SHOP 06279-xD-GB-1

Shop Manual

HYDRAULIC
MINING PC3000-6
SHOVEL
SERIAL NUMBERS
06279, 06308, 06309, 06310,
06314 and up
(TIER2 & KOMTRAX Plus)

Unsafe use of this machine may cause serious

injury or death. Operators and maintenance
personnel must read this manual before operating
or maintaining this machine.
This manual should be kept near the machine
for reference and must be periodically reviewed
by all personnel who will come into contact with it.

The original Shop Manual is written in English

language. If any translation of the Shop Manual is
used, the legal basis for liability and correctness of
the contents always remains in the English source
document.

SHOP 06279-xD-GB-1 PC3000-6

 COPYRIGHT

This material is property of Komatsu Germany GmbH and is not to be reproduced, used, or dis-
closed except in accordance with the written authorization of Komatsu Germany GmbH. It is our
policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or add improvements at any time without incurring any obligation to install such
changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to
this publication. It is recommended that the customer contact their distributor for information on the
latest revision.

PC3000-6 SHOP 06279-xD-GB-1

HYDRAULIC MINING EXCAVATOR

PC3000-6

Machine model Serial numbers

PC3000-6 06279, 06308, 06309, 06310, 06314 and up
with TIER2 & KOMTRAX Plus

00 Foreword and Safety Instructions

Release 1 04/2017

® Copyright 2017 KOMATSU GERMANY GmbH

PC3000-6 1
2 PC3000-6
Foreword

1 FOREWORD

SHOP 06279-xD-GB-1 PC3000-6 1 -1

BEFORE READING THIS MANUAL Foreword

1.1 BEFORE READING THIS MANUAL

This manual gives details of the methods of inspection, maintenance and troubleshooting for this machine that
must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental
safety rules for the inspection, maintenance and troubleshooting of machines.

Read, understand and follow all precautions and warnings in this manual and on the machine before performing
inspection, maintenance or troubleshooting. Failure to do so may result in serious injury or death.

Komatsu cannot predict every circumstance that may involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety
precautions. If you carry out any inspection, maintenance and troubleshooting under conditions that are not
described in this manual, understand that it is your responsibility to take the necessary precautions to ensure
safety. In no event should you or others engage in prohibited uses or actions described in this manual.
Improper inspection, maintenance and troubleshooting of the machine can be hazardous and could result in
serious injury or death.

If you sell the machine, be sure to give this manual to the new owner together with the machine.

This manual uses the international units (SI) for units of measurement. For reference, units that have been used
in the past are given in ( ).

The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the
latest available information concerning your machine or with questions regarding information contained in this
manual.

Komatsu delivers machines that comply with all applicable regulations and standards of the country to which
it has been shipped. If the machine has been purchased in another country, it may lack certain safety devices
and specifications that are necessary for use in your country. If there is any question about whether your
product complies with the applicable standards and regulations of your country, consult Komatsu or your
Komatsu distributor before operating the machine.

1 -2 PC3000-6 SHOP 06279-xD-GB-1

Foreword CONTENTS OF THIS BINDER

1.2 CONTENTS OF THIS BINDER

This Shop Manual has been prepared as a SERVICE GUIDE for the mechanic responsible for the upkeep of your
hydraulic mining shovel.
It is compiled into different sections and summarizes the procedures for inspection, maintenance and trouble-
shooting on the machine.

All information, illustrations and specifications contained herein are based on the development at printing time
and may be subject to possible future changes by KOMATSU without prior notice.
Also note that all procedures given in this manual are for a basic machine. Your machine may be differently
equipped and/or otherwise customized.

This manual may contain attachments and optional equipment that are not available in your area. Please consult
your local Komatsu distributor for those items you may require. Materials and specifications are subject to change
without notice.

If, after reading this Shop Manual, you can give us suggestions and comments for improvements - please do not
hesitate to contact us.

Komatsu Mining GmbH

Mining Division

Service Information
Department 8151.40
P.O. Box 18 03 61
D - 40570 Düsseldorf
GERMANY

1.2.1 CONTACTING THE SERVICE

In all your written or phoned inquiries, please indicate the model and serial number of your shovel.

1.2.2 GUARANTEE
Damages and defects caused by incorrect inspection, maintenance or troubleshooting are not covered by the
manufacturer’s guarantee.

In order to keep your shovel in first-class operating condition only use genuine spare and wear parts.

The use of any part other than the genuine part releases the KOMATSU GERMANY GmbH from any guarantee.

SHOP 06279-xD-GB-1 PC3000-6 1 -3

DIVISION OF THE BINDER Foreword

1.3 DIVISION OF THE BINDER

Part 00 Foreword:

– Foreword
– Safety Instructions

Part 01 Specifications:

– Machine Specifications

Part 10 Structure & Function

– Service Manual

Part 40 Troubleshooting

– Troubleshooting Manual

Part 50 Disassembly & Assembly

– Disassembly & Assembly Manual

1 -4 PC3000-6 SHOP 06279-xD-GB-1

SAFETY

2 SAFETY

IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS

INJURY OR DEATH.
Please read and make sure that you fully understand the precautions described in this section and the
safety labels on the machine. When operating or servicing the machine, always follow these precaution
strictly.

General Safety Version 6 2-1

SAFETY INFORMATION SAFETY

2.1 SAFETY INFORMATION

To enable you to use this machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed.

The safety information in this manual does not replace any safety rules or laws in your area.

To identify important safety messages in the manual and on the machine labels, the following signal words are
used.

The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.

DANGER
This signal word indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.

WARNING
This signal word indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.

CAUTION
This signal word indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.

NOTICE
This signal word is used to alert you to information that must be followed to avoid damage to the machine.
This precaution is given where the machine may be damaged or the service life reduced if the precaution
is not followed.

NOTE! This word is used in regard to non-specific safety relevant information.

REMARKS: This word is used for information that is useful to know.

2-2 General Safety Version 6

SAFETY OVERVIEW

2.2 OVERVIEW
The appropriate safety information for specific working modes on the excavator can be found in the following:-

2.2.1 NORMAL OPERATIONS

– For normal operating procedures, refer to the OPERATION section of the Operation and Maintenance Manual.
– For operational safety information, refer to section 2.4 on page 2-5.
– For on site safety information, refer to section 2.4.10 on page 2-14.

2.2.2 REGULAR MAINTENANCE

– For information on regular maintenance, including maintenance intervals, refer to the MAINTENANCE section
of the Operation and Maintenance Manual.
– For maintenance safety information, refer to section 2.5 on page 2-26.

2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR

– For additional safety information for troubleshooting and adjustments refer to section 2.6 on page 2-39.
– For maintenance solutions, refer to the separate manuals TROUBLESHOOTING manual. Available through
Komatsu Germany.
– For servicing information and adjustments, refer to the separate SERVICE MANUAL. Available through
Komatsu Germany.

2.2.4 ADDITIONAL SAFETY PRECAUTIONS

For Assembling, Disassembling and Transportation of the Excavator

– Prior to starting assembling, disassembling and transportation of the excavator read and follow the additional
safety precautions given in the ASSEMBLY PROCEDURE MANUAL.

General Safety Version 6 2-3

SOUND PRESSURE AND VIBRATION LEVELs IN THE OPERATOR’S CAB. SAFETY

2.3 SOUND PRESSURE AND VIBRATION LEVELS IN

THE OPERATOR’S CAB.

Fig. 2-1

2.3.1 SOUND
The sound pressure level in the operator’s cab is measured according to ISO 6396 (Dynamic test method), see
Fig. 2-1.

2.3.2 VIBRATION
Information concerning hand - arm and whole body vibrations according to 2002/44/EC

– Hand-arm vibration emission is below the limit value of 2.5 m/s²

– Whole body vibration emission is below the limit value of 0.5 m/s²

2-4 General Safety Version 6

SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4 GENERAL PRECAUTIONS COMMON TO OPERA-

TION ON THE EXCAVATOR
WARNING
WHEN MISUSED, THESE MACHINES ARE DANGEROUS.
Mistakes in operation, inspection, or maintenance may result in personal injury or death.
Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels
on the machine carefully and obey the warnings.

2.4.1 UNDERSTANDING THE MACHINE

Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not
understand, ask the person in charge of safety to give an explanation.

2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE

EXCAVATOR

2.4.2.1 ENSURING SAFE OPERATION

– Only trained and authorized personnel can operate and maintain the machine.
– During operations, personnel are not allowed outside of the operator’s cabin.
– Follow all safety rules, precautions and instructions when operating or performing inspection or maintenance
on the machine.
– If you are not feeling well, or are under the influence of alcohol or medication, your ability to safely operate or
repair your machine may be severely impaired putting yourself and everyone else on your jobsite in danger.
– When working with another operator or with a person on worksite traffic duty, discuss the content of the opera-
tion beforehand and use pre-determined signals when carrying out these operations.

2.4.3 PREPARATIONS FOR SAFE OPERATION

2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT

– Be sure that all guards, covers and mirrors are in their proper positions. Have guards and covers repaired
immediately if they are damaged.
– Understand the method of use of safety features and use them properly.
– Never remove any safety features. Always keep them in good operating condition.

2.4.3.2 INSPECTING THE MACHINE

Check the machine before starting operations. If any abnormality is found, do not operate the machine until repairs
of the problem location have been completed.

General Safety Version 6 2-5

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT

Refer to Fig. 2-2:

– Do not wear loose clothing and accessories. If these catch on

the control levers or moving parts, there is a danger that it
may cause the machine to move unexpectedly.
– Always wear a hard hat and safety shoes when working on
the machine outside of the cabin. If the nature of the work
requires it, wear safety glasses, mask, gloves, ear plugs and
a safety belt when operating or maintaining the machine.
– If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine, so
tie your hair up and be careful not to let it get caught.
– Check that all protective equipment functions properly before Fig. 2-2
using it.

2.4.3.4 KEEP MACHINE CLEAN

Refer to Fig. 2-3:

– If you get on or off the machine or carry out inspection or

maintenance when the machine is dirty with mud or oil, there
is a hazard that you will slip and fall. Wipe off any mud or oil
from the machine. Always keep the machines clean.
– If water gets into the electrical system, there is a hazard that it
will cause malfunctions or a misoperation. If there is any
misoperation, there is a danger that the machine may move
unexpectedly and cause serious personal injury or death.
When washing the machine with water or steam, do not allow
the water or steam to come into direct contact with electrical
components.
Fig. 2-3

2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT

– When entering the operator’s compartment, always remove all mud and oil from your shoes. If you operate the
pedal with mud or oil affixed to your shoes, you may slip and this may cause a serious accident.
– Do not leave tools or machine parts lying around inside the operator’s compartment. If tools or parts get into
the control devices, they may obstruct operation and cause the machine to move unexpectedly, resulting in
serious personal injury or death.
– Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
– Do not use a cell phone when driving or operating the machine. This may lead to mistakes in operation, which
could cause serious personal injury or death.
– Never bring any dangerous objects such as flammable or explosive items into the operator’s compartment.

2-6 General Safety Version 6

SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT

Always follow the precautions below to prepare for action if any
injury or fire should occur, refer to Fig. 2-4.

– Be sure that fire extinguishers have been provided and read

the labels to ensure that you know how to use them in emer-
gencies.
– Carry out periodic inspection and maintenance to ensure that
the fire extinguisher can always be used.
– Provide a first aid kit. Carry out periodic checks and add to
the contents if necessary.

Fig. 2-4

2.4.3.7 IF A PROBLEM IS FOUND

If you find any problems in the machine during operation and maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil, leakage, etc., or any abnormal display on the warning devices or monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the problem has been corrected.

2.4.4 FIRE PREVENTION

2.4.4.1 PRECAUTIONS TO PREVENT FIRE

Fire caused by fuel, oil, antifreeze, or window washer fluid.

Do not bring any flame or fire close to flammable substances such as fuel, oil, antifreeze, or window washer fluid.
There is a danger they may catch fire. To prevent fire, always observe the following:

Refer to Fig. 2-5:

– Do not smoke or use any flame near fuel or other flamma-

ble substances.
– Stop the motors before adding fuel.
– Do not leave the machine while adding fuel or oil.
– Tighten all fuel and oil caps securely.
– Be careful not to spill fuel on overheated surfaces or on
parts of the electrical system.
– After adding fuel or oil, wipe up any spillage.
– Put greasy rags and other flammable materials into a safe
container to maintain safety in the workplace. Fig. 2-5
– When washing parts with oil, use a non-flammable oil. Do
not use diesel oil or gasoline. There is a danger that they
may catch fire.
– Do not weld or use a cutting torch to cut any pipe or tubes
that contain flammable liquids.
– Determine well ventilated areas for storing oil and fuel. Keep
the oil and fuel in the determined place and do not allow
unauthorised persons to enter.

General Safety Version 6 2-7

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

NOTICE
Before carrying out grinding or welding work on the machine, remove any flammable materials.

– Fire caused by accumulation of flammable material.

Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
affixed around the motors, exhaust manifold, muffler or battery, or inside the undercovers.
– Fire coming from electrical wiring
Short circuits in the electrical system can cause fire. To prevent fire, always observe the following:
– Keep all electrical connections clean and securely tightened.
– Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps.
Repair or replace any damaged wiring.
– Fire coming from piping
Check that all hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. There is a danger that this
may lead to damage to the hoses and cause high pressure oil to spurt out, leading to fire, personal injury, or
death.
– Explosion caused by lighting equipment
– When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifica-
tions.
– When taking the electrical power for the lighting from the machine itself, follow the instructions of this man-
ual.

2-8 General Safety Version 6

SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.4.2 ACTION IF FIRE OCCURS

– Activate the STOP switch to stop the motor.
– Use the access ladders and steps to get off the machine.
– When escaping from the cab, use the rope ladder provided
for emergency escape or the mechanically operated ladder to
descend down the side of the cab, refer to Fig. 2-6.

Fig. 2-6

– After escaping with the emergency escape ladder, activate

the motor stop chains ( Fig. 2-7 Pos. 1) to shut down the
motor if they are equipped on your shovel.

Fig. 2-7

2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB

– If the cab door does not open, or is unabled to be used cor-

rectly, use the window for an emergency escape from the
operator’s cab (1).
– Break the glass using the emergency hammer (2)
– Remove the glass to get safe access to the locks.
– Turn the four levers (4) mounted on the sun visor 180° in any
direction to remove the sun visor.
– Push out the visor and let it drop down.
– Exit the cabin very carefully through the window.

Fig. 2-8

General Safety Version 6 2-9

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE

2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE
To prevent personal injury caused by slipping or falling off the machine, always do as follows.

– Always use the handrails and steps when getting on or off the
machine.
– To ensure safety, always face the machine and maintain
three-point contact (both feet and one hand, or both hands
and one foot - see Fig. 2-9). with the handrails and steps to
ensure that you support yourself.
– When walking on the machine, move only in areas that have
non-slip padded walkways and non-slip gratings. Extra care is
to be taken when moving outside of these areas.
– Before getting on or off the machine, check the handrails and
steps. If there is any oil, grease, or mud on the handrails or
steps, wipe it off immediately. Always keep these parts clean.
Repair any damage and tighten any loose bolts. Fig. 2-9

2.4.5.2 NO JUMPING ON OR OFF THE MACHINE

– Never jump on or off the machine. Never get on or off a moving machine.
– If the machine starts to move when there is no operator on the machine, do not jump onto the machine and try
to stop it.

2.4.5.3 NO PEOPLE ON THE ATTACHMENT

Never let any person mount the boom, arm, bucket, or other attachment without appropriate safety equipment.
There is danger of falling and suffering serious personal injury. Refer to further information refer to section 2.7 on
page 2-40.

2.4.5.4 WORKING IN HIGH PLACES

When working in high places, use safety harness and fall absorber to ensure that the work can be carried out
safely. For further information refer to section 2.7 on page 2-40.

2 - 10 General Safety Version 6

SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK

Refer to Fig. 2-10:

– Before standing up from the operator's seat in order to adjust

the seat, always lower the work equipment to the ground, turn
off the motor, relieve the pressure in the hydraulic system and
set lock lever to LOCK position (Position L). If the lock is not
applied, there is danger of serious personal injury if the work
equipment control levers are touched by mistake and the
machine moves suddenly. For information on relieving the
pressure in the hydraulic system, refer to chapter ’RELIEV-
ING THE PRESSURE IN THE HYDRAULIC SYSTEM’ in the
’OPERATION’ part of this manual.

Fig. 2-10

2.4.5.6 LEAVING THE MACHINE

– When leaving the machine, always lower the work equipment
completely to the ground, turn off the motor, relieve the pres-
sure in the hydraulic system and set lock lever (1) securely to
the LOCK position (L), then stop the motor. Always lock the
cabin and take the cabin key with you, and keep it in a speci-
fied place. For information on relieving the pressure in the
hydraulic system, refer to chapter ’RELIEVING THE PRES-
SURE IN THE HYDRAULIC SYSTEM’ in the ’OPERATION’
part of this manual.

