Komatsu PC3000-11 Mining Excavator Shop Manual (GZEBM06373-UP)

Table of Contents:

• Shop Manual Cover
• 00 Foreword and Safety
  • 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
  • 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 IN THE OPERATOR’S CAB.
      • 2.3.1 SOUND
      • 2.3.2 VIBRATION
    • 2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
      • 2.4.1 UNDERSTANDING THE excavator
      • 2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR
        • 2.4.2.1 ENSURING SAFE OPERATION
      • 2.4.3 PREPARATIONS FOR SAFE OPERATION
        • 2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT
        • 2.4.3.2 INSPECTING THE excavator
        • 2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT
        • 2.4.3.4 KEEP excavator CLEAN
        • 2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT
        • 2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT
        • 2.4.3.7 IF A PROBLEM IS FOUND
      • 2.4.4 FIRE PREVENTION
        • 2.4.4.1 PRECAUTIONS TO PREVENT FIRE
        • 2.4.4.2 ACTION IF FIRE OCCURS ON PC3000
        • 2.4.4.3 ACTION IF FIRE OCCURS ON PC4000, PC5500, PC7000, PC8000
        • 2.4.4.4 EMERGENCY EXIT FROM OPERATOR’S CAB
      • 2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR
        • 2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE excavator
        • 2.4.5.2 NO JUMPING ON OR OFF THE excavator
        • 2.4.5.3 NO PEOPLE ON THE ATTACHMENT
        • 2.4.5.4 WORKING IN HIGH PLACES
        • 2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK
        • 2.4.5.6 LEAVING THE excavator
      • 2.4.6 BURN PREVENTION
        • 2.4.6.1 Hot coolant
        • 2.4.6.2 Hot oil
      • 2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS
      • 2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
      • 2.4.9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS
        • 2.4.9.1 UNAUTHORIZED MODIFICATION
        • 2.4.9.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS
      • 2.4.10 ELECTROMAGNETIC COMPATIBILITY (EMC)
      • 2.4.11 PRECAUTIONS AT JOBSITE
        • 2.4.11.1 VISIBILITY FROM OPERATOR’S SEAT
        • 2.4.11.2 CAMERA SYSTEM WITH MONITORS
        • 2.4.11.3 ENSURE GOOD VISIBILITY
        • 2.4.11.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS
        • 2.4.11.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS
        • 2.4.11.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES
        • 2.4.11.7 Lightning Strikes
        • 2.4.11.8 WORKING ON LOOSE GROUND
        • 2.4.11.9 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES
        • 2.4.11.10 VENTILATION OF ENCLOSED AREAS
      • 2.4.12 STARTING motor
        • 2.4.12.1 WARNING TAG
        • 2.4.12.2 CHECKS BEFORE STARTING motor
        • 2.4.12.3 PRECAUTION WHEN STARTING motor
        • 2.4.12.4 PRECAUTION IN COLD AREAS
      • 2.4.13 OPERATION
        • 2.4.13.1 CHECKS BEFORE OPERATION
        • 2.4.13.2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE
        • 2.4.13.3 PRECAUTIONS WHEN traveling
        • 2.4.13.4 TRAVELING ON SLOPES
        • 2.4.13.5 OPERATIONS ON SLOPES
        • 2.4.13.6 PROHIBITED OPERATIONS
        • 2.4.13.7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES
        • 2.4.13.8 PARKING THE excavator
        • 2.4.13.9 TRANSPORTATION
    • 2.5 PRECAUTION FOR MAINTENANCE
      • 2.5.1 GENERAL PRECAUTIONS
        • 2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES
        • 2.5.1.2 STOP motor FOR MAINTENANCE
        • 2.5.1.3 WARNING TAG
        • 2.5.1.4 Maintenance safety Switch
        • 2.5.1.5 KEEP WORKPLACE CLEAN AND TIDY
        • 2.5.1.6 APPOINT LEADER WHEN WORKING WITH OTHERS
        • 2.5.1.7 TWO WORKERS FOR MAINTENANCE WHEN THE excavator IS RUNNING
        • 2.5.1.8 INSTALLING, REMOVING OR STORING ATTACHMENTS
        • 2.5.1.9 PRECAUTIONS WHEN WORKING UNDER THE excavator OR EQUIPMENT
        • 2.5.1.10 NOISE
        • 2.5.1.11 WHEN USING A HAMMER
        • 2.5.1.12 PROPER TOOLS
        • 2.5.1.13 ACCUMULATOR
        • 2.5.1.14 PERSONNEL
      • 2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE
        • 2.5.2.1 PRECAUTION WHEN WELDING
        • 2.5.2.2 BATTERY HANDLING
      • 2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID
        • 2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE
        • 2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES
        • 2.5.3.3 REPLACEMENT OF HOSE LINES
        • 2.5.3.4 INSPECTION OF HOSE LINES
        • 2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
        • 2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE
        • 2.5.3.7 AIR CONDITIONING MAINTENANCE
        • 2.5.3.8 COMPRESSED AIR
        • 2.5.3.9 WASTE MATERIALS
    • 2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS
      • 2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM
      • 2.6.2 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING ADJUSTMENTS
      • 2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR
    • 2.7 SPECIAL SAFETY EQUIPMENT
      • 2.7.1 FRONT GUARD PROTECTIVE STRUCTURE ’FOPS’ FOR OPERATOR’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 (EUROPEAN STANDARD)
        • 2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)
        • 2.7.5.2 INSTRUCTIONS FOR USE
        • 2.7.5.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS
        • 2.7.5.4 INSTRUCTIONS FOR USE
• 01 Specification
• 10 Structure and Function
  • Table of Contents
  • 1 Introduction
    • 1.1 Foreword
    • 1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels
    • 1.3 Explanation of abbreviations
    • 1.4 Diagrams and illustrations in this manual
  • 2 Specifications
    • 2.1 Fluids and lubricants
    • 2.2 Lifting Gears
    • 2.3 Safety hints for sling accessory
    • 2.4 Standard Tightening Torque Chart
      • 2.4.1 Metric standard thread
      • 2.4.2 Metric fine thread
      • 2.4.3 Cummins motor torques – Metric
      • 2.4.4 Cummins motor torques – U.S. customary
    • 2.5 Conversion Tables
      • 2.5.1 Method of using the conversation table
      • 2.5.2 Millimeter – inch and kilogram – pound
      • 2.5.3 Liter to U.S. gallon and liter – U.K. gallon
      • 2.5.4 Nm – ft.lb
      • 2.5.5 Bar – PSI – kPa – MPa
      • 2.5.6 Temperature
    • 2.6 PT100 temperature charts (PT100) g Centigrade – Ohm
    • 2.7 Blind plugs
      • 2.7.1 Dummy plates for hydraulic-flanges
      • 2.7.2 Classification of threads to the nominal width
      • 2.7.3 Plugs and fittings according to ISO 8434-1 / DIN 2353
  • 3 Main assembly groups
    • 3.1 General layout
    • 3.2 Superstructure
    • 3.3 Machinery house
      • 3.3.1 Machinery house roof
    • 3.4 Hydraulic oil tank
    • 3.5 Hydraulic oil cooler
    • 3.6 Fuel tank
    • 3.7 Counterweight
    • 3.8 Cab base
    • 3.9 Operator’s cab
      • 3.9.1 HYDRAULIC CONTROL SYSTEM – CONTROL PATTERN
      • 3.9.2 SAFETY CIRCUIT FOR CONTROLS
      • 3.9.3 ANTENNA AND LIGHTING TRAVERSE OF THE CABIN
    • 3.10 Main Control blocks
      • 3.10.1 Main control blocks (FSA)
      • 3.10.2 Main control blocks (BHA)
    • 3.11 Slew Gear
      • 3.11.1 Slew Gear Type 2063
      • 3.11.2 Slew Gear type 632770
    • 3.12 Undercarriage
    • 3.13 Backhoe attachment (BHA)
    • 3.14 Front shovel attachment (FSA)
