan motor
- 3.2.8.4 Assembling of the radiator fan motor
- 3.2.8.5 Disassembling of the radiator assembly
- 3.2.8.6 Assembling of the radiator assembly
- 3.2.9 Main pump assemblies
- 3.2.9.1 Disassembling and assembling of the auxiliary pumps
- 3.2.9.2 Disassembling of the main pump assemblies
- 3.2.9.3 Assembling of the main pump assemblies
- 3.2.10 Universal PTO
- 3.2.10.1 Disassembling of the universal PTO
- 3.2.10.2 Assembling of the universal PTO
- 3.2.10.3 Disassembling of the PTO gear oil pump
- 3.2.10.4 Assembling of the PTO gear oil pump
- 3.3 Hydraulic system
- 3.3.1 Hydraulic oil cooler assembly
- 3.3.1.1 Disassembling of hydraulic cooler fan and motor
- 3.3.1.2 Assembling of hydraulic cooler fan and motor
- 3.3.1.3 Disassembling of the hydraulic oil radiators
- 3.3.1.4 Assembling of the hydraulic oil radiators
- 3.3.1.5 Disassembling of the hydraulic oil cooler assembly
- 3.3.1.6 Assembling of the hydraulic oil cooler assembly
- 3.3.2 Hydraulic oil tank
- 3.3.2.1 Disassembling of the main shut-off valve
- 3.3.2.2 Assembling of the main shut-off valve
- 3.3.2.3 Disassembling of the hydraulic oil tank
- 3.3.2.4 Assembling of the hydraulic oil tank
- 3.3.3 Main control valve frame (BHA)
- 3.3.3.1 Disassembling of the main control valve assembly
- 3.3.3.2 Assembling of the main control valve assembly
- 3.3.3.3 Disassembling of the ACV-block on ACV/SRV distributor frame
- 3.3.3.4 Assembling of the ACV-block on ACV/SRV distributor frame
- 3.3.3.5 Disassembling of the slow return valve on main control valve frame
- 3.3.3.6 Assembling of the slow return valve on main control valve frame
- 3.3.3.7 Disassembling of the SSRV-block on ACV/SRV distributor frame
- 3.3.3.8 Assembling of the SSRV-block on ACV/SRV distributor frame
- 3.3.3.9 DISASSEMBLING OF THE MAIN RELIEF VALVE (MRV)
- 3.3.3.10 ASSEMBLING OF THE MAIN RELIEF VALVE (MRV)
- 3.4 Slew system
- 3.4.1 Slew gears
- 3.4.1.1 Disassembling of the slew gear
- 3.4.1.2 Assembling of the slew gear
- 3.4.2 Slew motor
- 3.4.2.1 Disassembling of the slew motor
- 3.4.2.2 Assembling of the slew motor
- 3.4.3 Slew parking brake
- 3.4.3.1 Disassembling of the slew parking brake
- 3.4.3.2 Assembling of the slew parking brake
- 3.4.4 Slew service brake valve
- 3.4.4.1 Disassembling of the slew service brake valve
- 3.4.4.2 Assembling of the slew service brake valve
- 3.4.5 Slew circle
- 3.4.5.1 Disassembling of the slew circle
- 3.4.5.2 Assembling of the slew circle
- 3.4.6 Slew circle lubrication pinion (dummy wheel)
- 3.4.6.1 Disassembling of the lubrication pinion assembly
- 3.4.6.2 Assembling of the lubrication pinion assembly
- 3.5 Lubrication pump station
- 3.5.1 Disassembling of the lubrication pumps
- 3.5.2 DISASSEMBLING OF LUBRICANT PUMP DRIVE
- 3.5.3 DISASSEMBLING OF LUBRICANT PUMP
- 3.5.4 Assembling of the lubrication pumps
- 3.5.5 ASSEMBLING OF LUBRICANT PUMP DRIVE
- 3.5.6 ASSEMBLING OF LUBRICANT PUMP
- 3.5.7 ASSEMBLING OF LUBRICANT PUMP TO LUBLICANT PUMP DRIVE
- 3.5.8 Disassembling of the lubrication pump station
- 3.5.9 Assembling of the lubrication pump station
- 3.6 Operator’s cab
- 3.6.1 Disassembling of the operator’s cab