Fig. 2-11

2.4.6 BURN PREVENTION

2.4.6.1 HOT COOLANT

Refer to Fig. 2-12:

– To prevent burns from hot water or steam spurting out when

checking or draining the coolant, wait for the water to cool to a
temperature where it is possible to touch the radiator cap
(Fig. 2-13) by hand before starting the operation. Even when
the coolant has cooled down, loosen the cap slowly to relieve
the pressure inside the radiator before removing the cap.

Fig. 2-12

General Safety Version 6 2 - 11

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

2.4.6.2 HOT OIL

Refer to Fig. 2-13:

– To prevent burns from hot oil spurting out when checking or

draining the oil, wait for the oil to cool to a temperature where
it is possible to touch the cap or plug by hand before starting
the operation. Even when the oil has cooled down, loosen the
cap or plug slowly to relieve the internal pressure before
removing the cap or plug.

Fig. 2-13

2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS

Always keep the cab glass clean to ensure good visibility when operating.

Use an ethyl alcohol based washer liquid. Methyl alcohol based liquid may irritate your eyes, so do not use it.

If the cab glass on the work equipment side is broken, there is a hazard that the intruding objects may contact the
operator's body directly. Stop operation immediately and replace the glass.

2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

On jobsites where there is a hazard that falling objects (Fig. 2-14),
flying objects (Fig. 2-15), or intruding objects may hit or enter the
operator's cab, consider the operating conditions and install the
necessary guards to protect the operator.

– When carrying out operations in mines or quarries where

there is danger of falling or flying rocks, order/use the option-
ally available front guard.
– When carrying out the above operations, always ensure that
bystanders are a safe distance away and are not in hazard
from falling or flying objects.

Fig. 2-14

– The above recommendations assume that the conditions are

for standard operations, but it may be necessary to add addi-
tional guards according to the operating conditions on the job-
site. Always contact your Komatsu distributor for advice.

Fig. 2-15

2 - 12 General Safety Version 6

SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.8.1 UNAUTHORIZED MODIFICATION

– Komatsu will not be responsible for any injuries, accidents, product failures or other property damage resulting
in modifications made without authorisation from Komatsu.
– Any modifications made without authorisation from Komatsu can create hazards. Before making a modifica-
tion, consult your Komatsu distributor.

2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS

– Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not
be the responsibility of Komatsu.

2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)

The use of retrofitted electrical and electronic equipment such as radars, computers, radio units and other appli-
ances, working with high frequency electromagnetic waves, can interfere with the electronic control system of the
excavator which can lead to damage to the machine and to personnel.

Only use equipment which meets the requirements of the standard ISO 13766 - Electromagnetic Compatibility for
Earth-Moving Machinery. Obtain advice from authorized electricians regarding the electromagnetic compatibility of
the equipment, prior to installation.

REMARKS: If appliances which interfere with the electronic control system of the excavator are installed, control
of the excavator will be impaired. If a malfunction is experienced, release the operating levers and
the pedals and strike the emergency shut-down button.

Komatsu can not be made liable for any injuries, accidents, product failures or other property dam-
age resulting from installation of non-EMC certified equipment.

General Safety Version 6 2 - 13

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

2.4.10 PRECAUTIONS AT JOBSITE

Fig. 2-16

2 - 14 General Safety Version 6

SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4.10.1 VISIBILITY FROM OPERATOR’S SEAT

WARNING
THE AREA AROUND THE EXCAVATOR DURING OPERATION IS EXTREMELY DANGER-
OUS!
Death and serious injury can occur. Make sure the job site is organized in such a way, that the safety of
man and equipment is always ensured.

Fig. 2-16 shows an example of general blind areas of large Komatsu hydraulic mining shovels.

The shaded areas (A) show the areas where the view is blocked when the operator is sitting in the operator’s seat,
and the shovel is equipped with standard mirrors. The boundary line (B) shows the distance of 1 meter from out-
side surface of the shovel. Please be fully aware that there are places that can not seen when operating the
machine.

REMARKS: The blind areas (A) differ depending on the machine type, attachment and position of attachment.

The International Standard ISO 5006 defines criteria for Operator’s visibility. This standard is not met
and does not apply to large hydraulic mining shovels.

2.4.10.2 CAMERA SYSTEM WITH MONITORS

Komatsu Germany offers optionally camera systems and monitors to improve the overall visibility. See latest ver-
sion of the OMM for typical arrangement of cameras and monitors.

The camera system can be installed ex works and can also be retrofitted in the field. If you need more information,
please contact your local Komatsu distributor.

2.4.10.3 ENSURE GOOD VISIBILITY

When operating or travelling in places with poor visibility, if it is impossible to confirm the condition of the job side
or obstacle is in the area around the machine, there is danger that the machine may suffer damage or the operator
may suffer serious personal injury. When operating or travelling in places with poor visibility, always observe the
following items strictly.

– If the visibility cannot be sufficiently assured, position a flagman if necessary. The operator should pay careful
attention to the signs and follow the instructions of the flagman.
– The signals should be given only by one flagman.
– When working in dark places, turn on the working lamps and front lamps of the machine, and if necessary, set
up additional lighting in the area.
– Stop operations if there is poor visibility, such as in fog, snow, rain, or sand storms.
– Check the mirrors on the machine before starting operations every day. Clean off any dirt and adjust the view
to ensure good visibility.
– In areas where it is impossible to confirm the area around the machine and observation cameras have been
set up, clean off any dirt from the lens and make sure that the cameras give a clear view of the working area of
the machine.

2.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS

– Set up signs to inform of road shoulders or soft ground. If the visibility is not good, position a signalman if nec-
essary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
– Only one signalman should give signals.
Make sure that all workers understand the meaning of all signals and signs before starting work.

General Safety Version 6 2 - 15

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS

On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting opera-
tions, always check the following to confirm there are no dangers on the jobsite.

– When carrying out operations near combustible materials,

there is a hazard of fire, so be careful when operating.
– Check the terrain and condition of the ground at the worksite,
and determine the safest method of operation. Do not operate
where there is a hazard of landslides or falling rocks.
– If water lines, gas lines, or high-voltage electrical lines may be
buried under the worksite, contact each utility and identify
their locations. Be careful not to sever or damage any of
these lines (Fig. 2-17).
– Take necessary measures to prevent any unauthorized per-
son from entering the operating area.
– If there is a fire near the machine, there is danger of sparks
being sucked in and causing a fire on the machine. Fig. 2-17

– When travelling or operating in shallow water or on soft

ground, check the shape and condition of the bedrock, and
the depth and speed of flow of the water before starting oper-
ations.
– Maintain the travel path on the jobsite so that there is no
obstruction to travel operations.

2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES

DANGER
HIGH VOLTAGE!
Do not travel or operate the machine near electric cables
(Fig. 2-18). There is a hazard of electric shock, which may
cause serious injury or property damage. Even going close
to high-voltage cables can cause an electric shock, which
may cause serious burns or even death.

Fig. 2-18

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SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

On jobsites where the machine may go close to electric cables,

always do as follows.
Voltage of Cables Safety Distance
– Before starting work near electric cables, inform the local 100 V - 200 V Over 2 m (7 ft)
power company of the work to be performed, and ask them to 6,600 V Over 2 m (7 ft)
take the necessary action. 22,000 V Over 3 m (10 ft)
– Always maintain a safe distance (see the table on the right) 66,000 V Over 4 m (14 ft)
between the machine and the electric cable. Check with the 154,000 V Over 5 m (17 ft)
local power company about safe operating procedure before 187,000 V Over 6 m (20 ft)
starting operations. 275,000 V Over 7 m (23 ft)
– To prepare for any possible emergencies, wear rubber shoes 500,000 V Over 11 m (36 ft)
and gloves. Lay a rubber sheet on top of the seat, and be
careful not to touch the chassis with any exposed part of your
body.
– Use a signalman to give warning if the machine approaches
too close to the electric cables.
– When carrying out operations near high voltage cables, do
not let anyone near the machine.
– If the machine should come too close or touch the electric
cable, to prevent electric shock, the operator should not leave
the operator's compartment until it has been confirmed that
the electricity has been shut off. Also, do not let anyone near
the machine.

2.4.10.7 WORKING ON LOOSE GROUND

– Avoid travelling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or
after earthquakes is weak in these areas.
– When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of
the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is
safe and to prevent the machine from rolling over or falling.

2.4.10.8 GAS, DUST, STEAM AND SMOKE

WARNING
RISK OF EXPOLSION AND FIRE!
Welding, flame-cutting and grinding work on the machine increases the risk of explosion and fire which
may result in serious injury or death.

All relevent safety measures must be followed and only under expressly obtained authorization.

Special care must be taken before welding, flame-cutting and grinding operations are carried out on the
counterweight. The filling of the counterweight chambers can create explosive gases which will accumu-
late in the chambers of the counterweight.

These gases must be expelled before welding, flame-cutting and grinding operations are carried out on
the counterweight.

REMARKS: Follow the instructions given in PARTS & SERVICE NEWS No. AH04518 for expelling the gases
from the counterweight chambers. (See Volume 2 binder)

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GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

WARNING
RISK OF EXPLOSION!
Substances and objects igniting can lead to fire or explosion resulting in serious injury or death.
Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surround-
ings from dust and other inflammable substances and make sure that the premises are adequately venti-
lated as there is a risk of explosion.

2.4.10.9 VENTILATION OF ENCLOSED AREAS

WARNING
POISONOUS FUMES!
Unventilated areas where poisonous fumes can accumulate can kill.
Always ensure adequate ventilation.

Refer to Fig. 2-19:

– Operate internal combustion motors and fuel operated heat-

ing systems only on adequately ventilated premises. Before
starting the machine on enclosed premises, make sure that
there is sufficient ventilation.
Observe the regulations in force at the respective site.
– If it is necessary to start the motor within an enclosed area, or
when handling fuel, flushing oil, or paint, open the doors and
windows to ensure that adequate ventilation is provided to
prevent gas poisoning.

Fig. 2-19

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2.4.11 STARTING MOTOR

2.4.11.1 WARNING TAG

– If there is a "DANGER DO NOT OPERATE!" warning tag dis-
played, it means that someone is carrying out inspection and
maintenance on the machine (Fig. 2-20). If the warning sign
is ignored and the machine is operated, there is a danger that
the person carrying out the inspection or maintenance may
be caught in the rotating parts or moving parts and suffer per-
sonal injury or death. Do not start the motor or touch the
levers.

Fig. 2-20

2.4.11.2 CHECKS BEFORE STARTING MOTOR

Carry out the following checks before starting the motor at the beginning of the day's work to ensure that there is
no problem with the operation of the machine. If this inspection is not carried out properly, problems may occur
with the operation of the machine, and there is the danger that this could lead to serious personal injury or death.

– Remove all dirt from the surface of the window glass to

ensure a good view.
– Completely remove all flammable materials accumulated
around the motor and battery, and remove any dirt from the
windows, mirrors, handrails, access ladder and steps.
– Check the coolant levels, fuel levels, and oil levels, and check
for damage to the electric wiring.
– Adjust the operator's seat to a position where it is easy to
carry out operations, check the camera system functions and
check that there is no damage or wear to the seat belt or
mounting clamps.
– Check the operation of the instruments and gauges, check
the angle of the mirror, and check that the control levers are Fig. 2-21
all at the Neutral position.
– Before starting the motor, check that lock lever (Fig. 2-21) is
in LOCK position (L).
– Adjust the mirrors so that the rear of the machine can be seen
clearly from the operator's seat.
– Check that there are no persons or obstacles above, below,
or in the area around the machine.

2.4.11.3 PRECAUTION WHEN STARTING MOTOR

– Start and operate the machine only while seated.
– Do not short circuit the starting motor circuit to start the motor. Short circuiting can cause fire.
– When starting the motor, sound the horn as a warning.
– Do not let any person on the machine other than the operator and the operator's assistant (1 person). For
demonstration purposes or during training, more than two people can be present in the operator’s cabin at the
same time. All personnel within the cabin at such times must secure good hand-holds and be aware of sudden
movements. All appropriate relevant safety measures are to be observed.

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2.4.11.4 PRECAUTION IN COLD AREAS

– Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control
levers or control pedals are operated, the reaction of the machine will be slow or the machine may move in a
way not expected by the operator. Particularly in cold weather, be sure to carry out the warming-up operation
thoroughly.
– If the battery electrolyte is frozen, do not charge the battery or start the motor with a different power source.
There is a hazard that this will ignite the battery and cause the battery to explode.
– Before charging or starting the motor with a different power source, melt the battery electrolyte and check that
there is no leakage of electrolyte before starting.

2.4.12 OPERATION

2.4.12.1 CHECKS BEFORE OPERATION

If the checks before starting are not carried out properly, the machine will be unable to display its full performance,
and there is also danger that it may lead to serious personal injury or death.

When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.

– Always fasten your seat belt.

– Check that the movement of the machine matches the display on the control pattern label in the cabin. If it
does not match, replace it immediately with the correct control pattern label.
– Check the operation of the gauges and equipment, and check the operation of the bucket, arm, boom, travel
system and swing system.
– Check for any problem in the sound of the machine, vibration, heat, smell, or gauges; check also that there is
no leakage of oil or fuel.
– If any problem is found, carry out repairs immediately.

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2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE

– Before travelling, set the machine so that sprocket (1) is
behind the operator's seat (Fig. 2-22).
– If sprocket (1) is in front of the operator's cab, the machine
moves in the opposite direction from the operation of the ped-
als (front and rear travel is reversed, left and right steering is
reversed). Be extremely careful when operating the machine
in this situation.

Fig. 2-22

– Before travelling, check again that there is no one in the sur-

rounding area, and that there are no obstacles (Fig. 2-23).
– Before travelling, sound the horn to warn people in the area.
– Always operate the machine only when seated.
– Do not allow anyone apart from the operator to ride on the
machine.
– Check that the travel alarm works properly.
– Secure the cab door when it is both open and closed.
– Always keep the cab door closed when operating the
machine.

Fig. 2-23

– If there is an area to the rear of the machine which cannot be

seen, position a signal person. Take special care not to hit
other machines, objects or people when turning or swinging
the machine (Fig. 2-24)

Fig. 2-24

NOTE! Always be sure to carry out the above precautions even when the machine is equipped with mirrors
or camera systems.

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2.4.12.3 PRECAUTIONS WHEN TRAVELLING

– When travelling on flat ground, keep the work equipment 100
to 150 cm (39 to 59 in) high above the ground (Fig. 2-25).
– If the view to the right side is poor, raise the boom to ensure
better visibility.
– When travelling on rough ground, travel at low speed and do
not operate the steering suddenly. There is danger that the
machine may turn over. The work equipment may hit the
ground surface and cause the machine to lose its balance, or
may damage the machine or structures in the area.
–

Fig. 2-25

– Avoid travelling over obstacles when possible. If the machine

has to travel over an obstacle, keep the work equipment close
to the ground and travel at low speed. Never travel over
obstacles which make the machine tilt strongly to one side
(Fig. 2-26).
– When travelling or carrying out operations, always keep a
safe distance from people, structures or other machines to
avoid coming into contact with them.

Fig. 2-26

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2.4.12.4 TRAVELLING ON SLOPES

To prevent the machine from tipping over or slipping to the side,
always do as follows.

– Keep the work equipment 100 - 150 cm (39 - 59 in) above the
ground surface so that the work equipment can be lowered to
the ground immediately to stop the machine in emergencies
(Fig. 2-27).
– When travel up slopes, set the operator's cab facing uphill,
when travel down slopes, set the operator's cab facing down-
hill. Always be aware and informed about the firmness and
bearing capacity of the ground under the machine when trav-
elling. Cavaties and underground mines may cause the
ground beneath the excavator to collapse.
Fig. 2-27

– When travelling up a steep slope, extend the work equipment

to the front to improve the balance, keep the work equipment
approximately 100 to 150 cm (39 to 59 in) above the ground,
and travel at low speed (Fig. 2-28).

Fig. 2-28

– When travelling downhill, keep the travel pedals close to the

neutral position, and travel at low speed.
– Always travel straight up or down a slope. travelling at an
angle or across the slope is extremely dangerous.
– Do not turn on slopes or travel across slopes. Always go
down to a flat place to change the position of the machine,
then travel on to the slope again (Fig. 2-29).
– Travel on slippery ground with low speed. Even with slight
slopes there is a hazard that the machine may slip

Fig. 2-29

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GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY

2.4.12.5 OPERATIONS ON SLOPES

– When working on slopes, there is a hazard that the machine
may lose its balance and turn over when the swing or work
equipment are operated. This may lead to serious injury or
property damage, so always provide a stable place when car-
rying out these operations, and operate carefully.
– Do not swing the work equipment from the uphill side to the
downhill side when the bucket is loaded. This operation is
dangerous, and may cause the machine to tip over.
– If the machine has to be used on a slope, pile the soil to make
a platform (A on Fig. 2-30) that will keep the machine as hori-
zontal as possible.

Fig. 2-30

2.4.12.6 PROHIBITED OPERATIONS

– Never dig the work face under an overhang. There is a haz-
ard that rocks may fall or that the overhang may collapse and
fall on top of the machine (Fig. 2-31).

Fig. 2-31

– Do not excavate too deeply under the front of the machine.