    • 3.15 Safety circuit PPC control
      • 3.15.1 Safety circuit – Refilling arm
      • 3.15.2 Safety circuit – Ladder
      • 3.15.3 Safety circuit – Lock lever
    • 3.16 KomVision camera system
    • 3.17 PLM (Payload Management)
  • 4 Drive
    • 4.1 Prime drive assembly
    • 4.2 Engine mounts
    • 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 Exhaust gas aftertreatment (T4 final)
      • 4.4.1 DEF system layout
      • 4.4.2 DEF tank – Location and overview
      • 4.4.3 Dosing pumps at DEF tank
      • 4.4.4 Coolant supply for DEF tank heating circuit
      • 4.4.5 Information on DEF (Diesel exhaust fluid)
        • 4.4.5.1 DEF refilling line
        • 4.4.5.2 DEF maintenance information
        • 4.4.5.3 Notes on DEF quality and temperature – Important
        • 4.4.5.4 DEF storage
        • 4.4.5.5 Common names used for DEF
      • 4.4.6 DEF tank level
      • 4.4.7 SCR catalyst for exhaust gas Aftertreatment
        • 4.4.7.1 Dosing valve
      • 4.4.8 Wiring between engine – DEF tank – SCR catalyst
    • 4.5 Fuel cooling (T4 equipment)
    • 4.6 Radiator assembly and fan drive
      • 4.6.1 Radiator assembly
        • 4.6.1.1 Hydraulic schematic of radiator fan drive
      • 4.6.2 Fan pump drive type HPV140
      • 4.6.3 Radiator fan speed testing and adjustment
        • 4.6.3.1 Testing & readjustment procedure
        • 4.6.3.2 Basic adjustment procedure
    • 4.7 Pump distributor gearbox (PTO)
      • 4.7.1 PTO lubrication and cooling
      • 4.7.2 Pump spline lubrication
        • 4.7.2.1 Oil level in the main pump and gear oil pump drive shaft housing
        • 4.7.2.2 Checks and adjustments – PTO lubrication pressure
    • 4.8 Hydraulic pumps – arrangement
    • 4.9 Air filter
  • 5 Hydraulic oil tank
    • 5.1 General layout
    • 5.2 Hydraulic oil tank, location of the electric equipment
    • 5.3 Suction oil manifold with strainers
    • 5.4 Return oil collector manifold with strainer
    • 5.5 Back pressure valve
    • 5.6 Transfer pump
    • 5.7 Return and leak oil filter
    • 5.8 Breather filter
  • 6 Hydraulic oil cooling
    • 6.1 Overall view of the hydraulic oil cooling
    • 6.2 Function of the hydraulic oil cooling circuit
    • 6.3 Adjustment of the back pressure valve
    • 6.4 Stepless cooler fan rpm control
    • 6.5 Pressure limiting valve
      • 6.5.1 Components of the fan drive circuits
    • 6.6 Fan pump drive type HPV140
    • 6.7 Oil cooler fan speed testing/Adjustment
      • 6.7.1 Adjustment procedures for radiator fan speed
        • 6.7.1.1 General information – Testing
        • 6.7.1.2 Basic adjustment procedure
  • 7 Controlling
    • 7.1 General layout
    • 7.2 Control and filter plate – location of components
    • 7.3 Pilot control frame – location of components
    • 7.4 Pilot pressure supply and adjustments
      • 7.4.1 Pilot pressure circuit
      • 7.4.2 Checks and adjustment of pilot pressure
  • 8 Components
    • 8.1 Main control blocks and high pressure filters (FSA)
    • 8.2 Main control blocks and high pressure Screens (BHA)
    • 8.3 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA)
    • 8.4 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA)
    • 8.5 Single control blocks (floating) for stick and boom (FSA)
    • 8.6 Restrictor block with secondary relief valve
    • 8.7 Anti-cavitation valve (ACV) block
    • 8.8 High-pressure screen
    • 8.9 Control blocks and valves
      • 8.9.1 Spool types
      • 8.9.2 MRV, SRV and ACV
      • 8.9.3 Load holding valve
    • 8.10 Travel brake valve
    • 8.11 4/2 Directional solenoid valves
    • 8.12 4/3 Directional solenoid valves
    • 8.13 Pressure double stage valve
    • 8.14 Hydraulic cylinder
      • 8.14.1 with NOK-3 sealing
      • 8.14.2 With dual stacked sealing
      • 8.14.3 Cylinder data markings
    • 8.15 Auxiliary gear pumps
  • 9 Main hydraulic pumps and pump regulation
    • 9.1 General
      • 9.1.1 Pump locations and pump data
    • 9.2 Main pumps
      • 9.2.1 Hydraulic pump type HPV375+375
        • 9.2.1.1 Main pump sectional drawings
      • 9.2.2 Servo valve
        • 9.2.2.1 VC valve  servo piston
        • 9.2.2.2 EPC valve
    • 9.3 Electronic pump regulation system
      • 9.3.1 Cut-off function
      • 9.3.2 Slew control (volume reduction)
      • 9.3.3 Temperature control
        • 9.3.3.1 Hydraulic oil temperature charts
    • 9.4 Pump and valve controller CR730
    • 9.5 Monitoring, error indication, adjustment
      • 9.5.1 Monitoring items of the pump controller
      • 9.5.2 Error indication of the pump controller
      • 9.5.3 Adjustable parameters of the pump controller
        • 9.5.3.1 Description of the Primary P-Factor
      • 9.5.4 Pump sol ’min’ current values according to pump type plate
      • 9.5.5 Pump sol ’max’ current values according to pump type plate
    • 9.6 Checks and adjustments
      • 9.6.1 Engine power check
      • 9.6.2 Cut-off function check
        • 9.6.2.1 Cut-off for clam close (FSA only)
    • 9.7 Engine speed sensor (pick-up)
      • 9.7.1 General
      • 9.7.2 Engine speed sensor (pick-up) adjustment
      • 9.7.3 In case of problems – When correct speed sensor Adjustment is guaranteed
  • 10 Operating hydraulics
    • 10.1 General
      • 10.1.1 Floating system (FSA)
    • 10.2 Checks and adjustments of the main relief valve (MRV)
    • 10.3 Hydraulics for the attachment cylinders
      • 10.3.1 Checks and adjustments of the secondary relief valves (SRV)
        • 10.3.1.1 Boom cylinders, piston side (BHA and FSA), boom up
        • 10.3.1.2 Boom Cylinder, Piston Rod Side (BHA and FSA), boom down
        • 10.3.1.3 Stick cylinders, piston side (FSA), stick out
        • 10.3.1.4 Stick cylinders, piston side (BHA), stick in
        • 10.3.1.5 Stick cylinders, piston rod side (FSA), stick in
        • 10.3.1.6 Stick cylinders, piston rod side (BHA), stick out
        • 10.3.1.7 Bucket cylinders, piston side (FSA), bucket fill
        • 10.3.1.8 Bucket cylinders, piston side (BHA), bucket fill
        • 10.3.1.9 Bucket cylinders, piston rod side (FSA), bucket dump
        • 10.3.1.10 Bucket cylinders, piston rod side (BHA), bucket dump
        • 10.3.1.11 Clam cylinders, piston rod side (FSA), clam open
        • 10.3.1.12 Clam cylinders, piston side (FSA), clam close
      • 10.3.2 Checks and adjustments of the lowering speed
        • 10.3.2.1 Checks and adjustments of the lowering speed – boom (FSA)
        • 10.3.2.2 Checks and adjustments of the lowering speed – boom (BHA)
        • 10.3.2.3 Checks and adjustments of the lowering speed – stick (FSA)
        • 10.3.2.4 Checks and adjustments of the lowering speed – stick (BHA)
        • 10.3.2.5 Checks and adjustments of the lowering speed – bucket (FSA)
        • 10.3.2.6 Checks and adjustments of the lowering speed – bucket (BHA)
        • 10.3.2.7 Checks and adjustments of the lowering speed – clam (FSA)
    • 10.4 Hydraulics for the slew circuit
      • 10.4.1 Slew circuit
      • 10.4.2 Slew motor
      • 10.4.3 Slew gearbox of type 2063
      • 10.4.4 Slew gearbox of type 632770
      • 10.4.5 Slew parking brake of type 2063
      • 10.4.6 Slew parking brake of type 632770
      • 10.4.7 Slew brake valve