- 3.6.2 Assembling of the operator’s cab
- 3.6.3 Cab-mounts
- 3.6.3.1 Disassembling of the cab-mounts
- 3.6.3.2 Assembling of the cab-mounts
- 3.6.4 OPERATOR’S CAB GLASS
- 3.6.4.1 REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS)
- 3.6.4.2 REMOVE AND INSTALL OPERATOR’S CAB GLASS (ASSEMBLING TYPE)
- 3.6.5 Operator’s seat
- 3.6.5.1 Disassembling of the operator’s seat
- 3.6.5.2 Assembling of the operator’s seat
- 3.6.5.3 Disassembling of the control carrier left
- 3.6.5.4 Assembling of the control carrier left
- 3.6.5.5 Disassembling of the control carrier right
- 3.6.5.6 assembling of the control carrier right
- 3.6.5.7 Disassembling of the operator’s seat belt
- 3.6.5.8 Assembling of the operator’s seat belt
- 3.6.6 Co-driver seat
- 3.6.6.1 Disassembling of the Co-driver seat belt
- 3.6.6.2 Assembling of the Co-driver seat belt
- 3.6.7 ETM monitor
- 3.6.7.1 Disassembling of the ETM monitor
- 3.6.7.2 Assembling of the ETM monitor
- 3.7 Cab base
- 3.7.1 Disassembling of the cab base
- 3.7.2 Assembling of the cab base
- 3.7.3 Disassembling of the VALVE controller
- 3.7.4 Assembling of the VALVE controller
- 3.7.5 Disassembling of the KOMTRAX Plus controller
- 3.7.6 Assembling of the KOMTRAX Plus controller
- 3.8 Ladders, stairways and steps
- 3.8.1 Hydraulically operated stairway
- 3.8.1.1 Disassembling of the hydraulically operated stairway
- 3.8.1.2 Assembling of the hydraulically operated stairway
- 3.8.1.3 Disassembling of the stairway cylinder
- 3.8.1.4 Assembling of the stairway cylinder
- 3.8.2 Fuel tank step
- 3.8.2.1 Disassembling of the fuel tank step
- 3.8.2.2 Assembling of the fuel tank step
- 3.8.3 Emergency escape ladders
- 3.8.3.1 Disassembling of the emergency escape ladder assembly at the cab base
- 3.8.3.2 Assembling of the emergency escape ladder assembly at the cab base
- 3.8.3.3 Disassembling of the emergency escape ladder assembly at the superstructure platform
- 3.8.3.4 Assembling of the emergency escape ladder assembly at the superstructure platform
- 3.9 Platforms
- 3.9.1 Hydraulic oil cooler front platform
- 3.9.1.1 Disassembling of the hydraulic oil cooler front platform
- 3.9.1.2 Assembling of the hydraulic oil cooler front platform
- 3.9.2 Hydraulic oil cooler R.H. platform
- 3.9.2.1 Disassembling of the hydraulic oil cooler R.H. platform
- 3.9.2.2 Assembling of the hydraulic oil cooler R.H. platform
- 3.9.3 Hydraulic oil tank R.H. platform
- 3.9.3.1 Disassembling of the hydraulic oil tank R.H. platform
- 3.9.3.2 Assembling of the hydraulic oil tank R.H. platform
- 3.9.4 Hydraulic tank step
- 3.9.4.1 Disassembling of the hydraulic tank step
- 3.9.4.2 Assembling of the hydraulic tank step
- 3.9.5 Superstructure floor
- 3.9.5.1 Disassembling of the superstructure floor
- 3.9.5.2 Assembling of the superstructure floor
- 3.9.6 Fuel tank platforms
- 3.9.6.1 Disassembling of the fuel tank platforms
- 3.9.6.2 Assembling of the Fuel tank top platforms
- 3.10 Counterweight
- 3.10.1 Disassembling of the counterweight
- 3.10.2 Assembling of the counterweight
- 3.11 Fuel tank
- 3.11.1 Disassembling of the fuel tank
- 3.11.2 Assembling of the fuel tank