The ground under the machine may collapse and cause the
machine to fall (Fig. 2-32).

Fig. 2-32

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SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

– To make it easier to escape if there is any problem, set the

tracks at right angles to the road shoulder or cliff with the
sprocket at the rear when carrying out operations (Fig. 2-33).
– Generally speaking, the machine is more liable to overturn
when the work equipment is at the side than when it is at the
front or rear.
– Do not suddenly lower, swing, or stop the work equipment.
– Do not suddenly extend or retract the boom cylinder.
There is a hazard that impact will cause the machine to tip
over.
– Do not pass the bucket over the head of other workers or over
the operator's seat of dump trucks or other hauling equip-
ment. The load may spill or the bucket may hit the dump truck Fig. 2-33
and cause serious injury or property damage.

2.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES

– Snow-covered or frozen surfaces are slippery, so be extremely careful when travelling or operating the
machine, and do not operate the pedals suddenly. Even a slight slope may cause the machine to slip, so be
particularly careful when working on slopes.
– With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over.
– If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be care-
ful not to leave the road shoulder or to get trapped in a snow drift.
– When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot
be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out opera-
tions carefully.

2.4.12.8 PARKING THE MACHINE

– Park the machine on firm, level ground. Select a place where
there is no hazard of falling rocks or landslides, or of flooding
if the land is low.
– Lower the work equipment completely to the ground.
– When leaving the machine, set lock lever (Fig. 2-34, Pos 1) to
the LOCK position (L), then stop the motor.
– Always close the operator's cab door, and use the key to lock
all the equipment in order to prevent any unauthorized person
from moving the machine. Always remove the key, take it with
you, and leave it in the specified place.
– If it is necessary to park the machine on a slope, always set
the bucket on the downhill side, then dig it into the ground.
Fig. 2-34

2.4.12.9 TRANSPORTATION
This machine must be disassembled for transportation. When transporting the machine, please consult your
Komatsu distributor.
Use only appropriate means of transport and lifting gear of adequate capacity.
The recommissioning procedure must be strictly in accordance with the General Assembly Procedure Manual.

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PRECAUTION FOR MAINTENANCE SAFETY

2.5 PRECAUTION FOR MAINTENANCE

2.5.1 GENERAL PRECAUTIONS

– Observe the adjusting, maintenance and inspection activities and intervals set out in the Operation,- Lubrica-
tion and Maintenance Manual, including information on the replacement of parts and equipment. These activi-
ties may be executed by skilled personnel only.
– Brief operating personnel before beginning special operations and maintenance work, and appoint a person to
supervise the activities.
– In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices
or any work related to maintenance, inspection and repair, always observe the start-up and shut-down proce-
dures set out in the Operation,- Lubrication and Maintenance Manual and the information on maintenance
work.
– Ensure that the maintenance area is adequately secured.
– If the machine is completely shut down for maintenance and repair work, it must be secured against inadver-
tent starting by:
– locking the principal control elements and removing the ignition key and/or
– attaching a warning tag to the main switch or control levers.
– setting the maintenance safety switch to the 0 position and securing it with a padlock
– Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has
been secured against inadvertent movement and buckling.
– To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes
should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear
and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.
– The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only.
The marshaller giving the instructions must be within sight or sound of the operator.
– For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders
and working platforms. Never use machine parts as a climbing aid. Wear a safety harness when carrying out
maintenance work at greater heights.
Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.
– Always tighten any screwed connections that have been loosened during maintenance and repair.
– Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immedi-
ately upon completion of the maintenance and repair work.
– Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental
impact.
– Before starting any lubrication or maintenance work read the Fundamental Safety Instructions on page 2-1.
– Park the Excavator at a safe place on level ground. Proceed according to the instructions ”Parking the
Shovel”. Lower the attachment flat onto the ground. Move all control levers to neutral position.
– Stop the motors and move all control levers through their shift positions to relieve the pressure in the hydraulic
system. Refer to ”Stopping the motors” for detailed description of the stopping procedure.
– Before any maintenance work is started, set the maintenance safety switch to 0 position.
Find to the location of the maintenance safety switch refer to section 2.5.1.3 on page 2-29. In the 0 position
the motors can not be started. Secure this position by inserting a padlock into the holes of the switch. Up to ten
padlocks can be attached to the holes provided.
– A warning plate ”Caution Machine Maintenance” must be fixed in the Operator’s cab before any lubrication or
maintenance work is started.
– Block the machine to prevent machine movement
– Always use safety devices to block hydraulic cylinders. Never rely on the machine hydraulic system to hold
when working on the loader attachment. A hydraulic line or cylinder could fail or someone could accidently
strike the control levers causing the loader to fall.

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SAFETY PRECAUTION FOR MAINTENANCE

– Relieve all pressure in the hydraulic system before servicing the hydraulic system.For information on relieving
the pressure in the hydraulic system, refer to chapter ’Relieving The Pressure In The Hydraulic System’ in the
’Operation’ part of this manual.
– Oily cloth and inflammable material must be removed from the machine. Clean the excavator before starting
maintenance work.
– Switch-off battery main switch and remove key, before working on the electrical system.
– Wear safety clothing, goggles, respirator and other safety devices, whenever working conditions make this
necessary. Observe the local safety rules.
– Never allow unauthorized persons access to the machine during lubrication and maintenance work.
– After servicing, remove oily cloth, inflammable material and all tools from the machine.
– Clean the Excavator with a steam jet, especially after servicing the hydraulic system and fuel system.

WARNING
BEWARE OF STEAM!
Hot steam can cause serious personal injury. When using a steam cleaner, wear safety glasses and pro-
tective clothing.

– For cleaning the Excavator and its components use only fresh water with a salt content of less than 0.05%.
– DO NOT use steam jet, high pressure cleaning device or strong water jet for cleaning headlights, solenoid
valves, sensors, cable connections and bearings.
– Be sure to reinstall safety devices, guards or shields after adjusting and/or servicing the machine.

2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC

RESPONSIBILITIES
– Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits
must be observed.
– Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for
operation, set-up, maintenance and repair.
– All personnel must be aware of the appropriate safety measures when working on or around the machine.
– Make sure that only authorized personnel works on or with the machine.
– Define the machine operator’s responsibilities - also with regard to observing traffic regulations - giving the
operator the authority to refuse instruction by third parties that are contrary to safety.
– Do not allow persons to be trained or instructed or persons taking part in a general training course on or with
the machine without being permanently supervised by an experienced person.
– Work on the electrical system and equipment of the machine must be carried out only by skilled electricians or
by persons instructed under the supervision and guidance of a skilled electrician and in accordance with elec-
trical motorering rules and regulations.
– Work on the chassis, brake and steering systems must be performed only by skilled personnel who have been
specifically trained for such work.
Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of
hydraulic equipment.

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PRECAUTION FOR MAINTENANCE SAFETY

2.5.1.2 STOP MOTOR FOR MAINTENANCE

Refer to Fig. 2-35:

– Stop the machine on firm, level ground.

– Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
– Lower the work equipment completely to the ground and stop
the motor.

Fig. 2-35

– Turn the main key switch to the ON position. Operate the

work equipment control lever back and forth, left and right at
the full stroke 2 to 3 times to eliminate the remaining internal
pressure in the hydraulic circuit, and then push up lock lever
(Fig. 2-36, Pos 1) to the LOCK position (L).
– Check that the battery main switch is off and main power is
not conducted. (Wait for approx. one minute after activating
the motor STOP switch and press the horn switch. If the horn
does not sound, it is not activated.)

Fig. 2-36

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SAFETY PRECAUTION FOR MAINTENANCE

2.5.1.3 WARNING TAG

– Always attach the “DO NOT OPERATE“ warning tag
(Fig. 2-37) to the work equipment control lever in the opera-
tor's cab to alert others that you are performing service or
maintenance on the machine. Attach additional warning tags
around the machine if necessary.
– Keep this warning tag in the tool box while it is not used. If
there is not the tool box, keep the tag in the operation manual
pocket.
– If any other person starts the motor, or touches or operates
the control levers or control pedals while you are performing
service or maintenance, you may suffer serious injury.

Fig. 2-37

– Before entering the machinery house, switch off maintenance

safety switch (Fig. 2-38)
– The maintenance safety switch is located in the machinery
house, next to the entrance door (Pos. 1 on Fig. 2-39).
– Before beginning maintenance operations, set the safety
switch to "0" to prevent a starting of the motors. Secure this
position by inserting a padlock into the holes of the safety
switch. Up to ten padlocks can be attached.

Fig. 2-38

Fig. 2-39

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PRECAUTION FOR MAINTENANCE SAFETY

2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY

CAUTION
HAZARD OF ACCIDENTS!
If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over and injure
yourself.

Observe the following points.

– Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other sub-
stances that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out oper-
ations safely.
– Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying
– Never block walkways, doors ladders or emergency escape routes with foreign objects.

2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his
instructions during the operation.

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SAFETY PRECAUTION FOR MAINTENANCE

2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING

– To prevent injury, do not perform maintenance or adjustments
while the motor runs. If work must be carried out with the
motor running, carry out the operation with at least two work-
ers and do as follows:
– One worker must always sit in the operator's seat and be
ready to stop the motor at any time. All workers must
maintain contact with each other and be fully aware of all
relevant safety measures.
– For safety information when working with high pressure oil in
the hydraulic system, refer to section 2.6 on page 2-39.
– When carrying out operations near rotating parts, there is a
hazard of being caught in the parts, so be careful not to come
close (Fig. 2-40). Fig. 2-40
– Do not touch any control levers or pedals. If they must be
operated, always give a signal to other workers to warn them
to move to a safe place.

2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS

– Appoint a leader before starting removal or installation opera-
tions for attachments.
– Place attachments that have been removed from the machine
in a stable condition so that they do not fall (Fig. 2-41). And
take steps to prevent unauthorized persons from entering the
storage area.

Fig. 2-41

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PRECAUTION FOR MAINTENANCE SAFETY

2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT

– If it is necessary to go under the work equipment or the
machine to carry out service and maintenance (Fig. 2-42),
support the work equipment and machine securely with
blocks and stands strong enough to support the weight of the
work equipment and machine.
– It is extremely dangerous to work under the machine if the
track shoes are lifted off the ground and the machine is sup-
ported only with the work equipment. If any of the control
levers are touched by accident, or there is damage to the
hydraulic piping, the work equipment or the machine will sud-
denly drop. This is extremely dangerous. Never work under
the work equipment or the machine.

Fig. 2-42

2.5.1.9 NOISE
When carrying out maintenance of the motor and you are exposed to noise for long periods of time, wear ear cov-
ers or ear plugs while working. If the noise from the machine is too loud, it may cause temporary or permanent
hearing problems.

2.5.1.10 WHEN USING A HAMMER

When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury.
Always do as follows.

– If hard metal parts such as pins, bucket teeth, cutting edges,

or bearings are hit with a hammer, there is a hazard that
pieces might be scattered and cause injury. Always wear
safety glasses and gloves (Fig. 2-43).
– When hitting pins or bucket teeth, there is a hazard that bro-
ken pieces might be sent flying and injure people in the sur-
rounding area. Always check that there is no one in the
surrounding area.
– There is a hazard that the pin hit with strong force may fly out
and injure people in the surrounding area.

Fig. 2-43

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SAFETY PRECAUTION FOR MAINTENANCE

2.5.1.11 PROPER TOOLS

Refer to Fig. 2-44:

– Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools
or improper use of the tools could cause serious personal
injury.

Fig. 2-44

2.5.1.12 ACCUMULATOR
Refer to Fig. 2-45:

The accumulator is charged with high-pressure nitrogen gas.

When handling the accumulator, careless procedure may cause
an explosion which could lead to serious injury or property dam-
age. For this reason, always observe the following precautions.

– Do not disassemble the accumulator.

– Do not bring it near flame or dispose of it in fire.
– Do not make holes in it, weld it, or use a cutting torch.
– Do not hit or roll the accumulator, or subject it to any impact.
– When disposing of the accumulator, the gas must be
released. Please contact your Komatsu distributor to have Fig. 2-45
this work performed.

2.5.1.13 PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
If necessary, employ an observer.

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PRECAUTION FOR MAINTENANCE SAFETY

2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE

2.5.2.1 PRECAUTION WHEN WELDING

WARNING
RISK OF EXPOLSION AND FIRE!
Welding, flame-cutting and grinding work on the machine increases the risk of explosion and fire which
may result in serious injury or death.
All relevent safety measures must be followed and only under expressly obtained authorization.

Welding operations must always be carried out by a qualified welder and in a place equipped with proper equip-
ment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified
personnel to carry out welding.

2.5.2.2 BATTERY HANDLING

WARNING
RISK OF EXPLOSION AND FIRE!
Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may
explode. Wrong handling can lead to serious injury or fire. For this reason, always observe the following
precautions.

– Do not use or charge the battery if the battery electrolyte level

is below the LOWER LEVEL line. This may cause an explo-
sion. Check the battery electrolyte level periodically and add
distilled water to bring the electrolyte level to the UPPER
LEVEL line.
– When working with batteries, always wear safety glasses and
rubber gloves.
– Never smoke or use any flame near the battery (Fig. 2-46).

Fig. 2-46

– If you spill acid on your clothes or skin, immediately flush the

area with large amount of water.
– If acid gets into your eyes (Fig. 2-47), flush them immediately
with large amount of water and seek medical attention.
– Before working with batteries, activate the STOP switch and
remove battery main switch key.

Fig. 2-47

2 - 34 General Safety Version 6

SAFETY PRECAUTION FOR MAINTENANCE

As there is a hazard that sparks will be generated, always do as follows.

– Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or
other metal objects lying around near the battery.
– When disconnecting the battery terminals, wait for approx. one minute after activating the motor STOP switch
and be sure to disconnect the grounding terminal
(negative (-) terminal) first. Conversely, when connecting them, begin with the positive (+) terminal and then
the grounding (-) terminal. Make sure that all the terminals are connected securely.
– Attach the battery terminal securely.
– Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis,
take it to a well-ventilated place, and remove the battery caps before charging it.
– Tighten the battery caps securely.
– Install the battery securely to the determined place.

2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID

WARNING
FLUID UNDER HIGH PRESSURE!
The hydraulic system is always under internal pressure and can lead to serious injury when leaking.
When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has
been released.

2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE

– For details of the method of releasing the pressure, see the
latest version of the Operation and Maintenance Manual. If
the circuit is still under pressure, do not carry out any inspec-
tion or replacement operation.
– If there is any leakage from the piping or hoses, the surround-
ing area will be wet, so check for cracks in the piping and
hoses and for swelling in the hoses.
– When carrying out inspections, wear full-face protection and
penetration resistant clothing and gloves (leather).
– There is a hazard that high-pressure oil leaking from small
holes may penetrate your skin or cause blindness if it con-
tacts your eyes directly (Fig. 2-48). If you are hit by a jet of
high-pressure oil and suffer injury to your skin or eyes, wash Fig. 2-48
the place with clean water, and consult a doctor immediately
for medical attention.

High pressure is generated inside the motor fuel piping when the motor is running. When carrying out inspection or
maintenance of the fuel piping system, wait for at least 30 seconds after stopping the motor to let the internal pres-
sure go down before starting inspection or maintenance.

General Safety Version 6 2 - 35

PRECAUTION FOR MAINTENANCE SAFETY

2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES

– If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury or death. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged
hoses are found, stop operations immediately and contact your Komatsu distributor.
Replace the hose if any of the following problems are found.

– Damaged or leaking hydraulic fitting.

– Frayed or cut covering or exposed reinforcement wire layer.
– Covering swollen in places.
– Twisted or crushed movable portion.
– Foreign material embedded in covering.

2.5.3.3 REPLACEMENT OF HOSE LINES

Hydraulic hoses are subjected to natural aging. Hence, their usable lifetime is limited to maximum 6 years.

NOTICE
The maximum permissible storage time of hydraulic hoses must be observed.

– This storage period is part of the usable lifetime and must be considered when installing a new hose line. If, for
example, a hose line with a one year storage time is to be installed, the remaining service life of the hose line
must be considered. All hose lines are marked with the date of production.
– Hose lines considered as Safety Critical Parts have to be replaced earlier. Refer to the chapter "Lubrication
and Maintenance Schedule" in the MAINTENANCE section of the Operation and Maintenance Manual for fur-
ther information.

All hydraulic hoses of the Shovel have to be replaced when their service life has expired, even if there is no visible
damage. Refer to the chapter "Lubrication and Maintenance Schedule" in the MAINTENANCE section of the
Operation and Maintenance Manual for further information.

NOTICE
Repairs on hydraulic hoses are not allowed. Use ONLY GENUINE Komatsu Germany replacement hose
lines.

2.5.3.4 INSPECTION OF HOSE LINES

WARNING
FLUID UNDER HIGH PRESSURE!
The hydraulic system is always under internal pressure and can lead to serious injury when leaking.
When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has
been released.

Inspect all hoses, hose lines and fittings carefully during the course of the daily walk-around inspection. Check for
leaks and damages. Beware of pinhole leakages. Replace damaged parts without delay.