      • 10.4.8 Checks and adjustments for the slew circuit
        • 10.4.8.1 Checks and adjustments, double stage valve
        • 10.4.8.2 checks and adjustments, slew Brake pilot pressure
        • 10.4.8.3 Cycle time inspection slew
        • 10.4.8.4 Slew brake performance test
      • 10.4.9 Function check for the hydraulic slew brake
    • 10.5 Hydraulics for the travel circuit
      • 10.5.1 Travel circuit
      • 10.5.2 Travel motor
      • 10.5.3 Rotary joint
      • 10.5.4 Travel gearbox
      • 10.5.5 Travel parking brake
        • 10.5.5.1 Travel parking brake
    • 10.6 Travel brake valve
      • 10.6.1 Checks and adjustments
        • 10.6.1.1 Checks and adjustments for the travel circuit
        • 10.6.1.2 Function check for the travel parking brake
  • 11 Hydraulic track tensioning system
    • 11.1 General
    • 11.2 Functional description
    • 11.3 Double stage valve
    • 11.4 Tensioning cylinder
    • 11.5 Adjustments / checks
  • 12 Access stairway, hydraulically operated
    • 12.1 General
    • 12.2 Function of the hydraulically operated access stairway
    • 12.3 Adjustments / checks
  • 13 Central refilling system (refilling arm)
    • 13.1 Refilling arm location
    • 13.2 Function
  • 14 Hints for reading the hydraulic diagram
    • 14.1 General
    • 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
  • 15 Hints for reading the electric Wiring Diagram
    • 15.1 General
    • 15.2 Reference code of the electrical components
      • 15.2.1 Area code
      • 15.2.2 Component identifying letter
    • 15.3 Graphical symbols
    • 15.4 Concept of the Wiring Diagram
      • 15.4.1 Cover page of the Komatsu W/D
      • 15.4.2 Example 1 from the schematics in the W/D
      • 15.4.3 Example 2 from the schematics in the W/D
      • 15.4.4 Table of contents in the W/D (page 1 of 2)
      • 15.4.5 Location list
      • 15.4.6 Cross reference list for electr. components in the W/D
      • 15.4.7 Cross reference list for terminals in the W/D
      • 15.4.8 Cross reference list for connectors in the W/D
      • 15.4.9 Cross reference list for terminal boards in the W/D
      • 15.4.10 Connection table
    • 15.5 Cable and connector marking
    • 15.6 Cable color identification
  • 16 Monitoring and Control system
    • 16.1 Controller system overview
      • 16.1.1 location of KOMTRAX Plus components in cab base
    • 16.2 System layout
      • 16.2.1 CAN BUS #0 overview
      • 16.2.2 CAN BUS #1 overview
      • 16.2.3 CAN BUS #2 overview
    • 16.3 Interface connection
      • 16.3.1 General description
    • 16.4 K+ monitor – Operator level
    • 16.5 Main gauge screens
    • 16.6 Operator menus
      • 16.6.1 Operator menu → ECO Guidance – Operation Records
      • 16.6.2 Operator menu → ECO Guidance – Average Fuel Consumption Logs
      • 16.6.3 Operator menu → Machine Setting
      • 16.6.4 Operator menu → Aftertreatment cleaning
        • 16.6.4.1 Introduction
        • 16.6.4.2 Operator menu: SCR Information
      • 16.6.5 Operator menu → Maintenance
        • 16.6.5.1 Reset of ’remaining time’ till next maintenance interval
        • 16.6.5.2 Usage limitation
      • 16.6.6 Operator menu → Monitor Setting – Screen Adjustment
      • 16.6.7 Operator menu → Monitor Setting – Clock Adjustment – Calender
      • 16.6.8 Operator menu → Monitor Setting – Clock Adjustment – Time
      • 16.6.9 Operator menu → Monitor Setting – Clock Adjustment – 12h/24h Mode
      • 16.6.10 Operator menu → Monitor Setting – Clock Adjustment – Daylight Saving Time
      • 16.6.11 Operator menu → Monitor Setting – Language
    • 16.7 Status indication and errors on the operator level
      • 16.7.1 Prompts (status indication)
      • 16.7.2 Cautions
      • 16.7.3 Emergency shutdown screen
      • 16.7.4 Fault levels for error messages
      • 16.7.5 Action code level L01
      • 16.7.6 Action code level L02
      • 16.7.7 Action code level L03
      • 16.7.8 Action code level L04
      • 16.7.9 Error list
    • 16.8 Table of failure codes
      • 16.8.1 Table of failure codes for Mechanical Systems PC3000-11 T4
      • 16.8.2 Table of failure codes for Electrical Systems PC3000-11 T4
      • 16.8.3 Failure codes without monitor indication
      • 16.8.4 Additional text information for action codes
    • 16.9 Table of C-codes – Diesel engine QSK38 T4
    • 16.10 Flow charts of K+ monitor screens
      • 16.10.1 Flow chart service level
    • 16.11 K+ monitor
      • 16.11.1 Entering the Service Level
      • 16.11.2 Key symbols (F1…F6) on the Service Level
      • 16.11.3 Service Menu selection screens
    • 16.12 Service Menu – item 01 Monitoring / Custom
      • 16.12.1 Monitoring list for: ENG controller
      • 16.12.2 Monitoring list for: PUMP controller
      • 16.12.3 Monitoring list for: VALVE0 controller
      • 16.12.4 Monitoring list for: MON (monitor)
      • 16.12.5 Monitoring list for: KOM PLS (K+ controller)
      • 16.12.6 How to perform the monitoring function
    • 16.13 Service Menu – item 02 PM Clinic
      • 16.13.1 PM Clinic (General)
      • 16.13.2 PM Clinic (Power Check)
      • 16.13.3 Functions of PM CLINIC (Power check)
    • 16.14 Service Menu – item 03 Abnormality record
      • 16.14.1 Reset error messages
    • 16.15 Service Menu – item 04 Maintenance record
    • 16.16 Service Menu – item 05 Maintenance Mode Setting
    • 16.17 Service Menu – item 06 Snap Shot
    • 16.18 Service Menu – item 07 Phone Number Entry
    • 16.19 Service Menu – item 08 Default
    • 16.20 Service Menu – item 09 Unit
    • 16.21 Service Menu – item 10 Adjustment
      • 16.21.1 Adjustments for: PUMP controller
      • 16.21.2 Pump sol ’min’ current values according to pump type plate
      • 16.21.3 Pump sol ’max’ current values according to pump type plate
      • 16.21.4 Adjustments for: MON (Monitor)
        • 16.21.4.1 Using the Idling Stop Timer
    • 16.22 Service Menu – item 11 Machine Configuration
      • 16.22.1 Details of Machine Configuration for PC3000-11 T4
      • 16.22.2 Changing lever control from EURO to KMG
      • 16.22.3 Changing attachment type from FSA to BHA
      • 16.22.4 In case of problems during changing procedure for lever control or attachment type (OPTIONAL)
      • 16.22.5 Hydraulic Oil and PTO Gear Oil Definition Tables
        • 16.22.5.1 Hydraulic oil temperature charts
        • 16.22.5.2 PTO gear oil temperature charts
      • 16.22.6 Idling Stop Timer
    • 16.23 KOMTRAX Plus controller (UM600)
    • 16.24 CR730 controller
      • 16.24.1 Location of CR730 controllers and K+
    • 16.25 Controller replacement procedure
      • 16.25.1 Sequence of the controller replacement procedure
      • 16.25.2 After controller replacement
  • 17 Lubrication system
    • 17.1 General overview (SLS and CLS)
      • 17.1.1 General description
    • 17.2 Basic function of the lubrication systems
    • 17.3 Lubrication systems (SLS / CLS)
      • 17.3.1 Lubrication pump station
      • 17.3.2 General Information on CLS
      • 17.3.3 General information on SLS
      • 17.3.4 Manual lube activation
    • 17.4 Lubrication cycle
      • 17.4.1 Operation and control
      • 17.4.2 Lubrication cycle – processing
      • 17.4.3 Time segments and switch points of a lubrication cycle