- 3.12 Superstructure Lifting
- 3.12.1 Disassembling the superstructure from the undercarriage
- 3.12.2 Assembling the superstructure onto the undercarriage
- 4 Undercarriage
- 4.1 Undercarriage overview
- 4.2 Travel system
- 4.2.1 Crawler track
- 4.2.1.1 Changing the crawler track
- 4.2.2 Sprocket assembly
- 4.2.2.1 Disassembling of the sprocket assembly
- 4.2.2.2 Assembling of the sprocket assembly
- 4.2.3 Guide wheels (Idlers)
- 4.2.3.1 Disassembling of the guide wheel assembly
- 4.2.3.2 Assembling of the guide wheel assembly
- 4.2.4 Track tensioning accumulators
- 4.2.4.1 Disassembling of the low pressure accumulators
- 4.2.4.2 Assembling of the low pressure accumulators
- 4.2.4.3 Disassembling of the high pressure accumulators
- 4.2.4.4 Assembling of the high pressure accumulators
- 4.2.5 Track tension valve block
- 4.2.5.1 Disassembling of the track tensioning valve block
- 4.2.5.2 Assembling of the track tensioning valve block
- 4.2.6 Track tensioning cylinders
- 4.2.6.1 Disassembling of the track tensioning cylinders
- 4.2.6.2 Assembling of the track tensioning cylinders
- 4.2.7 Replace the Hydraulic hoses of the track tensioning system
- 4.2.7.1 Precursory work
- 4.2.7.2 Replace the hydraulic hoses inside the undercarriage center body
- 4.2.7.3 Replace the hydraulic hose between undercarriage center body and crawler frame
- 4.2.7.4 Replace the hydraulic hoses inside the crawler frame
- 4.2.7.5 Subsequent work
- 4.2.8 Travel brake valve block (overspeed valve)
- 4.2.8.1 Disassembling of the travel brake valve block
- 4.2.8.2 Assembling of the travel brake valve block
- 4.2.9 Travel motor
- 4.2.9.1 Disassembling of the travel motors
- 4.2.9.2 Assembling of the travel motors
- 4.2.10 Travel parking brake
- 4.2.10.1 Disassembling of the travel parking brake
- 4.2.10.2 Assembling of the travel parking brake
- 4.2.11 Travel gear box assembly
- 4.2.11.1 Disassembling of the travel gear box assembly
- 4.2.11.2 Assembling of the travel gear box assembly
- 4.2.12 Carrier roller
- 4.2.12.1 Disassembling of the carrier roller assembly
- 4.2.12.2 Assembling of the carrier roller assembly
- 4.2.13 Track roller
- 4.2.13.1 Disassembling of the track roller assembly
- 4.2.13.2 Assembling of the track roller assembly
- 4.2.14 Replace the hydraulic hoses of the traveling system
- 4.2.14.1 Precursory work
- 4.2.14.2 Replace the hydraulic hose to travel gear box
- 4.2.14.3 Replace hydraulic hose to travel parking brake
- 4.2.14.4 Replace th hydraulic hose leak oil
- 4.2.14.5 Replace the hydraulic hose to t ravel motor
- 4.2.14.6 Subsequent work
- 4.3 Undercarriage center body
- 4.3.1 Disassembling of the undercarriage center body and the crawler carriers
- 4.3.2 Assembling of the undercarriage center body and the crawler carriers
- 4.3.2.1 Install crawler carrier mounting bolts
- 4.3.2.2 Special hydraulic torque wrench
- 4.3.3 Rotary joint
- 4.3.3.1 Disassembling of the rotary joint
- 4.3.3.2 Assembling of the rotary joint
- 5 Attachment
- 5.1 Repair procedures
- 5.1.1 Replacement of bushings at the attachment
- 5.1.1.1 Removal of the bushings
- 5.1.1.2 Installation of the bushings