2 - 36 General Safety Version 6

SAFETY PRECAUTION FOR MAINTENANCE

Some examples of faults on hydraulic hoses requiring replacement of the concerned part:

– Damage to the outer layer (e.g. chafed spots, cuts or scratches).

– Brittle top layers. Flaws on the hose material
– Distortion of the hose line (strong deviation from the original shape) under pressurized and pressureless con-
ditions or when kinked or crushed, e.g. disintegration of hose layers or blistering.
– Leaks.
– Detachment of hose and fitting. Damaged hose fitting.

2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

To ensure safety at all times when operating the machine, the user of the machine must always carry out periodic
maintenance. In addition, to further improve safety, the user should also carry out periodic replacement of the parts
given in the table. These parts are particularly closely connected to safety and fire prevention.

With these parts, the material changes as time passes, or they easily wear or deteriorate. However, it is difficult to
judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed
time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function
completely. However, if these parts show any abnormality before the replacement interval has passed, they should
be repaired or replaced immediately.

If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same time
as the hoses.

When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.

– Ask your Komatsu distributor to replace safety critical parts.

2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE

DANGER
HIGH VOLTAGE!
High voltage appliances cause serious injury or death.
Authorized staff only.

– When the motor is running and immediately after it is stopped, high voltage is generated inside the motor con-
troller and the motor injector.
– The headlights also operates using high voltage. Never perform maintenance on the headlights.
– If it is necessary to touch the inside of the controller or the motor injector portion, or the headlight electrics
please contact your Komatsu distributor.
– The cab base contains high voltage electrical appliances. Access to the cab base for authorized service staff
only.

2.5.3.7 AIR CONDITIONING MAINTENANCE

WARNING
AIR CONDITIONING REFRIGERANT IS HARMFUL!
If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may
cause frostbite.
Never touch refrigerant.

General Safety Version 6 2 - 37

PRECAUTION FOR MAINTENANCE SAFETY

2.5.3.8 COMPRESSED AIR

WARNING
COMPRESSED AIR IS HAZARDOUS!
When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying parti-
cles.
Wear protective clothing.

– When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves,
and other protective equipment.
– Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying.

2.5.3.9 WASTE MATERIALS

Operation

– Avoid motor idling over long periods. Long periods of idling

(more than 10 minutes), will not only waste fuel, but is also
harmful to the motor.
– Avoid operation against the main relief valves of the hydraulic
system. Move control lever to neutral position before the
loader attachment stalls due to overload.
– Position trucks in such a way, that loading operation can be
carried out in a safe and economic manner. Avoid swing
angles over 90°.

Maintenance Fig. 2-49

– Preserve our environment. To prevent environmental pollu-
tion, pay careful attention to the method of disposing waste
materials.
– Always drain fluids from your machine into containers. Never
drain fluids onto the ground or dump it into the sewage sys-
tem, rivers, the sea or lakes. (Fig. 2-49).
– Dispose of harmful material, such as oil, fuel, coolant, sol-
vent, filters and batteries in accordance with local environ-
mental regulations and laws.

2 - 38 General Safety Version 6

SAFETY ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS

2.6 ADDITIONAL SAFETY INFORMATION

FOR TROUBLESHOOTING AND ADJUSTMENTS

2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM

A hands-on approach to inspecting the hoses and pipes of the hydraulic system can only be made when the exca-
vator is shut down and there is no oil pressure in the hydraulic system.

– Do not use your hands during inspection or move in the vicinity of the hydraulic system’s piping or tubing when
the motor is running before checking for leaks, as hydraulic fluid escaping under pressure can cause serious
injuries.
– Additional to the general personal protective clothing as described on page 2-6, full face protection and pene-
tration resistant clothing and gloves must be worn.
– Troubleshooting and adjustments may only be performed by personnel trained by Komatsu Germany in safe
and correct hydraulic handling procedures.
– Before troubleshooting or adjustments, the inspection of areas of potential dangers for damages, leaks or
loose connections on the pressure lines and hydraulic components must be carried out visually only when the
motor is shutdown and when there is no hydraulic pressure in the system.
– When the machine is running, the areas of potential danger can only be entered when no leakages or other
irregularities have been noticed when the high pressure oil circulation has been brought up to maximum pres-
sure from a safe distance (operator’s cab, machinery house roof, ladder platform).

2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING

DURING ADJUSTMENTS
To prevent injury, do not carry out adjustments with the motor running. If work must be carried out with the motor
running, perform the task with, at maximum, two maintenance workers and an operator and do as follows.

– An operator that has been trained on the machine he is oper-

ating, must always sit in the operator's seat and be ready to
stop the motor at any time. All workers must maintain contact
with the other workers and be fully aware of all relevant safety
measures.
– When carrying out operations near the fan, fan belt, or other
rotating parts, there is a hazard of being caught in the parts,
so be careful not to come close (Fig. 2-50).
– Do not touch any control levers or control pedals. If any con-
trol levers or control pedals must be operated, always give a
signal to the other workers to warn them to move to a safe
place.
Fig. 2-50

2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR

General safety rules for working on the excavator

– Only trained personnel who are aware of all dangers are allowed to work on the hydraulic system
– Visually inspect all potential danger areas for leakages before pressure build up.
– Do not remain on or around the excavator for longer than is absolutely necessary in order to perform your
tasks.

General Safety Version 6 2 - 39

SPECIAL SAFETY EQUIPMENT SAFETY

2.7 SPECIAL SAFETY EQUIPMENT

Fig. 2-51

2 - 40 General Safety Version 6

SAFETY SPECIAL SAFETY EQUIPMENT

2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR

OPERATOR’S CAB
The Shovel must be equipped with a front guard protective structure ”OPG Front Guard” if it is used for applica-
tions where there is a risk of hitting objects from the front.

2.7.2 OBJECT HANDLING

Object handling operations are not allowed.

2.7.3 LIGHTING
The Shovel must only be operated when the operator has sufficient visibility in relation to the work area.
Disturbing shady areas or dazzling effects must be avoided.

If necessary, the Shovel must be retrofitted with additional lighting equipment (working lights) in order to ensure
sufficient visibility conditions.

2.7.4 WARNING BEACON

The Shovel can be retrofitted with a warning beacon which is fitted on the cab roof by means of a magnetic
bracket.

REMARKS: The above-mentioned special safety devices can be ordered as accessories together with the
Shovel.
They are also available as a field package for installation through our service organization.

2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN

STANDARD)
The safety harness should only be used together with connectors according to EN 354, and fall arrest according to
EN 355, or fall protection devices according to EN 360.

See the following pages for further information.

2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)

WARNING
RISK OF FALLING!
Falling from the boom can cause serious injury or death.
Always use a Safety Harness (1) in conjunction with a strap type Fall Absorber (2), illust. (Fig. 2-51) before
boarding the loader attachment or other unsecured areas on the Shovel.

– The Safety Harness is located in the Cabinet in the Operator’s Cab.

– The illustration (Fig. 2-51) shows the standard use of the safety harness with a strap type fall absorber.

General Safety Version 6 2 - 41

SPECIAL SAFETY EQUIPMENT SAFETY

2 - 42 General Safety Version 6

SAFETY SPECIAL SAFETY EQUIPMENT

Legend for Fig. 2-51:

(1) Safety Harness according to EN 361

(2) Strap-Type Fall Absorber according to DIN EN 355

(3) Swivel type ring bolt. Attachment point for strap-type fall absorber of the saftey harness.

NOTICE
DO NOT attach any other object to the ring bolts (3). Use only for attaching the strap-type fall
absorber in connection with safety harness.

(4) Walkway on the boom

(A) Shoulder Strap

(B) Back Plate

(C) Catching Hook

(D) Shoulder-Strap Fixing

(E) Belly Strap

(F) Holding Hook

(G) Hold-Back Hook

(H) Pelvis Strap

(J) Leg Strap

2.7.5.2 INSTRUCTIONS FOR USE

Open the lock, lift the harness by the catch hook (C), ensuring the leg straps hang below (J). Pull the harness over
the shoulders as you would a jacket. Insert the end of the belly strap (E) through the buckle and tighten securely,
as shown in the illustration (Fig. 2-51).

Prevent the shoulder straps from slipping by fastening the breast strap. Pull the leg straps (J) between the legs
and securely buckle them at the front as illustrated. Adjust the harness so that it snugly fits the body ensuring that
the catching hook (C) is in the center of the back.

The safety harness is a personal accessory and should only belong to its owner.

The safety harness should only be used together with connectors acc. to EN 354, and fall arrest acc. to EN 355, or
fall protection devices acc. to EN 360.

The special attachment points for the safety harness should be used only, and the carrying capacity of the attach-
ment point should be sufficient to correspond with the minimum carrying capacity acc. to EN 795.

General Safety Version 6 2 - 43

SPECIAL SAFETY EQUIPMENT SAFETY

2 - 44 General Safety Version 6

SAFETY SPECIAL SAFETY EQUIPMENT

2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL

– Carry out a visual check of the system or component; correct functioning and perfect working order have to be
assured.
– Make sure that the recommendations for use with other components of the system be observed in conformity
with the instructions for use.
The system or component must no longer be used, if there are any doubts in respect of its safe condition. The
equipment has to be inspected by the manufacturer or by a qualified person.

It is essential for safety reasons that a fall protection system or system component which has already been sub-
jected to fall be removed from service and sent back to the manufacturer or an authorized qualified repair shop for
maintenance and renewed testing.

Fall protection systems have to be treated with care and to be kept clean and ready for use. It has to be warned
against bringing the systems into contact with acids or other caustic liquids and gases, oils, detergents, or sharp-
edged objects.

Should the harness have become wet during use or cleaning, do not dry near a fire or other sources of heat, but
rather in a natural way in not too warm rooms. Keep the harness freely suspended or loosely rolled up.

When using the fall protection systems, the pertaining safety regulations in force and the "Rules for Use of Per-
sonal Fall Arrest Systems" have to be observed for protection against danger.

The safety harness and its components have to be inspected at least every 12 months by a competent person
authorized by the manufacturer and maintained, if the manufacturer considers it necessary.

2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-

BACK HOOKS OF THE SAFETY HARNESS
The holding hooks should only be attached to the special attachment points (3) on the boom. Free-fall must be lim-
ited to 0.5m.

With the lateral holding hooks, work may only be carried out on horizontal or almost horizontal surfaces (roofs).
The connectors have to be adjusted in such a way that the area, where danger of falling down prevails, cannot be
reached.

General Safety Version 6 2 - 45

SPECIAL SAFETY EQUIPMENT SAFETY

2 - 46 General Safety Version 6

SAFETY SPECIAL SAFETY EQUIPMENT

2.7.5.5 INSTRUCTIONS FOR USE

Strap-Type Fall Absorber acc. to DIN EN 355 (Type E.K.N.-BFD)

Use

Within a fall-arrest system, the strap-type fall absorber (2) has to be used in conjunction with a safety harness (1)
acc. to DIN EN 361. The maximum length including the safety rope must not exceed 2.0 m. For longer ropes, a
rope-shortening device has to be applied in addition.

Fix the rope to the attachment point and attach the strap-type fall absorber to the catching hook in the back of the
safety harness. The special attachment points (3) should be used for this purpose attachment and the minimum
carrying capacity of the strap-type fall absorber should be 10 KN, acc. to DIN EN 795. Only move when the fall
absorber is attached to the attachment point. Disengage and only continue moving when the fall absorber is
attached to the next point.

The strap-type fall absorber and the safety rope must not be damaged, e.g. never pull them over sharp edges nor
get them burnt by welding sparks.

Storing and maintenance

The strap-type fall absorber has to be kept dry in an airy and shady room. It must not be ex-posed to acids, caustic
chemicals, nor to an aggressive atmosphere, and contact with oils has to be avoided. If the strap-type fall absorber
is dirty, it may be cleaned with a little water and a light-duty detergent. Dry it in a shady place (nowhere near fire or
other sources of heat). Protect it from sharp-edged objects.

Inspection

Prior to use, all parts have to be inspected for safe condition and damages. At least once a year, the strap-type fall
absorber has to be tested by a competent person. A damaged or used strap-type fall absorber has to be removed
from service immediately. The strap-type fall absorber must not be changed in any way.

General Safety Version 6 2 - 47

SPECIAL SAFETY EQUIPMENT SAFETY

2 - 48 General Safety Version 6

HYDRAULIC MINING EXCAVATOR

PC3000-6

Machine model Serial numbers

PC3000-6 06279, 06308, 06309, 06310, 06314 and up
with TIER2 & KOMTRAX Plus

01 Specification

Release 1 04/2017

® Copyright 2017 KOMATSU GERMANY GmbH

PC3000-6 1
2 PC3000-6
 ENGINE POWER
940 kW / 1260 HP @ 1800 rpm
OPERATING WEIGHT
250-261 ton / 551,300-575,500 lb
SHOVEL CAPACITY
16 m³ / 21 yd³ SAE 2:1 heaped
BACKHOE CAPACITY

PC3000-6 Loading Shovel

15 m³ / 19�5 yd³ SAE 1:1 heaped

PC3000-6 Backhoe

HYDRAULIC EXCAVATOR
 H Y D R A U L I C E X C AVAT O R

WaLK-aRoUnD

Quality in Manufacturing Reliability and Durability

Commitment to „Quality and Reliability“ Long life and low operating cost by design
• Quality management ISO 9001 • Robust structural design developed from field
• Environmental management ISO 14001 experience and finite element analysis
• Occupational health and safety management system Undercarriage
BS OHSAS 18001:2007
• Large diameter rollers, idlers and sprockets
• High consistent quality through continuous investment
• Large surface area and extensive precision hardening
in personnel, design and manufacturing systems and
of all engaging components reduce track wear
processes
• Hardened track link pin bores

Powerful Diesel Engine

Version 1 – Komatsu SSA12V159 (Tier 1)
Version 2 – Komatsu SDA12V159E-2 (Tier 2)
• Rated 940 kW / 1260 HP, at 1800 rpm
• Electronic engine management
• Low engine emission levels
• Optional time saving Engine Oil Management
System; Centinel, Engine Reserve Oil Supply
and Eliminator Oil Filter System

2
 H Y D R A U L I C E X C AVAT O R
MATCHES
85 to 165 U.S. ton TRUCKS

OPERATING WEIGHT
Productivity Shovel 250-258 ton
Designed for more tons per hour 551,300-568,900 lb
• Powerful digging forces Backhoe 252-261 ton
555,700-575,500 lb
• Ease of bucket filling
• Proven attachment design BUCKET CAPACITY
• All cylinders mounted in the shadow of the attachment for protection Shovel 16 m³ / 21 yd³
Backhoe 15 m³ / 19.5 yd³
• Various buckets and wear packages to suit all material densities and properties

Advanced Hydraulics
Extended reliability and precise control
• Electronic pump management
• Comprehensive monitored filtration
• Simple open circuit hydraulic system

Large Comfortable Cab

Comfortable for the whole day
• Komatsu low noise cab on multiple viscous mounts for reduced
noise and vibration
• Large volume cab with full height front window
• Comprehensive climate control with pressurised filtered air
ventilation and air conditioning
• High specification multi-adjustable air suspension seat plus trainer seat
• Well elevated operator position giving good all round view
• Large twin wiper covers windshield area for excellent visibility

Easy and Safe Maintenance

Simple, common-sense design provides easy access to all major components
• Hydraulically operated ground access ladder
• Generous access to all major service points from machinery house floor level
• Enclosed, walk-in machinery house with partition wall separating engine from pump area
• Automatic central lubrication
• KOMTRAX Plus electronic monitoring system providing real time information about the operating status of the machine
• Ground-level access to hydraulically powered swing down service arm with Wiggins connections
• Acknowledges EMESRT design philosophies
• Swing out oil coolers for eased cleaning

3
 H y d r a u l i c E x c avat o r

Specifications
Version 1 – Tier 1 engine: Hydraulic motors and drives������������������������������������������������������������������� 1
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Komatsu SSA12V159 Swing brake, service ������������������������������������������������������ Hydraulic brake
Type . . . . . . . . . . . . . . . . . . . 4-cycle, water-cooled, direct injection Swing brake, parking��������������������������������������������������� Wet, multiple-disc
Aspiration . . . . . . . . . . . . . . . . . . . . . Turbocharged and aftercooled Swing speed (maximum) ������������������������������������������������������������ 4,6 rpm
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rated power. . . . . . . . . . . . . . . . . . 940 kW / 1260 HP @ 1800 rpm
(SAE 1995)
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All-speed, electronic
The power train consists of one main drive. Diesel engine or electric motor
Version 2 – Tier 2 engine:
can be supplied. One gearbox drives three identical main pumps which
Model . . . . . . . . . . . . . . . . . . . . Komatsu SDA12V159E-2 Tier 2 certificated
draw hydraulic oil from an unpressurized hydraulic tank. Open circuit hy-
Type . . . . . . . . . . . . . . . . . . . 4-cycle, water-cooled, direct injection
draulics provide maximum cooling and filtering efficiency.
Aspiration . . . . . . . . . . . . . . . . . . . . . Turbocharged and aftercooled
Main hydraulic pumps . . . . . . . . . . . . . 3 x 910 ltr/min 3 x 240 U.S. gal
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Relief valve setting. . . . . . . . . . . . . . . . 310 bar 4,495 psi
Rated power. . . . . . . . . . . . . . . . . . 940 kW / 1260 HP @ 1800 rpm
Swing flow rate . . . . . . . . . . . . . . . . . . 800 ltr/min 211 U.S. gal
(SAE 1995)
High pressure in line filters. . . . . . . . .. . . . . . . . . . . . . . . . . . 200 microns
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All-speed, electronic
one per pump located at the valve blocks
Optional engine oil management system: Full flow return line filters 3 x 10 microns and leakage line filter 3 microns
The integrated engine oil and filter system combining the oil stabilising all with monitored 200 microns by pass filters. The three-circuit system
systems, Reserve and Centinel, with Eliminator oil filter extends the oil features a load-limiting governor with oil delivery summation to the working
change interval to 4.000 hours based on oil analysis. circuits and incorporates pressure cut-off control. Hydropilot prioritises
hydraulic flow giving smooth hydraulic response, simple system layout,
and a reduced number of components.