      • 17.4.4 Lubrication modes
        • 17.4.4.1 Automatic lubrication mode
        • 17.4.4.2 Manual lubrication mode
        • 17.4.4.3 Reduced pause time for service
    • 17.5 Hydraulically driven lube pump
      • 17.5.1 Adjustment of lube pump speed
        • 17.5.1.1 Stroke speed adjustment
        • 17.5.1.2 Working pressure
    • 17.6 Lubricant injectors
      • 17.6.1 Tightening torques for fittings at grease injectors
      • 17.6.2 Description
      • 17.6.3 Adjustment of the lubricant output
      • 17.6.4 Operation principle of lubricant injectors
        • 17.6.4.1 Function description
      • 17.6.5 Connection of one or more injectors
    • 17.7 Vent valve and grease outlet filter
      • 17.7.1 Vent valve description
    • 17.8 End-line switch
      • 17.8.1 Description
      • 17.8.2 CLS and SLS end-line switch adjustment
    • 17.9 Lubricant level sensors
      • 17.9.1 Description
        • 17.9.1.1 Checks
    • 17.10 Commissioning
      • 17.10.1 Commissioning of the CLS 1 lubrication system
      • 17.10.2 Fine adjustment
      • 17.10.3 Commissioning of the SLS lubrication system
  • 18 Air conditioner
    • 18.1 Large A/C Systems on Hydraulic Mining Excavators
    • 18.2 Working on A/C systems
      • 18.2.1 Refrigerant Recovery
      • 18.2.2 Compressor oil procedures
    • 18.3 Maintenance & preventive maintenance of A/C systems
    • 18.4 Commissioning of A/C systems
    • 18.5 Compressor oil – Lubrication chart
    • 18.6 Standard Air Conditioning System Diesel Drive
      • 18.6.1 A/C compressor type TM-16
      • 18.6.2 A/C compressor type TM-21
      • 18.6.3 Principle diagram of an electromagnetic clutch
      • 18.6.4 Filter-drier
    • 18.7 Air conditioner unit at operator’s cab
      • 18.7.1 Shut-Off valves at dryer cartridge
    • 18.8 A/C control panel
      • 18.8.1 Button layout
      • 18.8.2 Display/LEDs
  • 19 Deep temperature equipment (option)
    • 19.1 General information
      • 19.1.1 Introduction
      • 19.1.2 Deep temperature components overview
      • 19.1.3 Power supply preconditions for preheating
      • 19.1.4 Power requirements for preheating systems
    • 19.2 Preheating procedure
      • 19.2.1 Global flow chart of the preheating procedure
      • 19.2.2 Starting the preheating procedure
      • 19.2.3 Preheating of operator’s cab and Diesel engine (coolant system)
      • 19.2.4 Preheating of lubricants and superstructure (Diesel) (electric system)
    • 19.3 Constant heating of travel motors (TTT equipment below -40°C only)
    • 19.4 Component location examples
      • 19.4.1 Electric heating elements for hydraulic and batteries [electric excavator]
      • 19.4.2 Electric heating elements for hydraulics [Diesel excavator]
      • 19.4.3 Electric heating elements for engines and batteries [Diesel excavator]
    • 19.5 Components of TT equipment
      • 19.5.1 Preheating components on a Diesel excavator
      • 19.5.2 Preheating components on an electric excavator
      • 19.5.3 Wiring Diagrams for preheating systems
        • 19.5.3.1 Wiring diagram "Hydraulic Oil Tank Preheating" part 1 of 3
        • 19.5.3.2 Wiring diagram "Hydraulic Oil Tank Preheating" part 2 of 3
        • 19.5.3.3 Wiring diagram "Hydraulic Oil Tank Preheating" part 3 of 3
        • 19.5.3.4 Wiring diagram "Suction Oil Manifold Preheating"
        • 19.5.3.5 Wiring diagram "PTO Preheating"
        • 19.5.3.6 Wiring diagram "Battery heater pads"
• 40 Troubleshooting
  • Table of Contents
  • 1 Introduction
    • 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 troubleshooting
      • 2.4.1 Technical documentation
      • 2.4.2 Tools
        • 2.4.2.1 Reference Guide for Deutsch Removal 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
      • 2.9.3 Air bleeding from hydraulic cylinders
    • 2.10 Cylinder bypass test
    • 2.11 Basics about "How to crimp" (with strain relief)
      • 2.11.1 Crimp tool & repair kit
      • 2.11.2 General
      • 2.11.3 Select the required connector components
      • 2.11.4 Stripping a wire
      • 2.11.5 Crimping
      • 2.11.6 Connector assembly after crimping
    • 2.12 Cable shielding
    • 2.13 Relay checks
      • 2.13.1 Switch contact testing using the Test button
      • 2.13.2 Measuring of the coil resistance
  • 3 Mounting locations and connector types
    • 3.1 Component location
      • 3.1.1 Superstructure
      • 3.1.2 Location of battery box and emergency stop switches
      • 3.1.3 Location of service safety switch
      • 3.1.4 Engine – location of electrical components
      • 3.1.5 Control and filter plate – location of Components
      • 3.1.6 PTO, main pumps and suction oil tank – location of electrical components
      • 3.1.7 Main control blocks – location of components
      • 3.1.8 Lubrication system – location of electrical components
      • 3.1.9 Cab base – location of electrical components
        • 3.1.9.1 Pilot control frame – location of electrical components
      • 3.1.10 Hydraulic Oil Tank – Location of Electrical Components
      • 3.1.11 Hydraulic oil cooler – location of electrical components
      • 3.1.12 Refilling arm – location of electrical Components
      • 3.1.13 Hydraulically operated access stairway- location of electrical Components
      • 3.1.14 Air filter and fuel tank – location of electrical components
    • 3.2 Connector types overview
  • 4 Standard Value Table for Electrical Components
  • 5 Tables for Testing and Troubleshooting
    • 5.1 Test Value Tables for Transducers
      • 5.1.1 Pump press. transducers
      • 5.1.2 Hydraulic oil pressure transducers
      • 5.1.3 Miscellaneous Pressure Transducers
      • 5.1.4 Temperature Transducers
    • 5.2 Hydraulic oil temperature charts
    • 5.3 PTO gear oil temperature charts
    • 5.4 Table of failure codes
      • 5.4.1 Table of failure codes for Mechanical Systems PC3000-11 T4
      • 5.4.2 Table of failure codes for Electrical Systems PC3000-11 T4
    • 5.5 Table of C-codes – Diesel engine QSK38 T4
    • 5.6 Table of symptom codes
      • 5.6.1 Symptoms of the engines 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 colour identification
  • 6 Troubleshooting by Trouble Code
    • B@HANS – Hyd Oil Overheat
      • Monitoring hydraulic oil temperature
      • Hydraulic oil temperature charts for message B@HANS
    • 6A1BMA – Trouble Shut-Off (gate) valve not open error
      • View onto the gap of proximity switch 40B031
      • Wiring Diagram (40B031) for message 6A1BMA
    • AA10NX – Air Cleaner1 Clogging
      • View onto the engine air cleaner (AA10NX)
    • AB00KE – Charge Voltage Low
      • Wiring Diagram (alternator for message AB00KE)
    • K@3A00 – Fire In System
      • Configuration information for Fire Suppression System Machinery House
      • Wiring Diagram (20K351) for message K@3A00
    • B@F0MA – CLS1 Lubrication System Error
    • B@CPMA – SLS Lubrication System Error
    • B@F0N9 – CLS1 pressure increase time too long
    • B@CPN9 – SLS pressure increase time too long
      • Allocation of vent valves and end-of-line switches
      • Vent valve (62Q507a & 62Q509a)
      • Wiring Diagram and monitoring selections for message B@F0N9 and B@CPN9
    • B@F0N0 – CLS1 pressure decrease time too long