- 5.2 General installation instructions for attachment pins
- 5.3 Backhoe attachment (BHA)
- 5.3.1 Overview
- 5.3.2 Pin sealing bucket – steering rod – bucket link rod
- 5.3.3 Attachment bearings at superstructure
- 5.3.3.1 Boom foot bearings with full floating pins
- 5.3.3.2 Boom cylinder foot bearings with full floating pins
- 5.3.4 Boom assembly
- 5.3.4.1 Disassembling of the boom
- 5.3.4.2 Assembling of the boom
- 5.3.4.3 Disassembling of boom cylinders
- 5.3.4.4 Assembling of boom cylinders
- 5.3.4.5 Disassembling of boom ladder and handrails
- 5.3.4.6 Assembling of boom ladder and handrails
- 5.3.4.7 Boom regeneration valve at the attachment
- 5.3.5 Stick assembly
- 5.3.5.1 Disassembling of the stick
- 5.3.5.2 Assembling of the stick
- 5.3.5.3 Disassembling of the stick cylinders
- 5.3.5.4 Assembling of the stick cylinders
- 5.3.6 Bucket and steering
- 5.3.6.1 Disassembling of the bucket
- 5.3.6.2 Assembling of the bucket
- 5.3.6.3 Disassembling of bucket cylinders
- 5.3.6.4 Assembling of bucket cylinders
- 5.3.6.5 Disassembling of the bucket link rod
- 5.3.6.6 Assembling of the bucket link rod
- 5.3.6.7 Disassembling of the steering rods
- 5.3.6.8 Assembling of the steering rod
- 5.3.7 Hydraulic hoses at the backhoe attachment
- 5.3.7.1 Replace the boom arc hoses
- 5.3.7.2 Replace the boom cylinder hoses
- 5.3.7.3 Replace the stick cylinder hoses
- 5.3.7.4 Replace the bucket cylinder hoses
- 5.3.8 Bleeding the attachment Backhoe (BH)
- 5.3.8.1 BLEEDING THE BOOM AND STICK CYLINDER
- 5.3.8.2 Bleeding the bucket cylinder
- 5.4 Front shovel attachment (FSA)
- 5.4.1 Overview
- 5.4.2 Using the cylinder mounting device for front shovel attachments (PN 967 000 40)
- 5.4.2.1 Designated usage
- 5.4.2.2 Non-designated usage
- 5.4.3 Attachment bearings at superstructure
- 5.4.3.1 Boom foot bearings with full floating pins
- 5.4.3.2 Boom cylinder foot bearings with full floating pins
- 5.4.4 Boom assembly
- 5.4.4.1 Disassembling of the boom
- 5.4.4.2 Assembling of the boom
- 5.4.4.3 Disassembling of the boom cylinders
- 5.4.4.4 Assembling of the boom cylinders
- 5.4.5 STICK ASSEMBLY
- 5.4.5.1 DISASSEMBLING OF THE STICK
- 5.4.5.2 Assembling of the stick
- 5.4.5.3 Disassembling of the stick cylinders
- 5.4.5.4 Assembling of the stick cylinders
- 5.4.6 Bull clam bucket
- 5.4.6.1 Disassembling of the bull clam bucket
- 5.4.6.2 Assembling of the bull clam bucket
- 5.4.6.3 Disassembling of the bucket cylinders
- 5.4.6.4 Assembling of the bucket cylinders
- 5.4.6.5 Disassembling of the clam cylinders
- 5.4.6.6 Assembling of the clam cylinders
- 5.4.7 Hydraulic hoses at the FRONT shovel attachment
- 5.4.7.1 Replacing of the boom BLIDGE hoses
- 5.4.7.2 Replacing of the lubrication hoses
- 5.4.7.3 Replacing of the boom cylinder hoses
- 5.4.7.4 Replacing of the stick BLIDGE hoses
- 5.4.7.5 Replacing of the stick cylinder hoses
- 5.4.7.6 Replacing of the bucket cylinder hoses
- 5.4.7.7 Replacing of the clam cylinder hoses
- 5.4.8 Bleeding the attachment Front shovel (FS)
- 5.4.8.1 BLEEDING THE BOOM AND STICK CYLINDER
- 5.4.8.2 Bleeding the bucket cylinder
- 5.5 Metering valves (grease injectors) at the attachment