Type����������������������������������������������������������� Squirrel-cage induction motor

Power output ������������������������������������������������������������������������������� 900 kW
Voltage�������������������������������������������������������������������������� 6.000 – 7.200 V* The high capacity engine radiator is cooled by a mechanically driven fan
Amperage (approximate). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96-80 A for superior cooling efficiency and requires little maintenance. The hydraulic
Frequency (standard) . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hz @ 1500 rpm system includes large swing-out vertical air-to-oil hydraulic coolers with
Optional frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz @ 1800 rpm temperature-regulated hydraulically driven fans.
*Other voltages available on request

Two hydraulically powered Lincoln single line automatic lubrication systems

System ���������������������������������������������������������������������������������������������� 24 V are provided as standard, complete with time and volume variable controls.
Batteries (series/parallel) ������������������������������������������������������������ 4 x 12 V The central lube grease system is supplied from a refillable 200 litre 53 gal.
Alternator ���������������������������������������������������������������������������������������� 140 A barrel. A second, identical system supplies open gear lubricant to the swing
Standard working lights ��������������������������������������������������� 12 Xenon lights ring teeth through a lube pinion. Replenishment of the barrels is through the
Standard service lights ���������������������������������������������� throughout platform service arm.

Track adjustment ����������������������������������������������� Automatic hydraulic type Hydraulic oil tank. . . . . . . . . . . . . . . . . . . . . 2.670 ltr 705 U.S. gal
Number of shoes ����������������������������������������������������������������� 46 each side Hydraulic system . . . . . . . . . . . . . . . . . . . . . 4.400 ltr 1,160 U.S. gal
Number of top rollers������������������������������������������������������������� 3 each side Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.500 ltr 1,190 U.S. gal
Number of bottom rollers ������������������������������������������������������� 7 each side Engine coolant. . . . . . . . . . . . . . . . . . . . . . . . 254 ltr 67 U.S. gal
Engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 ltr 50 U.S. gal

Travel control����������������������������������������������������������������������� 2 foot pedals

Gradeability ���������������������������������������������������������������������������� Up to 57%
Travel speed (maximum)��������������������������������������������� 2,4 km/h / 1.5 mph
Service brake������������������������������������������������������������������ Hydraulic brake
Parking brake��������������������������������������������������������������� Wet, multiple-disc

4
 H y d r a u l i c E x c avat o r

The large and comfortable cab is mounted on 15 viscous damping Major cab engineering standards are:
pads and sound insulated. The cab has automatic climate control and is • ISO 3449 Falling Objects Protection Structure
pressurised. The operator’s seat is air suspended, electrically heated and • ISO 6396 Noise in operator’s cab is 77 dB(A)
has a lap seat belt and offers multiple adjustments. The trainer seat is also • ISO 2631-1 Whole body vibration and shock below 0,5 m/s²
equipped with a seat belt. Low-effort hydraulic joystick controls are com- • ISO 5349-1 Hand-lever vibration lower 2,5 m/s²
bined with foot controls for front shovel clam, crawler and swing brake. • ISO 10263-4 Heating and air conditioning
Full instrumentation, KOMTRAX Plus and an AM/FM radio with MP3 ready second heater or air conditioner as option
CD player is fitted. Two windshield wash wipers are synchronised and
have two speed and intermittent operation. Two heated rear view mirrors
are externally mounted. External metal sun blinds on the cab side win-
dows and internal roller blinds on all windows are standard. There is a left
hand sliding window. All windows are tinted parsol green. A walkway is The KOMTRAX Plus monitoring system is designed for Komatsu mining
mounted in front of cabin. (Subject to change without notice.) equipment to provide real time and stored information about the operating
status of the machine. Fault messages are immediately available to the
operator via a digital display and in the event of critical malfunctions the
engine is also shut down. The digital storage provides failure summary
and analysis, which can be down loaded by laptop computer. This data will
assist in predicting or reduction downtime.

PC 3000 Backhoe: PC 3000 Front Shovel:

Operating weight including 8.600 mm / 28'3" boom, 4.000 mm / 13'1" stick, Operating weight including 6.000 mm / 19'8" boom, 4.300 mm / 14'1" stick,
15 m³ / 19.5 yd³ backhoe bucket, operator, lubricant, coolant, full fuel tank 16 m³ / 21 yd³ shovel bucket, operator, lubricant, coolant, full fuel tank and
and standard equipment. standard equipment.

Shoe Width Operating Weight Ground Pressure Shoe Width Operating Weight Ground Pressure
800 mm 252 t 23.2 N/cm 2
800 mm 250 t 22.9 N/cm2
31" 555,700 Ib 33.6 psi 31" 551,300 Ib 33.2 psi
1.000 mm 261 t 19.2 N/cm2 1.000 mm 258 t 19.0 N/cm2
39" 575,500 Ib 26.5 psi 39" 568,900 Ib 27.5 psi
1.200 mm 261 t 16.0 N/cm2 1.200 mm 258 t 15.8 N/cm2
47" 575,500 Ib 23.2 psi 47" 568,900 Ib 22.9 psi

5
3

9
7

6 6
1

11 10

SKZ3006_167 SKZ3006_168

Explanation Variation for Electric Drive Version

1 Cab 7 Control Valves 2 Electric Motor
2 Diesel Engine 8 Swing Motors 6 High Voltage Electric Cabinet
3 Hydraulic Pumps 9 Counterweight
4 Hydraulic Tank 10 Secondary Egress
5 Hydraulic Cooler 11 See-through Cat Walk
Lower-Level
6 Engine Radiator Walkways
Upper-Level

5
 H Y D R A U L I C E X C AVAT O R

pRoDUctiVitY-featUReS

3006200

Boom length 8�600 mm 28'3" Max. digging height 14�100 mm 46'3"

Stick length 4�000 mm 13'1" Max. dumping height 9�000 mm 29'6"
Break-out force (SAE) 850 kN 191,000 lb Max. digging depth 7�900 mm 25'11"
Tear-out force (SAE) 800 kN 179,800 lb Max. digging reach 16�200 mm 53'2"
Max. digging reach at ground level 15�600 mm 51'2"

Bucket Capacity Wear Recommended

Width Teeth Weight Max. Material Density (Loose)
(Heaped 1:1) SAE Package Mining
cum cuyd mm foot/inch qty *) t Ib t/cum Ib/cuyd Uses
12,0 15�7 3�045 9'12" 5 3 15,2 33,500 2,2 3,700 Heavy Duty
15,0 19�5 3�260 10'8" 5 2 15,6 34,400 1,8 3,000 Standard
16,5 21�5 3�045 9'12" 5 2 16,5 36,400 1,6 2,700 General Purpose

*) WP 1 Light abrasive Alternative buckets on request

WP 2 Medium abrasive
WP 3 Severe abrasive

6
 H Y D R A U L I C E X C AVAT O R

3006199

Boom length 6�000 mm 19'8" Max. cutting height 15�100 mm 49'6"

Stick length 4�300 mm 14'1" Max. dumping height 10�200 mm 33'6"
Break-out force (SAE) 1�000 kN 225,000 lb Max. digging depth 3�300 mm 10'10"
Crowd force (SAE) 1�100 kN 247,500 lb Max. digging reach 13�300 mm 43'8"
Level crowd at ground level 4�700 mm 15'5"
Bucket opening width 2�330 mm 7'8"

Bucket Capacity Wear Recommended

Width Teeth Weight Max. Material Density (Loose)
(Heaped 1:2) SAE Package Mining
cum cuyd mm foot/inch qty *) t Ib t/cum Ib/cuyd Uses
12,0 15�7 3�430 11'3" 5 3 22,3 49,000 2,4 4,000 Heavy Duty
16,0 21�0 3�630 11'11" 6 2 23,6 52,000 1,8 3,000 Standard

*) WP 1 Light abrasive Alternative buckets on request

WP 2 Medium abrasive
WP 3 Severe abrasive 7
HYDRAULIC MINING SHOVEL SUPERSTRUCTURE • AM-FM radio with MP3 ready CD player
• Main frame mounted over an externally • External metal sun blinds on side windows
FRONT SHOVEL ATTACHMENT
toothed swing circle carries the drive module • Internal roller blinds on all windows
• 6,0 m / 19'8" boom
• Version 1 – Komatsu SSA12V159 • All windows tinted parsol green
• 4,3 m / 14'1" stick
Tier 1 diesel engine • Walkway in front of cab
• Set of cylinders
• Version 2 – Komatsu SDA12V159E-2
• 16 m³ / 21 yd³ (SAE 2:1) shovel bucket
Tier 2 certificated diesel engine LUBRICATION AND SERVICE
incl. standard wear package (WP2) with
• Oil and fuel reservoirs • LINCOLN central lubrication for basic
hammerless GET system
• Hydraulic components machine, attachment, and bucket
OR • Counterweight • LINCOLN automatic pinion lubrication system
BACKHOE ATTACHMENT for swing circle teeth
• 8,6 m / 28'3" boom LIGHTING • WIGGINS service arm carrying fluid receiving
• 4,0 m / 13'1" stick • 12 Xenon high performance working lights connectors for filling of fuel, engine oil and
• Set of cylinders • Service lights throughout platform coolant, hydraulic oil, and the evacuation of
• 15 m³ / 19.5 yd³ (SAE 1:1) bucket incl. coolant, hydraulic and engine oils
standard wear package (WP2) with OPERATOR CAB
hammerless GET system • Enclosed steel cab mounted on viscous pads ACCESSORIES INCLUDED
• FOPS structure ISO 3449 • Acoustic travel alarm
CRAWLER UNDERCARRIAGE • Air-conditioning unit Sütrak • Hydraulically actuated ground access ladder
• Heavy-duty shovel type undercarriage • Full suspension operator seat with belt • Electric air horn
• Centre carbody • Trainer seat with belt • Service transfer oil pump
• 2 heavy box-type track frames • Controls ergonomic • Sidewalks and stairs are provided with skid-
• 7 bottom rollers and 3 top rollers each side • KOMTRAX Plus (Monitoring System) resistant plates
• 800 mm / 31" cast steel track shoes • Joysticks and controls are hydraulic • Hand rails and steps on boom
• Hydraulic track adjustment and parking brake • 2 synchronised windshield wash wipers • Tie off points on boom

ATTACHMENT/BUCKET COLD WEATHER MISCELLANEOUS

• Boom cylinder sliding guard • Cold weather package down to -40° C • Fire suppression system
• Arm cylinder sliding guard (diesel and electro drive) • Additional lighting
• Bucket cylinder sliding guard (BH) • Arctic weather package down to -50° C • Additional cab A/C
(diesel and electro drive) • Additional cab heater
UNDERCARRIAGE • KIM Hotstart temperature treatment for ambient • Sound suppression kit
• 1.000 mm / 39" track shoes temperature down to -50° C (diesel and electro • Special painting
• 1.200 mm / 47" track shoes drive), external power source not included
POWER
• Engine oil management package (Centinel,
Reserve & Eliminator systems)
• Electric drive various voltages

BASIC MACHINE WITH COUNTERWEIGHT

A 800 mm 2'7" J 2635 mm 8'8"

B 1000 mm 3'3" K 6880 mm 22'7"
CA 5600 mm 18'4" L 7455 mm 24'7"
CB 5800 mm 19" MA 3740 mm 12'3"
D 2210 mm 7'3" MB 3010 mm 9'11"
E 935 mm 3'1" N 3060 mm 10'1"
F 3000 mm 9'10" O 6800 mm 22'6"
G 6000 mm 19'8" P 5950 mm 19'6"
H 7910 mm 25'11" PR 6410 mm 21'
I 2620 mm 8'7" SKZ3006_166_1 SKZ3006_165_1

QESS 0037 02 © 2013 Komatsu Printed in Germany

KOMATSU MINING GERMANY GMBH

BUSCHERHOFSTRASSE 10
D-40599 DÜSSELDORF
PHONE +49 (0) 211/71 09-0
FAX +49 (0) 211/71 58 22

www.komatsu-mining.de Materials and specifications are subject to change without notice.

Komatsu is a trademark of Komatsu Ltd. Japan.
HYDRAULIC MINING EXCAVATOR

PC3000-6

Machine model Serial numbers

PC3000-6 06279, 06308, 06309, 06310, 06314 and up
with TIER2 & KOMTRAX Plus

10 Structure & Function

Release 1 04/2017

® Copyright 2017 KOMATSU GERMANY GmbH

PC3000-6 1
2 PC3000-6
Table of Contents

1 INTRODUCTION........................................................................................ 1-1
1.1 FOREWORD ..................................................................................................................................... 1-2
1.2 RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND
MAINTENANCE OF HYDRAULIC MINING SHOVELS .................................................................... 1-3
1.3 EXPLANATION OF ABBREVIATIONS ............................................................................................ 1-4
1.4 DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL .................................................................. 1-5

2 SPECIFICATIONS ..................................................................................... 2-1

2.1 LIFTING GEARS ............................................................................................................................... 2-2
2.2 SAFETY HINTS FOR SLING ACCESSORY .................................................................................... 2-4
2.3 STANDARD TIGHTENING TORQUE CHART ................................................................................. 2-5
2.4 CONVERSION TABLES ................................................................................................................... 2-6
2.5 PT100 TEMPERATURE CHARTS (PT100) G CENTIGRADE - OHM............................................ 2-12
2.6 BLIND PLUGS ................................................................................................................................ 2-13
2.7 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH ..................................................... 2-15
2.8 PLUGS AND FITTINGS ACCORDING TO ISO 8434-1 / DIN 2353 ............................................... 2-16

3 MAIN ASSEMBLY GROUPS ..................................................................... 3-1

3.1 GENERAL LAYOUT ......................................................................................................................... 3-2
3.2 SUPERSTRUCTURE ........................................................................................................................ 3-4
3.3 MACHINE HOUSE ............................................................................................................................ 3-6
3.4 HYDRAULIC OIL TANK.................................................................................................................... 3-8
3.5 HYDRAULIC OIL COOLER ............................................................................................................ 3-10
3.6 FUEL TANK .................................................................................................................................... 3-12
3.7 COUNTERWEIGHT......................................................................................................................... 3-14
3.8 CAB BASE ..................................................................................................................................... 3-16
3.9 OPERATOR’S CAB ........................................................................................................................ 3-18
3.10 MAIN CONTROL BLOCKS............................................................................................................. 3-20
3.10.1 MAIN CONTROL BLOCKS (FSA) ...................................................................................... 3-20
3.10.2 MAIN CONTROL BLOCKS (BHA) ...................................................................................... 3-22
3.11 SLEW MACHINERY........................................................................................................................ 3-24
3.11.1 SLEW MACHINERY L&S ................................................................................................... 3-24
3.11.2 SLEW MACHINERY SIEBENHAAR ................................................................................... 3-26
3.12 UNDERCARRIAGE......................................................................................................................... 3-28
3.13 BACKHOE ATTACHMENT (BHA) ................................................................................................. 3-30
3.14 FRONT SHOVEL ATTACHMENT (FSA) ........................................................................................ 3-31

4 DRIVE ........................................................................................................ 4-1

4.1 PRIME DRIVE ASSEMBLY .............................................................................................................. 4-2
4.2 ENGINE MOUNTS ............................................................................................................................ 4-4
4.2.1 CHECKS AND ADJUSTMENTS........................................................................................... 4-5