    • B@CPN0 – SLS pressure decrease time too long
      • Vent valve (62Q507a & 62Q509a)
    • B@F0ZK – CLS1 grease level too low
    • B@CPZK – SLS grease level too low
      • Wiring Diagram – grease level sensors
    • B@HAZK – Hydraulic oil level too low
      • Hydraulic oil level in defined machine position
      • Wiring Diagram – hydraulic oil level sensor 40B004
    • B@CBNS – PTO1 Gear Oil Temp High
      • View onto the universal pump distributor gearbox (PTO)
    • B@CBZG – PTO1 Gear Lubrication Error
      • Monitoring PTO lube oil pressure
      • Shutdown adjustment for PTO lube oil pressure
    • B@H2NX – Breather Filter Clogging
      • Location of 40B024 and hydraulic oil level definitions
    • B@M9NX – PTO1 Gear Oil Filter Clogging
      • View onto the PTO1 gear oil filter with pressure sensor 57B027-1
    • B@HBNX – Return Oil Filter Clogging
    • B@L4NX – Leak Oil Filter Clogging
    • B@L5N9 – Pilot Press X2 Too Low
      • Valve cartridge block, location of components
    • B@L5N0 – Pilot Press X2 Too High
      • Valve cartridge block, location of components
    • B@BKPQ – Eng Remote Oil Tank1 Empty
    • B@HANX – Screen At Hyd Cooler Entry Clogging
      • Hydraulic oil tank & return oil collector pipe with strainer, location of components
    • AB30MA – Starter Circuit Abnormality
      • Wiring Diagram for message AB30MA
    • 989HMA – Emergency stop line abnormality
      • Wiring Diagram – emergency line for message 989HMA
      • Monitoring screens for message 989HMA
    • DGT3MA – PTO1 oil temperature sensor abnormality
      • Wiring Diagram and monitoring selections for 57B049-1
    • DGH2MA – Hydraulic oil temp sensor abnormality
      • Wiring Diagram and monitoring selections for 59B015
    • DHQ7MA – PTO1 lube pressure sensor abnormality
      • Wiring Diagram and monitoring selections for 57B017-1
    • D1E7KB – Starter cut relay short circuit
      • Wiring Diagram and monitoring screen for message D1E7KB
    • D1E7KY – Starter cut relay hot short circuit
      • Wiring Diagram and monitoring screen for message D1E7KY
    • DHPEMA – Pump-1/2 pressure sensor abnormality
    • DHPGMA – Pump-3/4 pressure sensor abnormality
    • DHPJMA – Pump-5/6 pressure sensor abnormality
      • Wiring Diagram – PWR and GND supply for pump pressure transducers
    • DLE2MA – Engine speed sensor abnormality
      • Wiring Diagram and monitoring selection for 57B064-1
    • DA27KP – 24V sensor power abnormality
      • Wiring Diagram – 24V sensor power supply for DA27KP
    • DA26KP – 5V sensor2 power abnormality
      • Wiring Diagram – 5V sensor power supply for DA26KP
    • DA22KK – Solenoid Power Low Error(Pump Con)
    • DA22MA – Solenoid Power Circuit Abnormality
      • Wiring Diagram 1 – emergency stop line for message DA22MA
      • Wiring Diagram and monitoring selections for message DA22MA
    • DXAAKA – Pump1 Solenoid open circuit
    • DXABKA – Pump2 Solenoid open circuit
    • DXACKA – Pump3 Solenoid open circuit
    • DXADKA – Pump4 Solenoid open circuit
    • DXAEKA – Pump5 Solenoid open circuit
    • DXAFKA – Pump6 Solenoid open circuit
      • Wiring Diagram – EPC valve control
    • DXAAKB – Pump1 Solenoid short circuit
    • DXABKB – Pump2 Solenoid short circuit
    • DXACKB – Pump3 Solenoid short circuit
    • DXADKB – Pump4 Solenoid short circuit
    • DXAEKB – Pump5 Solenoid short circuit
    • DXAFKB – Pump6 Solenoid short circuit
      • Wiring Diagram – EPC valve control
    • DWA5KA – CLS pump solenoid open circuit
    • DWA8KA – SLS pump solenoid open circuit
      • Wiring Diagram and monitoring selection for messages DWA5KA and DWA8KA
    • DWA5KB – CLS pump solenoid short circuit
    • DWA8KB – SLS pump solenoid short circuit
      • Wiring Diagram and monitoring selection for messages DWA5KB and DWA8KB
    • DWA5KY – CLS pump solenoid hot short circuit
    • DWA8KY – SLS pump solenoid hot short circuit
      • Wiring Diagram and monitoring selection for messages DWA5KY and DWA8KY
    • DWA7KA – CLS line release solenoid open circuit
    • DWA9KA – SLS lube line release sol. open circuit
      • Wiring Diagram and monitoring selection for messages DWA7KA and DWA9KA
    • DWA7KB – CLS line release solenoid short circuit
    • DWA9KB – SLS lube line release solenoid short circuit
      • Wiring Diagram and monitoring selection for messages DWA7KB and DWA9KB
    • DWA7KY – CLS line release sol. hot short circuit
    • DWA9KY – SLS lube line release sol hot short circuit
      • Wiring Diagram and monitoring selection for messages DWA7KY and DWA9KY
    • DWAAKA – PTO lube preload solenoid open circuit
      • Wiring Diagram and monitoring screen for message DWAAKA
    • DWAAKB – PTO lube preload solenoid short circuit
      • Wiring Diagram and monitoring screen for message DWAAKB
    • DWAAKY – PTO lube preload sol. hot short circuit
      • Wiring Diagram and monitoring screen for message DWAAKY
    • D168KB – Oil cooler preload sol relay short circuit
      • Wiring Diagram and monitoring selection for message D168KB
    • D162KB – Horn relay short circuit
      • Wiring Diagram and monitoring selection for message D162KB
    • D1F0KB – Engine1/motor1 shutdown relay short circuit
      • Wiring Diagram and monitoring selection for shutdown relay 11K064-1
    • D1F0KY – Engine1/motor1 shutdown relay hot short
      • Wiring Diagram and monitoring selection for shutdown relay 11K064-1
    • DWNCKA – Hyd. Oil Cooler fan pump1 Sol. open circuit
      • Wiring Diagram and monitoring selection for message DWNCKA
    • DWNCKB – Hyd. Oil Cooler fan pump1 Sol. short circuit
      • Wiring Diagram and monitoring selection for message DWNCKB
    • DWN5KA – Radiator fan pump1 Sol. open circuit
      • Wiring Diagram and monitoring selection for message DWN5KA
    • DWN5KB – Radiator fan pump1 Sol. short circuit
      • Wiring Diagram and monitoring selection for message DWN5KB
    • D110KA – Battery relay open circuit
      • Wiring Diagram and monitoring selection for message D110KA
    • D110KB – Battery relay short circuit
      • Wiring Diagram and monitoring selection for message D110KB
    • DA29KQ – Model Selection Abnormality
      • Monitoring screen for machine selection
      • Wiring Diagram for message DA29KQ
    • DA2YKQ – Motor/Engine Selection Abnormality
      • Monitoring screen for machine selection
    • DA20KQ – Pump Con Selection Abnormality
      • Monitoring screen for PUMP controller selection
    • DLM8MA – Oil cooler fan1 speed sensor abnormality
    • DLMAMA – Oil cooler fan2 speed sensor abnormality
      • Wiring Diagram and monitoring selections for messages DLM8MA and DLMAMA
    • FF11LK – Starter power cut relay1 abnormality
    • FF12LK – Starter power cut relay2 abnormality
    • DDABL4 – Lock lever switch mismatch
      • Wiring Diagram and monitoring selections for message DDABL4
    • DWNPKA – Service arm up solenoid open circuit
      • Wiring Diagram and monitoring screen for message DWNPKA
    • DWNPKB – Service arm up solenoid short circuit
      • Wiring Diagram and monitoring screen for message DWNPKB
    • DWNPKY – Service arm up solenoid hot short circuit
      • Wiring Diagram and monitoring screen for message DWNPKY