- 5.5.1 Disassembling of the metering valves (grease injectors)
- 5.5.2 Assembling of the metering valves (grease injectors)
- 5.6 Ground engaging tools (GET)
- 5.6.1 Disassembling and assembling of the GET
- 5.7 Cylinder bypass test
- 5.8 Disassemble and Assemble Work Equipment Cylinder Assembly
- 6 Service Information
- 6.1 Fluids and lubricants
- 6.2 Lifting gears
- 6.3 Safety hints for sling accessory
- 6.4 Weight tables
- 6.4.1 Superstructure
- 6.4.2 Undercarriage
- 6.4.3 Backhoe attachment (BHA)
- 6.4.4 FRONT shovel attachment (FSA)
- 6.5 Torque charts according to KOMATSU company standard
- 6.5.1 Metric standard thread
- 6.5.2 Metric fine thread
- 6.5.3 Cummins motor torques – metric
- 6.5.4 Cummins motor torques – U.S. customary
- 6.5.5 O-ring boss piping joints
- 6.5.6 O-ring boss plugs
- 6.5.7 Hose (taper seal type and face seal type)
- 6.5.8 Face seal joints
- 6.6 Blind plugs
- 6.6.1 Dummy parts for the face seal type hosed and tubes
- 6.6.2 Dummy parts for taper seal type hoses and tubes
- 6.6.3 Dummy parts for the split flange type hoses and tubes
- 6.6.4 Dummy parts for the O-ring boss type joint
- 6.6.5 Dummy parts for the taper pipe thread type joint
- 6.6.6 Dummy plates for SAE–flanges
- 6.6.7 Classification of threads to the nominal width
- 6.6.8 Plugs and fittings according to DIN 2353
- 6.7 Conversion table
- 6.7.1 Method of using the conversion table
- 6.7.2 Millimeter – inch & kilogram – pound
- 6.7.3 Liter – U.S. gallon & liter – U.K. gallon
- 6.7.4 Nm- ft.lb
- 6.7.5 Bar – PSI – kPa – MPa
- 6.7.6 Temperature
- 6.8 Tools
- 6.8.1 Standard tool case PN 912 702 40
- 6.8.2 Used special tools (Overview)
- 6.9 Work instructions
- 6.9.1 Bleeding the track tensioning system
- 6.9.2 Hints for hydraulic hose installation
- 6.9.3 Remove / install the crawler carrier
- 6.9.4 Repair procedure for the radiator assembly
- 80 Appendix
- List of the additional required forms
- Precautions before work
- Appendix-001 Air condition system (AH05537)
- Appendix-002 Track group – sprocket (AH02521)
- Appendix-003 Undercarriage – wear limit value for chain elongation (AH06507)
- Appendix-004 Diesel engine suspension (AH01521)
- Appendix-005 Swing circle pinion (AH05518)
- Appendix-006 Testing wear and tear of swing circle bearing (AH02513)
- Appendix-007 Non-Pressurized Wiggins Service System VR300 for Fuel Tank Refilling (AH08512)
- Appendix-008 User Manual Lubrication Pump (AH15824)
- Appendix-009 User Manual Lubrication Pump (AH00511)
- Appendix-010 Hydraulic accumulators – testing and refilling (AH01531)
- Appendix-011 Welding procedure for welded couterweight (AH04518)
- Appendix-012 Hydraulic cylinder bushings (AH06545)
- Appendix-013 Steel structure (AH08507)
- Appendix-014 Bushings of the attachment and at the undercarriage (AH08508)
- Appendix-015 Wishbone and rod (AH09522)
- Appendix-016 Bearing bushes (AH11511)
- Appendix-017 Bolted undercarriage (AH11507)
- Appendix-018 Exchange of Hydraulic cylinders (AH15840)
- Appendix-019 PTO and engine bearings (AH18909)
- Appendix-020 Adhesive Lubricants for the Slew Ring Gear (AH11501)
Komatsu