SHOP-10 06279-xD-GB-1 PC3000-6 TOC - 1

 4.3 FLEXIBLE COUPLING...................................................................................................................... 4-6
4.3.1 GEISLINGENR COUPLING.................................................................................................. 4-6
4.3.2 CENTAFLEX COUPLING ..................................................................................................... 4-8
4.3.2.1 INFORMATION FOR MAINTENANCE ............................................................... 4-10
4.3.2.2 COUPLING ELEMENTS..................................................................................... 4-11
4.3.2.3 SEPARATION AND ASSEMBLY OF THE COUPLING INNER AND
OUTER PART..................................................................................................... 4-12
4.3.2.4 OPERATION TROUBLES, CAUSES, AND RECTIFICATION ........................... 4-13
4.4 RADIATOR FAN DRIVE.................................................................................................................. 4-14
4.5 PTO.................................................................................................................................................. 4-16
4.5.1 PTO LUBRICATION AND COOLING ................................................................................. 4-18
4.5.1.1 CHECKS AND ADJUSTMENTS - PTO LUBRICATION PRESSURE ................ 4-20
4.5.2 PTO GEAR OIL TEMPERATURE CONTROL .................................................................... 4-22
4.5.2.1 TEMPERATURE ADJUSTMENT (OIL VISCOSITY) .......................................... 4-22
4.5.2.2 ADJUSTMENT OF THE LINE RESISTANCE COMPENSATION ...................... 4-23
4.5.3 PUMP SPLINE LUBRICATION........................................................................................... 4-24
4.5.3.1 OIL LEVEL IN THE MAIN PUMP & GEAR OIL PUMP DRIVE
SHAFT HOUSING .............................................................................................. 4-25
4.6 HYDRAULIC PUMPS - ARRANGEMENT ...................................................................................... 4-26
4.7 AIR FILTER ..................................................................................................................................... 4-28

5 HYDRAULIC OIL TANK ............................................................................. 5-1

5.1 GENERAL LAYOUT.......................................................................................................................... 5-2
5.2 HYDRAULIC OIL TANK, LOCATION OF THE ELECTRIC EQUIPMENT ....................................... 5-4
5.3 SUCTION OIL MANIFOLD WITH STRAINERS................................................................................ 5-6
5.4 RETURN OIL COLLECTOR MANIFOLD WITH STRAINER ............................................................ 5-8
5.5 BACK PRESSURE VALVE............................................................................................................. 5-10
5.6 TRANSFER PUMP .......................................................................................................................... 5-12
5.7 RETURN AND LEAK OIL FILTER.................................................................................................. 5-14
5.8 BREATHER FILTER ....................................................................................................................... 5-16

6 HYDRAULIC OIL COOLING ...................................................................... 6-1

6.1 OVERALL VIEW OF THE HYDRAULIC OIL COOLING .................................................................. 6-2
6.2 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT............................................................ 6-4
6.3 CHECK AND ADJUSTMENT OF THE BACK PRESSURE VALVE ................................................ 6-6
6.4 TWO STAGE COOLER FAN RPM CONTROL................................................................................. 6-8
6.4.1 SOLENOID VALVE FOR FAN SPEED CONTROL ............................................................ 6-10
6.4.2 PRESSURE REDUCING VALVE (FAN CONTROL VALVE).............................................. 6-12
6.4.3 TEMPERATURE CONVERTER RELAYS .......................................................................... 6-14
6.4.3.1 FUNCTION CHECK OF COOLER FAN RPM-CONTROL.................................. 6-15
6.4.3.2 ADJUSTMENT OF THE LINE RESISTANCE COMPENSATION ...................... 6-15
6.5 FAN PUMP ...................................................................................................................................... 6-16
6.6 CHECKS AND ADJUSTMENTS OF THE COOLER FAN DRIVE SPEEDS .................................. 6-18
6.6.1 FUNCTION CHECK OF FAN SPEED CONTROL .............................................................. 6-21

TOC - 2 PC3000-6 SHOP-10 06279-xD-GB-1

7 CONTROLLING ......................................................................................... 7-1
7.1 GENERAL LAYOUT ......................................................................................................................... 7-2
7.2 CONTROL AND FILTER PLATE - LOCATION OF COMPONENTS ............................................... 7-4
7.3 PILOT CONTROL FRAME - LOCATION OF COMPONENTS ......................................................... 7-8
7.4 PILOT PRESSURE SUPPLY AND ADJUSTMENTS ..................................................................... 7-10
7.4.1 PILOT PRESSURE CIRCUIT ............................................................................................. 7-10
7.4.2 CHECKS AND ADJUSTMENT OF PILOT PRESSURE ..................................................... 7-12

8 COMPONENTS ......................................................................................... 8-1

8.1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTERS (FSA) ............................................ 8-2
8.2 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTERS (BHA) ............................................ 8-6
8.3 DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI
CAVITATION VALVES (FSA)......................................................................................................... 8-10
8.4 DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND ANTI
CAVITATION VALVES (BHA) ........................................................................................................ 8-12
8.5 SINGLE CONTROL BLOCKS (FLOATING) FOR STICK AND BOOM (FSA)............................... 8-14
8.6 RESTRICTOR BLOCK WITH SECONDARY RELIEF VALVE....................................................... 8-16
8.7 ANTI-CAVITATION VALVE (ACV) BLOCK ................................................................................... 8-18
8.8 HIGH-PRESSURE FILTER (SCREEN)........................................................................................... 8-20
8.9 CONTROL BLOCKS AND VALVES............................................................................................... 8-22
8.9.1 SPOOL TYPES................................................................................................................... 8-28
8.9.2 MRV, SRV AND ACV.......................................................................................................... 8-30
8.9.3 LOAD HOLDING VALVE .................................................................................................... 8-32
8.10 TRAVEL BRAKE VALVE................................................................................................................ 8-36
8.11 4/2 DIRECTIONAL SOLENOID VALVES ....................................................................................... 8-38
8.12 4/3 DIRECTIONAL SOLENOID VALVES ....................................................................................... 8-40
8.13 PRESSURE DOUBLE STAGE VALVE .......................................................................................... 8-42
8.14 HYDRAULIC CYLINDER ................................................................................................................ 8-44
8.15 AUXILIARY GEAR PUMPS ............................................................................................................ 8-48

9 MAIN HYDRAULIC PUMPS AND PUMP REGULATION .......................... 9-1

9.1 GENERAL ......................................................................................................................................... 9-2
9.1.1 PUMP LOCATIONS AND PUMP DATA ............................................................................... 9-4
9.2 MAIN PUMPS.................................................................................................................................... 9-6
9.2.1 HYDRAULIC PUMP TYPE HPV375+375 ............................................................................. 9-6
9.2.1.1 MAIN PUMP SECTIONAL DRAWINGS ............................................................... 9-8
9.2.2 SERVO VALVE................................................................................................................... 9-10
9.2.2.1 VC VALVE ⇔ SERVO PISTON ......................................................................... 9-11
9.2.2.2 EPC VALVE........................................................................................................ 9-16
9.3 ELECTRONIC PUMP REGULATION SYSTEM ............................................................................. 9-18
9.3.1 CUT-OFF FUNCTION......................................................................................................... 9-20
9.3.2 SLEW CONTROL (VOLUME REDUCTION) ...................................................................... 9-21
9.3.3 DIAGNOSTICS AND MONITORING .................................................................................. 9-21
9.3.4 TEMPERATURE CONTROL .............................................................................................. 9-22
9.3.4.1 TEMPERATURE ADJUSTMENT (HYDRAULIC OIL VISCOSITY) .................... 9-22
9.3.4.2 ADJUSTMENT OF THE LINE RESISTANCE COMPENSATION ...................... 9-23

SHOP-10 06279-xD-GB-1 PC3000-6 TOC - 3

 9.4 PUMP CONTROLLER CR710 ........................................................................................................ 9-24
9.4.1 CONNECTOR AND PIN ARRANGEMENT AT CR710 (10K032)....................................... 9-26
9.5 MULTIMONITOR ............................................................................................................................. 9-30
9.5.1 SERVICE MENU SCREEN................................................................................................. 9-33
9.5.2 SERVICE MENU, OPTION: 01 MONITORING................................................................... 9-34
9.5.2.1 HOLD FUNCTION .............................................................................................. 9-37
9.5.3 SERVICE MENU, OPTION: 02 ABNORMALITY RECORD................................................ 9-38
9.5.3.1 TROUBLESHOOTING PROCEDURES ............................................................. 9-38
9.5.3.2 TABLE OF PUMP-CONTROLLER-CODES (MULTI MONITOR) ....................... 9-40
9.5.4 SERVICE MENU, OPTION: 03 DEFAULT.......................................................................... 9-42
9.5.5 SERVICE MENU, OPTION: 04 ADJUSTMENT.................................................................. 9-43
9.5.6 ADJUSTABLE PARAMETERS ........................................................................................... 9-45
9.5.7 EMERGENCY MODE ......................................................................................................... 9-45
9.5.8 DESCRIPTION OF THE PRIMARY P-FACTOR................................................................. 9-46
9.5.8.1 ADJUSTMENT, ITEM 1: PRIMARY P-FACTOR ................................................ 9-46
9.5.9 ADJUSTMENT, ITEMS 23...28: SOL_ADJ_MIN_P1...SOL_ADJ_MIN_P6 ........................ 9-47
9.5.10 ADJUSTMENT, ITEMS 39...44: SOL_ADJ_MAX_P1...SOL_ADJ_MAX_P6...................... 9-48
9.5.11 AVAILABLE PARAMETERS LIST ...................................................................................... 9-49
9.5.12 SERVICE MENU, OPTION: 05 DISPLAY SETUP.............................................................. 9-51
9.6 CHECKS AND ADJUSTMENTS ..................................................................................................... 9-52
9.6.1 ENGINE POWER CHECK .................................................................................................. 9-52
9.6.2 CUT-OFF FUNCTION CHECK ........................................................................................... 9-55
9.6.2.1 CUT-OFF FOR CLAM CLOSE (FSA ONLY) ...................................................... 9-56
9.7 ENGINE SPEED SENSOR (PICK-UP)............................................................................................ 9-58
9.7.1 GENERAL ........................................................................................................................... 9-59
9.7.2 ENGINE SPEED SENSOR (PICK-UP) ADJUSTMENT...................................................... 9-59

10 OPERATING HYDRAULICS .................................................................... 10-1

10.1 GENERAL ....................................................................................................................................... 10-2
10.1.1 FLOATING SYSTEM (FSA) ................................................................................................ 10-4
10.2 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVE (MRV) ...................................... 10-6
10.3 HYDRAULICS FOR THE ATTACHMENT CYLINDERS............................................................... 10-10
10.3.1 CHECKS AND ADJUSTMENTS OF THE SECONDARY RELIEF VALVES (SRV).......... 10-10
10.3.1.1 BOOM CYLINDERS, PISTON SIDE (BHA & FSA), BOOM UP ....................... 10-10
10.3.1.2 BOOM CYLINDER, PISTON ROD SIDE (BHA & FSA), BOOM DOWN .......... 10-14
10.3.1.3 STICK CYLINDERS, PISTON SIDE (FSA), STICK OUT ................................. 10-18
10.3.1.4 STICK CYLINDERS, PISTON SIDE (BHA), STICK IN ..................................... 10-22
10.3.1.5 STICK CYLINDERS, PISTON ROD SIDE (FSA), STICK IN ............................ 10-26
10.3.1.6 STICK CYLINDERS, PISTON ROD SIDE (BHA), STICK OUT ........................ 10-30
10.3.1.7 BUCKET CYLINDERS, PISTON SIDE (FSA), BUCKET FILL.......................... 10-34
10.3.1.8 BUCKET CYLINDERS, PISTON SIDE (BHA), BUCKET FILL ......................... 10-38
10.3.1.9 BUCKET CYLINDERS, PISTON ROD SIDE (FSA), BUCKET DUMP ............. 10-42
10.3.1.10 BUCKET CYLINDERS, PISTON ROD SIDE (BHA), BUCKET DUMP ............. 10-46
10.3.1.11 CLAM CYLINDERS, PISTON ROD SIDE (FSA), CLAM OPEN ....................... 10-50
10.3.1.12 CLAM CYLINDERS, PISTON SIDE (FSA), CLAM CLOSE .............................. 10-54

TOC - 4 PC3000-6 SHOP-10 06279-xD-GB-1

 10.3.2 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED ....................................... 10-58
10.3.2.1 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED
– BOOM (FSA) ................................................................................................. 10-58
10.3.2.2 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED
– BOOM (BHA) ................................................................................................. 10-64
10.3.2.3 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED
– STICK (FSA).................................................................................................. 10-66
10.3.2.4 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED
– STICK (BHA) ................................................................................................. 10-72
10.3.2.5 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED
– BUCKET (FSA).............................................................................................. 10-74
10.3.2.6 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED
– BUCKET (BHA) ............................................................................................. 10-76
10.3.2.7 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED
– CLAM (FSA) .................................................................................................. 10-78
10.4 HYDRAULICS FOR THE SLEW CIRCUIT ................................................................................... 10-80
10.4.1 SLEW CIRCUIT ................................................................................................................ 10-80
10.4.2 SLEW MOTOR ................................................................................................................. 10-82
10.4.3 SLEW GEARBOX (L&S)................................................................................................... 10-84
10.4.4 SLEW GEARBOX (SIEBENHAAR) .................................................................................. 10-86
10.4.5 SLEW PARKING BRAKE (L&S) ....................................................................................... 10-88
10.4.6 SLEW PARKING BRAKE (SIEBENHAAR)....................................................................... 10-90
10.4.7 SLEW BRAKE VALVE ...................................................................................................... 10-92
10.4.8 CHECKS AND ADJUSTMENTS FOR THE SLEW CIRCUIT ........................................... 10-96
10.4.8.1 CHECKS & ADJUSTMENTS, DOUBLE STAGE VALVE ................................. 10-96
10.4.8.2 CHECKS & ADJUSTMENTS, SLEW BRAKE PILOT PRESSURE .................. 10-99
10.4.8.3 CROSSCHECK OF THE DSV SETTING ......................................................... 10-99
10.4.8.4 ADJUSTMENT OF THE SLEW MOTION DETECTION ................................. 10-100
10.4.9 FUNCTION CHECK FOR THE HYDRAULIC SLEW PARKING BRAKE........................ 10-102
10.5 HYDRAULICS FOR THE TRAVEL CIRCUIT ............................................................................. 10-104
10.5.1 TRAVEL CIRCUIT .......................................................................................................... 10-104
10.5.2 TRAVEL MOTOR............................................................................................................ 10-106
10.5.3 ROTARY JOINT.............................................................................................................. 10-108
10.5.4 TRAVEL GEARBOX ....................................................................................................... 10-110
10.5.5 TRAVEL PARKING BRAKE............................................................................................ 10-112
10.5.5.1 TRAVEL PARKING BRAKE ........................................................................... 10-112
10.6 TRAVEL BRAKE VALVE............................................................................................................ 10-114
10.6.1 CHECKS AND ADJUSTMENTS..................................................................................... 10-116
10.6.1.1 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT ..................... 10-116
10.6.1.2 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE ......................... 10-120

11 HYDRAULIC TRACK TENSIONING SYSTEM ........................................ 11-1

11.1 GENERAL ....................................................................................................................................... 11-2
11.2 FUNCTIONAL DESCRIPTION........................................................................................................ 11-4
11.3 DOUBLE STAGE VALVE ............................................................................................................... 11-6
11.4 TENSIONING CYLINDER ............................................................................................................... 11-8
11.5 ADJUSTMENTS / CHECKS.......................................................................................................... 11-10

SHOP-10 06279-xD-GB-1 PC3000-6 TOC - 5

12 ACCESS LADDER, HYDRAULICALLY OPERATED............................... 12-1
12.1 GENERAL ....................................................................................................................................... 12-2
12.2 FUNCTION OF THE HYDRAULICALLY OPERATED ACCESS LADDER.................................... 12-4
12.3 ADJUSTMENTS / CHECKS............................................................................................................ 12-8

13 CENTRAL REFILLING SYSTEM (REFILLING ARM) .............................. 13-1

13.1 REFILLING ARM LOCATION ......................................................................................................... 13-2
13.2 FUNCTION ...................................................................................................................................... 13-4

14 HINTS FOR READING THE HYDRAULIC DIAGRAM............................. 14-1

14.1 GENERAL ....................................................................................................................................... 14-2
14.2 HYDRAULIC SYMBOLS ................................................................................................................. 14-4
14.2.1 LINES, UNIONS.................................................................................................................. 14-5
14.2.2 COMPONENTS, VALVES .................................................................................................. 14-7
14.2.3 SENSORS........................................................................................................................... 14-7
14.2.4 VALVES, VALVE COMPONENTS...................................................................................... 14-8
14.2.5 PUMP, MOTOR, CYLINDER ............................................................................................ 14-12

15 HINTS FOR READING THE ELECTRIC WIRING DIAGRAM ................. 15-1

15.1 GENERAL ....................................................................................................................................... 15-2
15.2 REFERENCE CODE OF THE ELECTRICAL COMPONENTS....................................................... 15-3
15.2.1 AREA CODE ....................................................................................................................... 15-3
15.2.2 COMPONENT IDENTIFYING LETTER .............................................................................. 15-5
15.3 GRAPHICAL SYMBOLS................................................................................................................. 15-6
15.4 DRAWING CONCEPT................................................................................................................... 15-10
15.5 CABLE MARKING ........................................................................................................................ 15-19