    • DWNQKA – Service arm down solenoid open circuit
      • Wiring Diagram and monitoring screen for message DWNQKA
    • DWNQKB – Service arm down solenoid short circuit
      • Wiring Diagram and monitoring screen for message DWNQKB
    • DWNQKY – Service arm down solenoid hot short circuit
      • Wiring Diagram and monitoring screen for message DWNQKY
    • DWACKA – Service arm check valve sol. open circuit
      • Wiring Diagram and monitoring screen for message DWACKA
    • DWACKB – Service arm check valve sol. short circuit
      • Wiring Diagram and monitoring screen for message DWACKB
    • DWACKY – Service arm check valveSol hotShortCircuit
      • Wiring Diagram and monitoring screen for message DWACKY
    • DWADKA – Ladder speed control solenoid open circuit
      • Wiring Diagram and monitoring screen for message DWADKA
    • DWADKB – Ladder speed control sol. short circuit
      • Wiring Diagram and monitoring screen for message DWADKB
    • DWADKY – Ladder speed control sol. hot short circuit
      • Wiring Diagram and monitoring screen for message DWADKY
    • DBW6MA – 5V sensor2 power abnormality
      • Wiring Diagram 1 – 5V power supply and GND output at VALVE0
      • Wiring Diagram 2 – 5V power supply and GND – 10B610 – 10B614
      • Wiring Diagram 3 – 5V power supply and GND – 10B615 – 10B619
      • Wiring Diagram 4 – 5V power supply and GND – 10B620 – 10B624
    • DBW9KQ – Model Selection Abnormality
      • Wiring Diagram and monitoring screen for message DBW9KQ
    • DBWZKQ – Lever control selection abnormality
      • Wiring Diagram and monitoring screens for message DBWZKQ
    • DBWYKQ – Attachment selection abnormality
      • Wiring Diagram and monitoring screens for message DBWYKQ
    • DBW2KK – Solenoid Power Low Error(VALVE/M Con)
      • Wiring Diagram 1 for message DBW2KK
      • Wiring Diagram 2 and monitoring selection for message DBW2KK
    • DBW0KQ – VALVE/M Con Selection Abnormality
      • Monitoring screen and Wiring Diagram for message DBW0KQ
    • DDDWMC – Ladder operation switch abnormality
      • Wiring Diagram and monitoring screen for message DDDWMC
    • DWNRKA – Ladder up solenoid open circuit
      • Wiring Diagram and monitoring selection for message DWNRKA
    • DWNRKB – Ladder up solenoid short circuit
      • Wiring Diagram and monitoring selection for message DWNRKB
    • DWNRKY – Ladder up solenoid hot short circuit
      • Wiring Diagram and monitoring selection for message DWNRKY
    • D5ZWKB – Travel hour meter short circuit
      • Wiring Diagram and monitoring selection for message D5ZWKB
    • D1EUKB – Travel alarm relay short circuit
      • Wiring Diagram and monitoring selection for message D1EUKB
    • DJH2KX – Hydraulic oil level sensor abnormality
      • Wiring Diagram and monitoring screen for message DJH2KX
    • DJE3KX – Remote engine oil level1 sens. abnormality
      • Wiring Diagram and monitoring screen for message DJE3KX
    • DH2GKX – Suction tank pressure sensor abnormality
      • Wiring Diagram and monitoring screen for message DH2GKX
    • DH2HKX – Oil cooler pressure sensor abnormality
      • Wiring Diagram and monitoring screen for message DH2HKX
    • DH2JKX – Preload valve return oil press abnormality
      • Wiring Diagram and monitoring screen for message DH2JKX
    • DHSUKX – X2 pressure sensor abnormality
      • Wiring Diagram and monitoring screen for message DHSUKX
    • DJF1KX – Fuel level sensor abnormality
      • Wiring Diagram and monitoring screen for message DJF1KX
    • DGE5MA – Ambient air temp sensor abnormality
      • Wiring Diagram and monitoring screen for message DGE5MA
    • DH2KKX – Return oil chamber press. sensor abnormal
      • Wiring Diagram and monitoring screen for message DH2KKX
    • DH2LKX – Leak oil chamber press. sensor abnormality
      • Wiring Diagram and monitoring screen for message DH2LKX
    • DJE5L4 – SLS sensor system abnormality
      • Wiring Diagram and monitoring screen for message DJE5L4
    • DJE6L4 – CLS sensor system abnormality
      • Wiring Diagram and monitoring screen for message DJE6L4
    • DBVLKA – Operating Lamp Open Circuit(KOMTRAX)
      • Wiring Diagram for message DBVLKA
    • DBVLKB – Operating Lamp Short Circuit(KOMTRAX)
      • Wiring Diagram for message DBVLKB
    • DBV1KK – KOMTRAX Plus source voltage Error
      • Wiring Diagram for message DBV1KK
    • DBV5KB – 5V sensor1 power abnormality
      • Wiring Diagram 1 and monitoring screen for message DBV5KB
      • Wiring Diagram 2 for message DBV5KB
    • DBV6KB – 24V Sensor Power Abnormality
      • Wiring Diagram 1 and monitoring screens for message DBV6KB
      • Wiring Diagram 2 for message DBV6KB
    • DAFGMC – GPS Module Error
      • Wiring Diagram for message DAFGMC
    • D862KA – GPS Antenna Open Circuit
    • DBVVKR – Ethernet 1 Disconnection
    • DBVWKR – Ethernet 2 Disconnection
    • DA2RKR – CAN1 Discon (Pump Con)
      • CAN1 overview for message DA2RKR
    • DBWRKR – CAN1 Discon (Valve/M Con)
      • CAN1 overview for message DBWRKR
    • DB2QKR – CAN2 Discon (Engine Con)
      • CAN2 overview for message DB2QKR
      • Wiring Diagram for PWR supply at 52K014-1 (DB2QKR)
    • DA2QKR – CAN2 Discon (Pump Con)
      • CAN2 overview for message DA2QKR
    • DBWQKR – CAN2 Discon (Valve/M Con)
      • CAN2 overview for message DBWQKR
    • DBVRKR – CAN1 Discon (KOMTRAX Plus)
      • CAN1 overview for message DBVRKR
    • DBVQKR – CAN2 Discon (KOMTRAX Plus)
      • CAN2 overview for message DBVQKR
    • DBPRKR – CAN1 Discon (KomVision)
      • CAN1 overview for message DBPRKR
    • DBPQKR – CAN2 Discon (KomVision)
      • CAN2 overview for message DBPQKR
    • DAFLKA – Operating Lamp Open Circuit(Monitor)
      • Wiring Diagram for message DAFLKA
    • DAFLKB – Operating Lamp Short Circuit(Monitor)
      • Wiring Diagram for message DAFLKB
    • D19YKB – Emergency Lighting Ladder Relay Short Circuit
      • Wiring Diagram and monitoring screen for message D19YKB
    • DV00KB – Shutdown Buzzer Short Circuit
      • Wiring Diagram and monitoring screen for message DV00KB
    • DAF0KM – Inconsistency of KomVision Setting
    • DBP5KP – Camera Power Output Voltage Low
      • Wiring Diagram for message DBP5KP
    • DBP0NR – KomVision Controller High Temperature Error
    • DPQ4KB – Short Circuit of KomVision Monitor ON/OFF Signal
      • Wiring Diagram for message DPQ4KB
    • DBP0KT – KomVision Controller Internal Error
    • DBP0KM – KomVision Controller Setting 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
      • Wiring Diagram for message DR10KA…DR90KA
    • DPQ4KT – KomVision Monitor Internal Error
    • DBPLKA – Operating Lamp Open Circuit (KomVision)
      • Wiring Diagram for message DBPLKA
    • DBPLKB – Operating Lamp Short Circuit (KomVision)
      • Wiring Diagram for message DBPLKB
    • DBPWKR – Ethernet 1 Discon (KomVision)
    • DBPXKR – Ethernet 2 Discon (KomVision)
  • 7 Troubleshooting by Symptoms
    • 7.1 Symptoms of the engine and related electrical system
    • SEL001 – Engine does not start (engine does not rotate)
      • Wiring Diagram 1 and monitoring selections for Lock lever switch 20S105a/b
      • Wiring Diagram 2 (engine start) for trouble code SEL001 & SEL001a