16 KOMTRAX PLUS ..................................................................................... 16-1

16.1 GENERAL ....................................................................................................................................... 16-2
16.1.1 LOCATION OF KOMTRAX PLUS COMPONENTS IN CAB BASE .................................... 16-4
16.2 SPECIFICATIONS FOR OPERATORS .......................................................................................... 16-6
16.2.1 OPENING SCREEN............................................................................................................ 16-7
16.2.2 MAIN GAUGE SCREENS 1 TO 2....................................................................................... 16-8
16.2.3 FUEL CONSUMPTION SCREEN ..................................................................................... 16-12
16.2.4 FAILURE MESSAGE HISTORY FOR THE OPERATOR ................................................. 16-14
16.2.5 MAIN GAUGE SCREENS - CHANGING OF TIME / SMR / DATE ................................... 16-15
16.2.6 MAINTENANCE MONITOR .............................................................................................. 16-16
16.2.7 SETTINGS FOR OPERATOR .......................................................................................... 16-18
16.2.7.1 USER ID SCREEN ........................................................................................... 16-19
16.2.7.2 RESET TRUCK COUNTER 1 & 2 .................................................................... 16-20
16.2.7.3 SCREEN ADJUSTMENT DISPLAYS ............................................................... 16-22
16.2.7.4 DATE AND TIME ADJUSTMENT ..................................................................... 16-24
16.2.7.5 LANGUAGE SELECTION ................................................................................ 16-25
16.2.8 AUTOMATIC MESSAGES................................................................................................ 16-26

TOC - 6 PC3000-6 SHOP-10 06279-xD-GB-1

 16.3 TABLES OF ALL PROVIDED MESSAGES ................................................................................. 16-28
16.3.1 TABLE OF CUMMINS TROUBLE CODES (TIER 2) ........................................................ 16-28
16.3.2 TABLE OF KOMTRAX PLUS TROUBLE CODES............................................................ 16-33
16.3.3 TABLE OF PUMP-CONTROLLER-CODES (MULTI MONITOR) ..................................... 16-37
16.3.4 TABLE OF AVAILABLE INSTRUCTION MESSAGES ..................................................... 16-39
16.4 FLOW CHARTS (1-4) OF KOMTRAX PLUS MAIN SCREENS ................................................... 16-42
16.5 KOMTRAX PLUS SERVICE LEVEL............................................................................................. 16-46
16.5.1 EXPLANATION OF THE BUTTON SYMBOLS (SERVICE LEVEL) ................................. 16-48
16.5.2 SERVICE MENU SELECT SCREEN................................................................................ 16-49
16.5.3 REAL TIME MENU SELECT SCREEN ............................................................................ 16-50
16.5.3.1 REAL TIME MENU, OPTION: 01 ENGINE 1.................................................... 16-51
16.5.3.2 REAL TIME MENU, OPTION: 02 PTO 1 .......................................................... 16-52
16.5.3.3 REAL TIME MENU, OPTION: 03 HYDRAULIC................................................ 16-53
16.5.3.4 REAL TIME MENU, OPTION: 04 ELECTRICAL EQUIPMENT........................ 16-54
16.5.3.5 REAL TIME MENU, OPTION: 05 EMERGENCY STOP .................................. 16-55
16.5.3.6 REAL TIME MENU, OPTION: 06 MANUAL SWITCH ...................................... 16-56
16.5.3.7 REAL TIME MENU, OPTION: 07 CENTRAL LUBE SYSTEM 1 ...................... 16-57
16.5.3.8 REAL TIME MENU, OPTION: 08 SLEW RING GEAR LUBE SYSTEM........... 16-58
16.5.3.9 REAL TIME MENU, OPTION: 09 PILOT CONTROL ....................................... 16-59
16.5.3.10 REAL TIME MENU, OPTION: 10 OTHER ITEMS............................................ 16-60
16.5.3.11 REAL TIME MENU, OPTION: 11 OUTPUT SIGNALS ..................................... 16-61
16.5.4 PM-CLINIC........................................................................................................................ 16-62
16.5.4.1 GENERAL......................................................................................................... 16-62
16.5.4.2 POWER CHECK............................................................................................... 16-63
16.5.5 SERIAL/GCC NO. SETTING ............................................................................................ 16-65
16.5.6 MEMORY CLEAR............................................................................................................. 16-66
16.5.6.1 INPUT MEMORY CLEAR ID ............................................................................ 16-66
16.5.6.2 MEMORY CLEAR SCREEN............................................................................. 16-67
16.5.7 FAILURE HISTORY.......................................................................................................... 16-68
16.5.8 MAINTENANCE MONITOR.............................................................................................. 16-69
16.5.9 SNAPSHOT ...................................................................................................................... 16-70
16.5.10 SETTINGS ........................................................................................................................ 16-72
16.5.10.1 CENTRAL LUBRICATION SYSTEM (CLS 1), SCREEN 1/4............................ 16-72
16.5.10.2 SLEW LUBRICATION SYSTEM (SLS), SCREEN 2/4 ..................................... 16-73
16.5.10.3 OTHER SETTINGS 1/2, SCREEN 3/4 ............................................................. 16-73
16.5.10.4 OTHER SETTINGS 2/2, SCREEN 4/4 ............................................................. 16-74
16.6 INTERFACE-CONNECTION KOMTRAX PLUS CONTROLLER ................................................. 16-76
16.6.1 KOMTRAX PLUS CONTROLLER .................................................................................... 16-77
16.7 7-SEGMENT ERROR CODE INDICATION .................................................................................. 16-78
16.8 WIRING OF THE KOMTRAX PLUS CONTROLLER ................................................................... 16-80
16.9 GLOBAL LAYOUT OF THE INTERNAL CAN BUS ..................................................................... 16-84
16.9.1 GENERAL INFORMATION ON A CAN BUS SYSTEM .................................................... 16-84
16.9.1.1 GENERAL CAN BUS DESCRIPTION .............................................................. 16-85
16.9.1.2 CAN BUS TROUBLESHOOTING..................................................................... 16-85
16.9.2 CAN BUS WIRING............................................................................................................ 16-86
16.9.2.1 CAN BUS END RESISTOR.............................................................................. 16-87

SHOP-10 06279-xD-GB-1 PC3000-6 TOC - 7

17 LUBRICATION SYSTEM ......................................................................... 17-1
17.1 GENERAL OVERVIEW (SLS & CLS)............................................................................................. 17-2
17.1.1 GENERAL DESCRIPTION ................................................................................................. 17-3
17.2 BASIC FUNCTION OF THE LUBRICATIONSYSTEMS ................................................................. 17-4
17.3 LUBRICATION SYSTEMS (SLS & CLS) ....................................................................................... 17-6
17.3.1 LUBRICATION PUMP STATION ........................................................................................ 17-6
17.3.2 GENERAL INFORMATION ON CLS .................................................................................. 17-8
17.3.3 GENERAL INFORMATION ON SLS................................................................................... 17-8
17.4 LUBRICATION CYCLE ................................................................................................................. 17-10
17.4.1 TIME SEGMENTS & SWITCH POINTS OF A LUBRICATION CYCLE............................ 17-11
17.4.2 AUTOMATIC LUBRICATION MODE CLS ........................................................................ 17-12
17.4.2.1 FUNCTION ....................................................................................................... 17-13
17.4.2.2 SYSTEM MONITORING................................................................................... 17-13
17.4.3 AUTOMATIC LUBRICATION MODE SLS ........................................................................ 17-14
17.4.3.1 FUNCTION ....................................................................................................... 17-15
17.4.3.2 SYSTEM MONITORING................................................................................... 17-15
17.4.4 AUTOMATIC LUBRICATION MODE ADJUSTMENTS .................................................... 17-16
17.4.4.1 PAUSE TIME ADJUSTMENT & FAULT TIME MONITORING ADJUSTMENT 17-16
17.4.4.2 LUBE CYCLE MONITORING TIME ADJUSTMENT ........................................ 17-17
17.4.5 MANUAL LUBRICATION MODE (CLS & SLS)................................................................. 17-18
17.4.6 RESETTING A FAULTY LUBRICATION SYSTEM .......................................................... 17-18
17.5 HYDRAULICALLY DRIVEN LUBE PUMP.................................................................................... 17-20
17.5.1 ADJUSTMENT OF LUBE PUMP SPEED ......................................................................... 17-22
17.5.1.1 STROKE SPEED ADJUSTMENT..................................................................... 17-23
17.5.1.2 WORKING PRESSURE ................................................................................... 17-23
17.6 LUBRICANT INJECTORS ............................................................................................................ 17-24
17.6.1 TIGHTENING TORQUES FOR FITTINGS AT GREASE INJECTORS ............................ 17-25
17.6.2 DESCRIPTION.................................................................................................................. 17-25
17.6.3 ADJUSTMENT OF THE LUBRICANT OUTPUT............................................................... 17-26
17.6.4 OPERATION PRINCIPLE OF LUBRICANT INJECTORS ................................................ 17-28
17.6.4.1 FUNCTION DESCRIPTION.............................................................................. 17-29
17.6.5 CONNECTION OF ONE OR MORE INJECTORS............................................................ 17-30
17.7 VENT VALVE AND GREASE OUTLET FILTER .......................................................................... 17-32
17.7.1 VENT VALVE DESCRIPTION .......................................................................................... 17-33
17.8 END-LINE SWITCH....................................................................................................................... 17-34
17.8.1 DESCRIPTION.................................................................................................................. 17-35
17.8.2 CLS & SLS END-LINE SWITCH ADJUSTMENT.............................................................. 17-36
17.9 LUBRICANT LEVEL SENSORS................................................................................................... 17-38
17.9.1 DESCRIPTION.................................................................................................................. 17-39
17.9.1.1 CHECKS........................................................................................................... 17-39
17.10 COMMISSIONING ......................................................................................................................... 17-40
17.10.1 COMMISSIONING OF THE CLS LUBRICATION SYSTEM ............................................. 17-40
17.10.2 FINE ADJUSTMENT......................................................................................................... 17-41
17.10.3 COMMISSIONING OF THE SLS LUBRICATION SYSTEM ............................................. 17-42

TOC - 8 PC3000-6 SHOP-10 06279-xD-GB-1

18 DEEP TEMPERATURE EQUIPMENT (OPTION).................................... 18-1
18.1 GENERAL INFORMATION............................................................................................................. 18-2
18.1.1 INTRODUCTION ................................................................................................................ 18-2
18.1.2 DEEP TEMPERATURE COMPONENTS OVERVIEW ....................................................... 18-2
18.1.3 POWER SUPPLY PRECONDITIONS FOR PREHEATING ............................................... 18-3
18.1.4 POWER REQUIREMENTS FOR PREHEATING SYSTEMS ............................................. 18-4
18.2 PREHEATING PROCEDURE ......................................................................................................... 18-5
18.2.1 GLOBAL FLOW CHART OF THE PREHEATING PROCEDURE ...................................... 18-5
18.2.2 STARTING THE PREHEATING PROCEDURE ................................................................. 18-6
18.2.3 PREHEATING OF OPERATOR’S CAB AND DIESEL ENGINE [COOLANT SYSTEM] .... 18-7
18.2.4 PREHEATING OF LUBRICANTS AND SUPERSTRUCTURE (DIESEL)
[ELECTRIC SYSTEM] ........................................................................................................ 18-8
18.3 CONSTANT HEATING OF TRAVEL MOTORS (TTT EQUIPMENT BELOW-40°C ONLY) .......... 18-9
18.4 COMPONENT LOCATION............................................................................................................ 18-10
18.4.1 ELECTRIC HEATING ELEMENTS FOR HYDRAULIC & BATTERIES
[ELECTRIC MACHINE]..................................................................................................... 18-10
18.4.2 ELECTRIC HEATING ELEMENTS FOR HYDRAULICS [DIESEL MACHINE]................. 18-12
18.4.3 ELECTRIC HEATING ELEMENTS FOR ENGINES & BATTERIES [DIESEL MACHINE] 18-14
18.5 COMPONENTS OF TT EQUIPMENT ........................................................................................... 18-16
18.5.1 PREHEATING COMPONENTS ON A DIESEL MACHINE............................................... 18-16
18.5.2 PREHEATING COMPONENTS ON AN ELECTRIC MACHINE ....................................... 18-18
18.5.3 EXEMPLARY WIRING DIAGRAMS FOR PREHEATING SYSTEMS .............................. 18-19
18.5.3.1 WIRING DIAGRAM "HYDRAULIC OIL TANK PREHEATING" PART 1 OF 3.. 18-19
18.5.3.2 WIRING DIAGRAM "HYDRAULIC OIL TANK PREHEATING" PART 2 OF 3.. 18-20
18.5.3.3 WIRING DIAGRAM "HYDRAULIC OIL TANK PREHEATING" PART 3 OF 3.. 18-21
18.5.3.4 WIRING DIAGRAM "SUCTION OIL MANIFOLD PREHEATING" .................... 18-22
18.5.3.5 WIRING DIAGRAM "PTO PREHEATING" ....................................................... 18-23
18.5.3.6 WIRING DIAGRAM "BATTERY HEATER PADS" ............................................ 18-24

SHOP-10 06279-xD-GB-1 PC3000-6 TOC - 9

 Please continue reading on the next page.

TOC - 10 PC3000-6 SHOP-10 06279-xD-GB-1

Introduction

1 INTRODUCTION

SHOP-10 06279-xD-GB-1 PC3000-6 1 -1

Foreword Introduction

1.1 FOREWORD
Observe the instructions in part 10 for:

– your Personal SAFETY

– Operating SAFETY, and
– READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.

With part 10 STRUCTURE & FUNCTION in this SHOP MANUAL KOMATSU provides you with the description of
the construction and the function of the major systems of the Hydraulic Excavator PC3000-6D.

We describe for you all functions and how to carry out the inspections and adjustments.

How do you find "your" desired information?

In the TABLE OF CONTENT all the functions and components are shown in their sequence of the description.

REMARKS: Periodic preventive inspections and maintenance are the surest means of keeping the machine in
proper working order. Prompt detection and correction of minor irregularities, and immediate
replacement of worn out or broken parts will prevent failures and avoid expenses.

Replace damaged graphics and symbols at the machine.

Observe safety precautions to prevent injury and damage.

If after reading this SHOP MANUAL you can give us suggestions and comments for improvements - please do not
hesitate to contact us.

Komatsu Germany GmbH

Mining Division

Buscherhofstr. 10
40599 Düsseldorf
GERMANY

NOTICE
RISKS FOR DAMAGES BY NOT FOLLOWING THE MACHINE’S DOCUMENTATION!
Personnel entrusted with work on the machine must have read the ASSEMBLY MANUAL, the OPERATION-
LUBRICATION- and MAINTENANCE MANUAL and in particular the section on SAFETY before beginning to
work.
Reading the instructions after work has begun, is too late.

Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturers
guarantee.

NOTE! If the Shovel is equipped with a fire suppression system, make sure that the system is ready for
operation.

In order to keep your Shovel in first-class operating condition use only genuine spare and wear parts.

The use of any part other than the genuine part releases the KOMATSU GERMANY GmbH from any guarantee.

1 -2 PC3000-6 SHOP-10 06279-xD-GB-1

Introduction Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels

Service

For all questions related to your Shovel please contact your local Service Center.

In all your written or phoned inquiries please indicate the model and serial number of your Shovel.

1.2 RECOMMENDATIONS FOR ENVIRONMENTALLY

FRIENDLY OPERATION AND MAINTENANCE OF
HYDRAULIC MINING SHOVELS
Operation

– Avoid engine idling over long periods. Long periods of idling, more than 10 minutes, will not only waste fuel,
but is also harmful to the engine.
– Avoid operation against the main relief valves of the hydraulic system.
Move control lever to neutral position before the loader attachment stalls due to overload.
– Position trucks in such a way, that loading operation can be carried out in a safe and economic manner.
Avoid slew angles over 90°.

Maintenance and repair

– Preserve our environment. To prevent environmental pollution, pay careful attention to the method of
disposing waste materials.
– Always drain fluids from your machine into containers. Never drain fluids onto the ground or dump it into the
sewage system rivers, the sea, or lakes.
– Disposal of harmful material, such as oil, solvent, filters and batteries has to be processed in accordance with
environmental regulations and laws.

SHOP-10 06279-xD-GB-1 PC3000-6 1 -3

Explanation of abbreviations Introduction

1.3 EXPLANATION OF ABBREVIATIONS

Abbreviation Definition

AC Alternating Current

A/C Air Condition

ACV Anti-Cavitation Valve

API American Petroleum Institute

BHA Backhoe Attachment

°C Degree Celsius

CCW Counterclockwise

CW Clockwise

CLS Central Lubrication System

CO Cut off function (main pump)

DC Direct Current

FSA Front Shovel Attachment

GET Ground Engaging Tools

HP High Pressure

K+ KOMTRAX Plus system

LED Light Emitting Diode

L.H. Left Hand

MH801 KOMTRAX Plus monitor / Multimonitor for pump control

MRV Main Relief Valve

PQ Pressure & Quantity (for pump control)

PTO Power Take-Off (Pump Distributor Gear)

Qmax Maximum pump delivery = maximum swash plate angle

Qmin Minimum pump delivery = minimum swash plate angle

½ Qmax ½ pump delivery

R.H. Right Hand

RPM Revolutions Per Minute [1/min]

SLS Slew circle pinion Lubrication System

SRV Secondary Relief Valve

1 -4 PC3000-6 SHOP-10 06279-xD-GB-1

Introduction Diagrams and illustrations in this manual

1.4 DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL

Wiring Diagrams & Hydraulic Diagrams

– During work or troubleshooting always make sure to use your Wiring Diagrams and Hydraulic Diagrams which
are assigned to your machine.
– Due to variable requirements in many respects, the samples of diagrams shown in this manual can not meet
the actual state of each machine in every case.