    • SEL001a – Engine does not start (Pre-lube does not stop)
    • SEL002 – Engine stops while in operation
      • View onto the fuel system water separator (SEL002)
    • SEL003 – Engine speed is hunting during boom-up movement
    • SEL004 – Engine does not stop
    • SEL005 – Engine lacks output (no power)
      • Judgment Table for SEL005
    • SEL006 – Engine does not start (Pre-lube does not stop)
    • SEL007 – Oil consumption is excessive
      • Judgment Table for SEL007
    • SEL008 – Oil becomes contaminated quickly
      • Judgment Table for SEL008
    • SEL009 – Fuel consumption is excessive
      • Judgment Table for SEL009
    • SEL010 – Oil is in engine coolant
      • Judgment Table for SEL010
    • SEL011 – Oil level rises
      • Judgment Table for SEL011
    • SEL012 – Coolant temperature becomes too high (overheating)
      • Judgment Table for SEL012
    • 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 big time lag
    • SHY006 – Excavator deviates during travel movement
    • SHY007 – Hydraulic system has lack of power
    • SHY008 – Excavator does not slew
      • Slew brake block (SHY008)
    • SHY009 – Slew acceleration is poor (or slew speed is very low)
    • SHY010 – Excessive overrun when stopping slew movement
    • SHY011 – Floating system without function (FSA only)
      • Floating system – overview (SHY011)
    • SHY012 – Abnormal noise coming from SRV or MRV
    • SHY013 – Track tensioning system without function
      • View onto the elements of the hydraulic track tensioning system (SHY013)
    • SHY014 – Stairway does not move, or slow movement
    • SHY015 – Refilling arm does not move, or slow movement
    • SHY016 – Refilling arm is sagging when engine is not running
    • SHY017 – The hydr. driven grease pump does not move
    • SHY018 – Abnormal track chain movement during digging
    • SHY019 – Slew parking brake without function
    • SHY020 – Travel parking brake without function
    • 7.3 Symptoms of the Mechanical System
    • SME001 – Abnormal noise is made
      • Judgment Table for SME001
    • SME002 – Abnormal noise around the PTO / hydraulic pumps
    • SME003 – Vibration is excessive (engine mountings)
      • Judgment Table for SME003
    • 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
    • SAD001 – Air conditioner for the cabin does not work
      • View onto the A/C unit (SAD001)
    • SAD002 – Air conditioner compressor clutch is burnt
      • View onto the A/C compressor and its mounting (SAD002)
    • SAD003 – Air conditioning system defective (pipes and hoses full of moisture)
      • View onto an A/C filling and service station
• 50 Disassembly and Assembly
  • Table of Contents
  • 1 Introduction
    • 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
    • 1.5 Explanation of abbreviations
  • 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
      • 2.3.7 Isolate the excavator using the transfer pump
      • 2.3.8 Isolate the excavator
      • 2.3.9 De-isolate the excavator
  • 3 Superstructure
    • 3.1 Superstructure
    • 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
        • 3.2.1.3 Disassembling of the SCR catalysts (T4 Equipment)
        • 3.2.1.4 Assembling of the SCR catalysts (T4 Equipment)
        • 3.2.1.5 Disassembling of the DEF tank assembly (T4 Equipment)
        • 3.2.1.6 Assembling of the DEF tank assembly (T4 Equipment)
      • 3.2.2 Disassembling of the Traverse Assembly
      • 3.2.3 Assembling of the traverse Assembly
        • 3.2.3.1 Disassembling of the handrails
        • 3.2.3.2 Assembling of the handrails
      • 3.2.4 Air intake system
        • 3.2.4.1 Disassembling of the air intake system
        • 3.2.4.2 Assembling of the air intake system
    • 3.3 Diesel engine
      • 3.3.1 Disassembling of the Diesel engine
      • 3.3.2 Assembling of the diesel engine
      • 3.3.3 Disassembling of the batteries
      • 3.3.4 Assembling of the batteries
    • 3.4 Flexible drive coupling
      • 3.4.1 Disassembling of the CentaFlex coupling assembly
      • 3.4.2 assembling of the CentaFlex coupling assembly
    • 3.5 Engine cooling system
      • 3.5.1 Radiator assembly
        • 3.5.1.1 Disassembling of the Radiator assembly
      • 3.5.2 assembling of the radiator assembly
      • 3.5.3 Disassembling of the radiator fan assembly
        • 3.5.3.1 Assembling of the radiator fan assembly
      • 3.5.4 Main pumps assemblies
        • 3.5.4.1 Preparatory works for main pump disassembling
        • 3.5.4.2 Disassembling of main pump 1…3 assembly
        • 3.5.4.3 Assembling of main pump 1…3 assembly
        • 3.5.4.4 Disassembling of the Auxiliary pump (Pilot oil pump)
        • 3.5.4.5 Assembling of the pilot oil pump
      • 3.5.5 Pump distributor gear box (PTO)
        • 3.5.5.1 Disassembling of the pump distributor gear box (PTO)
        • 3.5.5.2 Assembling of the pump distributor gear box (PTO)
    • 3.6 Hydraulic system
      • 3.6.1 hydraulic cooler fan assembly
        • 3.6.1.1 Disassembling of the hydraulic cooler fan assembly
        • 3.6.1.2 Assembling of the hydraulic cooler fan assembly
        • 3.6.1.3 Disassembling of hydraulic cooler fan and motor
        • 3.6.1.4 Assembling of hydraulic cooler fan and motor
        • 3.6.1.5 Disassembling of the hydraulic oil coolers
        • 3.6.1.6 Assembling of the hydraulic oil coolers
        • 3.6.1.7 Disassembling of the hydraulic oil cooler Assembly
        • 3.6.1.8 Assembling of the hydraulic oil cooler Assembly
      • 3.6.2 Main shut off valve
        • 3.6.2.1 Disassembling of the main shut off valve
        • 3.6.2.2 Assembling of the main shut off valve
      • 3.6.3 Hydraulic oil tank
        • 3.6.3.1 Disassembling of the hydraulic oil tank
        • 3.6.3.2 Assembling of the hydraulic oil tank
      • 3.6.4 Main control valve blocks
        • 3.6.4.1 Disassembling of the main control valve blocks
        • 3.6.4.2 Assembling of the main control valve blocks
        • 3.6.4.3 Disassembling of the MRV at the main control valve blocks
        • 3.6.4.4 Assembling of the MRV at the main control valve blocks
        • 3.6.4.5 Disassembling of SRV on main control valve block
        • 3.6.4.6 Assembling of SRV on main control valve blocks
        • 3.6.4.7 Disassembling of ACV-/SRV-block on main control valve blocks
        • 3.6.4.8 Assembling of ACV-/SRV-block on main control valve blocks
      • 3.6.5 Distributor Manifold
        • 3.6.5.1 Disassembling of anti cavitation valve blocks at the distributor manifold
        • 3.6.5.2 Assembling of anti cavitation valve blocks at the distributor manifold
        • 3.6.5.3 Disassembling of throttle check valves at the distributor manifold
        • 3.6.5.4 Assembling of throttle check valves at the distributor manifold
        • 3.6.5.5 Disassembling of the diffuser block on the distributor manifold (FSA only)
        • 3.6.5.6 Assembling of the diffuser block on the distributor manifold (FSA only)
        • 3.6.5.7 Disassembling of the manifold
        • 3.6.5.8 Assembling of the manifold
    • 3.7 Slew system
      • 3.7.1 Slew gear box
        • 3.7.1.1 Disassembling of the slew gear box
        • 3.7.1.2 Assembling of the slew gear box
      • 3.7.2 slew brake valve block
        • 3.7.2.1 Disassembling of the slew brake valve block
        • 3.7.2.2 Assembling of the slew brake valve block
      • 3.7.3 Slew motor
        • 3.7.3.1 Disassembling of the slew motor
        • 3.7.3.2 Assembling of the slew motor
      • 3.7.4 Slew parking brake
        • 3.7.4.1 Disassembling the slew parking brake of type 2063
        • 3.7.4.2 Assembling the slew parking brake of type 2063
        • 3.7.4.3 Disassembling of the slew parking brake assembly of type 632770
        • 3.7.4.4 Assembling of the slew parking brake assembly of type 632770
      • 3.7.5 Slew circle lubrication pinion (dummy wheel)
        • 3.7.5.1 Disassembling of the slew circle lubrication pinion assembly
        • 3.7.5.2 Assembling of the slew circle lubrication pinion assembly
      • 3.7.6 Slew circle
        • 3.7.6.1 Disassembling of the slew circle
        • 3.7.6.2 Assembling of the slew circle
    • 3.8 Lubrication pumps
      • 3.8.1 Disassembling of the lubrication pump
      • 3.8.2 Assembling of the lubricating pump
    • 3.9 Operator’s cab
      • 3.9.1 Disassembling of the operator’s cab
      • 3.9.2 Assembling of the operator’s cab
      • 3.9.3 Cab mounts
        • 3.9.3.1 Disassembling of the cab mounts
        • 3.9.3.2 Assembling of the cab mounts
      • 3.9.4 Front window (windshield)
        • 3.9.4.1 Disassembling of the front window
        • 3.9.4.2 Assembling of the front window
      • 3.9.5 Operator’s seat
        • 3.9.5.1 Disassembling of the operator’s seat
        • 3.9.5.2 Assembling of the operator’s seat
    • 3.10 Cab base
      • 3.10.1 Disassembling of the cab base
      • 3.10.2 Assembling of the cab base
    • 3.11 Hydraulic access Stairway
      • 3.11.1 Disassembling of access Stairway
      • 3.11.2 Assembling of access Stairway
      • 3.11.3 Disassembling of access ladder cylinder
      • 3.11.4 Assembling of access stairway cylinder
    • 3.12 Counterweight
      • 3.12.1 Disassembling of the counterweight
      • 3.12.2 Assembling of the counterweight
    • 3.13 Fuel tank
      • 3.13.1 Disassembling of the fuel tank
      • 3.13.2 Assembling of the fuel tank
      • 3.13.3 Disassembling of the fuel cooler box
      • 3.13.4 Assembling of the fuel cooler box
    • 3.14 Superstructure lifting
      • 3.14.1 Disassembling the superstructure from the undercarriage
      • 3.14.2 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
        • 4.2.2.1 Disassembling of the sprocket
        • 4.2.2.2 Assembling of the sprocket
      • 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 Substitute the hydraulic hoses of the track tensioning system
        • 4.2.7.1 Precursory work
        • 4.2.7.2 Replace the hydraulic hoses inside the car body
        • 4.2.7.3 Replace the hydraulic hose between the car body and the 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
        • 4.2.11.1 Disassembling of the travel gear box
        • 4.2.11.2 Assembling of the travel gear box
      • 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
    • 4.3 Car body
      • 4.3.1 Disassembling of the car body and the crawler carriers
      • 4.3.2 Assembling of the car body and the crawler carriers
        • 4.3.2.1 Install crawler carrier mounting bolts
      • 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
      • 5.1.2 General installation instructions for attachment pins
    • 5.2 Backhoe
      • 5.2.1 Overview
      • 5.2.2 Pin Sealing bucket – Steering Rod – bucket link rod
      • 5.2.3 Boom
        • 5.2.3.1 Disassembling of the boom
        • 5.2.3.2 Assembling of the boom
        • 5.2.3.3 Disassembling of boom cylinders
        • 5.2.3.4 Assembling of boom cylinders
      • 5.2.4 Stick assembly
        • 5.2.4.1 Disassembling of the stick
        • 5.2.4.2 Assembling of the stick
        • 5.2.4.3 Disassembling of the stick cylinders
        • 5.2.4.4 Assembling of the stick cylinders
      • 5.2.5 Bucket and steering
        • 5.2.5.1 Disassembling of the bucket
        • 5.2.5.2 Assembling of the bucket
        • 5.2.5.3 Disassembling of bucket cylinders
        • 5.2.5.4 Assembling of bucket cylinders
        • 5.2.5.5 Disassembling of the bucket link rod
        • 5.2.5.6 Assembling of the bucket link rod
        • 5.2.5.7 Disassembling of the steering rods
        • 5.2.5.8 Assembling of the steering rod
      • 5.2.6 Hydraulic hoses at the backhoe attachment
        • 5.2.6.1 Replacement of the boom arc hoses
        • 5.2.6.2 Replacement of the boom cylinder hoses
        • 5.2.6.3 Replacement of the stick cylinder hoses
        • 5.2.6.4 Replacement of the bucket cylinder hoses
    • 5.3 Face shovel
      • 5.3.1 Overview
      • 5.3.2 Using the Cylinder Mounting Device for Front shovel attachments (PN 967 000 40)
        • 5.3.2.1 Designated usage
        • 5.3.2.2 Non-designated usage
      • 5.3.3 Boom
        • 5.3.3.1 Disassembling of the boom
        • 5.3.3.2 Assembling of the boom
        • 5.3.3.3 Disassembling of the boom cylinders
        • 5.3.3.4 Assembling of the boom cylinders
      • 5.3.4 Stick assembly
        • 5.3.4.1 Disassembling of the stick
        • 5.3.4.2 Assembling of the stick
        • 5.3.4.3 Disassembling of the stick cylinders
        • 5.3.4.4 Assembling of the stick cylinders
      • 5.3.5 Bull clam bucket
        • 5.3.5.1 Disassembling of the bull clam bucket
        • 5.3.5.2 Assembling of the bull clam bucket
        • 5.3.5.3 Disassembling of the bucket cylinders
        • 5.3.5.4 Assembling of the bucket cylinders
        • 5.3.5.5 Disassembling of the clam cylinders
        • 5.3.5.6 Assembling of the clam cylinders
      • 5.3.6 Hydraulic hoses at the face shovel attachment
        • 5.3.6.1 Replace the boom arc hoses
        • 5.3.6.2 Replace the boom cylinder hoses
        • 5.3.6.3 Replace the stick arc hoses
        • 5.3.6.4 Replace the stick cylinder hoses
        • 5.3.6.5 Replace the bucket cylinder hoses
        • 5.3.6.6 Replace the clam cylinder hoses
    • 5.4 Metering valves (grease injectors) at the attachment
      • 5.4.1 Disassembling of the metering valves (grease injectors)
      • 5.4.2 Assembling of the metering valves (grease injectors)
    • 5.5 Ground engaging tools (GET)
      • 5.5.1 Disassembling and assembling of the GET
    • 5.6 Cylinder bypass test
  • 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 Face 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 Torque Charts for Flange Joints
      • 6.5.6 Tightening Torque for hydraulic hose connecting nut
    • 6.6 Blind plugs
      • 6.6.1 Dummy plates for hydraulic–flanges
      • 6.6.2 Classification of threads to the nominal width
      • 6.6.3 Plugs and fittings according to DIN 2353
    • 6.7 Conversion table
      • 6.7.1 Method of using the conversation 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
      • 6.8.2 Used special tools (Overview)
    • 6.9 Work instructions
      • 6.9.1 Bleeding the track tensioning system
      • 6.9.2 General installation procedures for hydraulic hose lines
      • 6.9.3 Remove / install the crawler carrier
      • 6.9.4 Repair procedure for the radiator assembly
  • 7 Parts & Service News
    • 7.1 List of The PARTS AND SERVICE NEWS