Illustrations & technical drawings

– The illustrations and technical drawings shown in this manual correspond to state of the technology at the time
of press date.
– Modifications of shown components are possible prior notice.

SHOP-10 06279-xD-GB-1 PC3000-6 1 -5

Diagrams and illustrations in this manual Introduction

Please continue reading on the next page.

1 -6 PC3000-6 SHOP-10 06279-xD-GB-1

Specifications

2 SPECIFICATIONS

SHOP-10 06279-xD-GB-1 PC3000-6 2 -1

Lifting Gears Specifications

2.1 LIFTING GEARS

– Heavy parts (25 kg or more) must be lifted with a hoist etc.
– If any part cannot be smoothly removed from the machine by hoisting, the following checks should be made:
– Check for removal of all bolts fastening the part to the relative parts.
– Check for existence of another part causing interference with the part to be removed.

WIRE ROPES

– Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:

Wire popes
(Standard "Z" or "S" twist ropes without galvanizing)

Rope diameter
10,0 11,2 12,5 14,0 16,0 18,0 20,0 22,4 30,0 40,0 50,0 60,0
[mm]

Allowable load
1,0 1,4 1,6 2,2 2,8 3,6 4,4 5,6 10,0 18,0 28,0 40,0
[tons]

Table 2-1 Rope diameter/allowable bend

NOTE! The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used.

– Sling wire ropes from the middle portion of the hook. Slinging
near the edge of the hook may cause the rope to slip off the
hook during hoisting, and a serious accident can result.
Hooks have maximum strength at the middle portion.

Fig. 2-1

– Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the
load.
NOTE! Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slip-
ping of the rope from its original winding position on the load, which can result in a dangerous acci-
dent.

2 -2 PC3000-6 SHOP-10 06279-xD-GB-1

Specifications Lifting Gears

– Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with
two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below
shows the variation of allowable load (kg) where hoisting g is made with two ropes, each of which is allowed to
sling up to 1000kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000kg of
total weight can be suspended. This weight becomes 1000kg when two ropes make a 120° hanging angle. On
the other hand two ropes are subject to an excessive force as large as 4000kg if they sling a 2000kg load at a
lifting angel of 150°.

Fig. 2-2

SHOP-10 06279-xD-GB-1 PC3000-6 2 -3

Safety hints for sling accessory Specifications

2.2 SAFETY HINTS FOR SLING ACCESSORY

– Always attend to local standards when using sling accessory.
NOTE! Eye bolts or sling accessory which is not suitable can result in serious accidents.

– Do not use rigid eye bolts from steel C 15 for lifting (e.g. ISO 580). These eye bolts may only be loaded verti-
cally or with a maximum permissible angle of 45° to the ring.
– Always use suitable swivel hoist rings according to local standards or Vario-Starpoint hoist rings recom-
mended by Komatsu, see following table:

Thread Komatsu Part Number Tightening Torque

M8 941 650 40 10 Nm

M10 941 651 40 10 Nm

M12 906 519 40 25 Nm

M16 906 780 40 60 Nm

M20 906 782 40 115 Nm

M24 906 783 40 190 Nm

M30 906 421 40 330 Nm

M36 906 233 40 590 Nm

Table 2-2 Vario-Starpoint hoist rings

NOTE! Vario-Starpoint hoist rings are not suited for turning under load.
After installing a Starpoint hoist ring disengage the star key.
Adjust the ring plane in direction of pull before attaching any sling accessory.

– Check that the wire rope, chains, and hooks are free from damage.
– Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places.
– Use a hoist or crane and operate slowly to prevent the component from hitting any other part.
Do not work with any part still raised by the hoist or crane.

2 -4 PC3000-6 SHOP-10 06279-xD-GB-1

Specifications Standard Tightening Torque Chart

2.3 STANDARD TIGHTENING TORQUE CHART

Bolt Wrench size Tightening torque
diameter [mm] [Nm]

Bolt quality grades

metric
regular
8.8 10.9 12.9

M 8 13 6 21 31 36

M 10 17 8 43 63 73

M 12 19 10 74 108 127

M 14 22 12 118 173 202

M 16 24 14 179 265 310

M 18 27 14 255 360 425

M 20 30 17 360 510 600

M 22 32 17 485 690 810

M 24 36 19 620 880 1030

M 27 41 19 920 1310 1530

M 30 46 22 1250 1770 2080

M 33 50 24 1690 2400 2800

M 36 55 27 2170 3100 3600

M 39 60 2800 4000 4700

M 42 65 32 3500 4950 5800

M 45 70 4350 6200 7200

M 48 75 35 5200 7500 8700

M 52 80 6700 9600 11200

M 56 85 41 8400 12000 14000

M 60 90 10400 14800 17400

M 64 95 46 12600 17900 20900

M 68 100 15200 21600 25500

Table 2-3

(1 kgm = 9,806 Nm)

REMARKS: Insert all bolts lubricated with multi purpose grease MPG (Multi Purpose Grease)
(same grease as used in the central lubrication system)

SHOP-10 06279-xD-GB-1 PC3000-6 2 -5

Conversion Tables Specifications

2.4 CONVERSION TABLES

Millimeter - Inch & Kilogram - Pound

Method of using the conversion table

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method
of using the Conversion Table, see the example given below.

Example:

Method of using the conversion table to convert from millimeters to inches.

Convert 55 mm into inches:

1. Locate the number 5 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A).

2. Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B).

3. Take the point where the two lines cross as (C). This point (C) gives the value when converting from millime-
ters to inches. Therefore, 55 millimeters = 2.165 inches.

Convert 550 mm into inches.

1. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to con-
vert it to 55 mm.

2. Carry out the same procedure as above to convert 55 mm to 2.165 inches.

3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to
the right) to return to the original value. This gives 550 mm = 21.65 inches.

2 -6 PC3000-6 SHOP-10 06279-xD-GB-1

Specifications Conversion Tables

Table 2-4

Table 2-5

SHOP-10 06279-xD-GB-1 PC3000-6 2 -7

Conversion Tables Specifications

Liter - U.S. Gallon & Liter - U.K. Gallon

Table 2-6

Table 2-7

2 -8 PC3000-6 SHOP-10 06279-xD-GB-1

Specifications Conversion Tables

Nm - ft.lb

0 1 2 3 4 5 6 7 8 9
0 0 0.74 1.47 2.21 2.95 3.69 4.42 5.16 5.90 6.63
10 7.37 8.11 8.84 9.58 10.32 11.06 11.79 12.53 13.27 14.00
20 14.74 15.48 16.21 16.95 17.69 18.43 19.16 19.90 20.64 21.37
30 22.11 22.85 23.58 24.32 25.06 25.80 26.53 27.27 28.01 28.74
40 29.48 30.22 30.95 31.69 32.43 33.17 33.90 34.64 35.38 36.11
50 36.85 37.59 38.32 39.06 39.80 40.54 41.27 42.01 42.75 43.48
60 44.22 44.96 45.69 46.43 47.17 47.91 48.64 49.38 50.12 50.85
70 51.59 52.33 53.06 53.08 54.54 55.28 56.01 56.75 57.49 58.22
80 58.96 59.07 60.43 61.17 61.91 62.65 63.38 64.12 64.86 65.59
90 66.33 67.07 67.80 68.54 69.28 70.02 70.75 71.49 72.23 72.96
100 73.70 74.44 75.17 75.91 76.65 77.39 78.12 78.86 79.60 80.33
110 81.07 81.81 82.54 83.28 84.02 84.76 85.49 86.23 86.97 87.70
120 88.44 89.18 89.91 90.65 91.39 92.13 92.86 93.60 94.34 95.07
130 95.81 96.55 97.28 98.02 98.76 99.50 100.23 100.97 101.71 102.44
140 103.18 103.92 104.65 105.39 106.13 106.87 107.60 108.34 109.08 109.81
150 110.55 111.29 112.02 112.76 113.50 114.24 114.97 115.71 116.45 117.18
160 117.92 118.66 119.39 120.13 120.87 121.61 122.34 123.08 123.82 124.55
170 125.29 126.03 126.76 127.50 128.24 128.98 129.71 130.45 131.19 131.92
180 132.66 133.40 134.13 134.87 135.61 136.35 137.08 137.82 138.56 139.29
190 140.03 140.77 141.50 142.24 142.98 143.72 144.45 145.19 145.93 146.66
200 147.40 148.14 148.87 149.61 150.35 151.09 151.82 152.56 153.30 154.03

Table 2-8 Conversion table Nm - ft.lb

1 Nm = 0.737 ft.lb

SHOP-10 06279-xD-GB-1 PC3000-6 2 -9

Conversion Tables Specifications

bar - PSI / PSI - bar

Conversion Table
bar / PSI
bar - PSI PSI - bar
bar PSI bar PSI PSI bar PSI bar
1 14,5033 205 2973 1 0,06895 3075 212
5 73 210 3046 75 5,17 3150 217
10 145 215 3118 150 10 3225 222
15 218 220 3191 225 16 3300 228
20 290 225 3263 300 21 3375 233
25 363 230 3336 375 26 3450 238
30 435 235 3408 450 31 3525 243
35 508 240 3481 525 36 3600 248
40 580 245 3553 600 41 3675 253
45 653 250 3626 675 47 3750 259
50 725 255 3698 750 52 3825 264
55 798 260 3771 825 57 3900 269
60 870 265 3843 900 62 3975 274
65 943 270 3916 975 67 4050 279
70 1015 275 3988 1050 72 4125 284
75 1088 280 4061 1125 78 4200 290
80 1160 285 4133 1200 83 4275 295
85 1233 290 4206 1275 88 4350 300
90 1305 295 4278 1350 93 4425 305
95 1378 300 4351 1425 98 4500 310
100 1450 305 4424 1500 103 4575 315
105 1523 310 4496 1575 109 4650 321
110 1595 315 4569 1650 114 4725 326
115 1668 320 4641 1725 119 4800 331
120 1740 325 4714 1800 124 4875 336
125 1813 330 4786 1875 129 4950 341
130 1885 335 4859 1950 134 5025 346
135 1958 340 4931 2025 140 5100 352
140 2030 345 5004 2100 145 5175 357
145 2103 350 5076 2175 150 5250 362
150 2175 355 5149 2250 155 5325 367
155 2248 360 5221 2325 160 5400 372
160 2321 365 5294 2400 165 5475 378
165 2393 370 5366 2475 171 5550 383
170 2466 375 5439 2550 176 5625 388
175 2538 380 5511 2625 181 5700 393
180 2611 385 5584 2700 186 5775 398
185 2683 390 5656 2775 191 5850 403
190 2756 395 5729 2850 197 5925 409
195 2828 400 5801 2925 202 6000 414
200 2901 3000 207

PSI
bar x 14,5033 = PSI = bar
14,5033

Table 2-9 Conversion table bar - PSI / PSI - bar

2 - 10 PC3000-6 SHOP-10 06279-xD-GB-1

Specifications Conversion Tables

Temperature

Fahrenheit – Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade
temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures.

These figures refer to the temperature in either degrees Fahrenheit or Centigrade.

If it is desired to convert from degrees Fahrenheit to Centigrade, consider the center column as a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.

If it is desired to convert from degrees Centigrade to Fahrenheit, consider the center column as a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.

Table 2-10 Conversion table °C - °F / °F - °C

SHOP-10 06279-xD-GB-1 PC3000-6 2 - 11

PT100 TEMPERATURE CHARTS (PT100) g Centigrade - Ohm Specifications

2.5 PT100 TEMPERATURE CHARTS

(PT100)  CENTIGRADE - OHM
Basic resistance values (Ohm) for measuring the resistance of PT100 sensors in relation to temperature
(degree centigrade)

Resistance values according to ISO 4376

Table 2-11 PT100 Temperature Charts (degree centigrade - resistance)

2 - 12 PC3000-6 SHOP-10 06279-xD-GB-1

Specifications Blind plugs

2.6 BLIND PLUGS

Dummy plates for SAE–flanges

Fig. 2-3 Forms / types of dummy plates for SAE–flanges

Up to 3000 PSI (207 bar)

SAE size Form / type Part Number DN (Diameter Nominal)

according to Fig. 2-3 (hose / pipe)

1/2" A 506 521 98 12

3/4" A 506 583 98 20

1 1/4" A 506 584 98 32

1 1/2" A 506 522 98 40

2" A 506 523 98 50

2 1/2" A 506 585 98 65

3" A 512 570 98 80

3/4" B 516 826 98 20

1 1/4 B 517 479 98 32

1 1/2" B 506 528 98 40

2" B 506 529 98 50

2 1/2" B 506 530 98 65

3" B 512 571 98 80

Table 2-12 Blind plugs up to 3000 PSI

SHOP-10 06279-xD-GB-1 PC3000-6 2 - 13

Blind plugs Specifications

Up to 6000 PSI (414 bar)

SAE size Form / type Part Number DN (Diameter Nominal)

according to Fig. 2-3 (hose / pipe)

3/4" A 506 580 98 20

1" A 506 519 98 25

1 1/4" A 506 520 98 32

1 1/2" A 506 581 98 40

2" A 506 582 98 50

1" B 506 524 98 25

1 1/4" B 506 525 98 32

1 1/2" B 506 526 98 40

2" B 506 527 98 50

1 1/4" C 516 499 98 32

1 1/2" C 509 375 98 40

2" C 509 376 98 50

Table 2-13 Blind plugs up to 6000 PSI

2 - 14 PC3000-6 SHOP-10 06279-xD-GB-1

Specifications Classification of threads to the nominal width

2.7 CLASSIFICATION OF THREADS TO THE NOMINAL

WIDTH
Heavy class Light class

(up to 6000 PSI / 414 bar) (up to 3000 PSI / 207 bar)

Size Ra DN Ra DN
(nominal width) (nominal width)

M 12 x 1.5 - - 6 5

M 14 x 1.5 - - 8 6

M 16 x 1.5 8 5 10 8

M 18 x 1.5 10 6 12 10

M 20 x 1.5 12 8 - -

M 22 x 1.5 14 10 15 12

M 24 x 1.5 16 12 - -

M 26 x 1.5 - - 18 16

M 30 x 1.5 - - - -

M 30 x 2 20 16 22 20

M 36 x 2 25 20 28 25

M 38 x 1.5 - - - -

M 42 x 2 30 25 - -

M 45 x 1.5 - - - -

M 45 x 2 - - 35 32

M 52 x 1.5 - - - -

M 52 x 2 38 32 42 40

M 65 x 2 - - - -

Table 2-14 Classification of threads to the nominal width

Method of using the above table to find appropriate plugs and fittings according to the table on page 2-16.

EXAMPLE:

To cover up a hose / tube with a diameter of 25 mm, for a pressure up to 3000 PSI perform the following steps:

1. Locate the 25 in the column "DN" in the category "up to 3000 PSI".

2. Check the digit in the column "Ra" next to DN 25 in the same row and category.
For this example the proper plug and fitting is BUZ 28-L and ROV 28-L, refer to the table on page 2-16.

REMARKS: The column "Size" indicates the thread-size for the ROV-fittings.

SHOP-10 06279-xD-GB-1 PC3000-6 2 - 15

Plugs and fittings according to ISO 8434-1 / DIN 2353 Specifications

2.8 PLUGS AND FITTINGS ACCORDING TO ISO 8434-1

/ DIN 2353
Up to 3000 PSI / 207 bar

BUZ (plugs) Part Number ROV (fittings) Part Number

8-L 501 692 98 8-L 518 113 98

10-L 371 852 99 10-PL 513 789 98

12-L 371 854 99 12-PL 513 547 98

15-L 371 855 99 15-PL 507 051 98

18-L 371 856 99 18-PL 513 787 98

22-L 371 857 99 22-PL 513 788 98

28-L 371 858 99 28-PL 509 377 98

35-L 371 859 99 35-PL 516 770 98

42-L 371 860 99 42-PL 513 790 98

Up to 6000 PSI / 414 bar

BUZ (plugs) Part Number ROV (fittings) Part Number

- - 8-PS 515 921 98

- - 10-PS 507 023 98

- - 12-PS 507 022 98

16-S 371 866 99 - -

20-S 371 853 99 20-PS 512 005 98

25-S 371 867 99 25-PS 508 033 98

30-S 371 868 99 30-PS 507 021 98

38-S 371 869 99 38-PS 507 020 98

Table 2-15 Plugs and fittings according to ISO 8434-1 / DIN 2353

2 - 16 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups

3 MAIN ASSEMBLY
GROUPS

SHOP-10 06279-xD-GB-1 PC3000-6 3 -1

General layout Main assembly groups

3.1 GENERAL LAYOUT

Fig. 3-1 General layout

3 -2 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups General layout

Legend for Fig. 3-1:

A View onto Back Hoe Attachment (BHA) (5A) Clam (FSA)

B View onto Face Shovel Attachment (FSA) (5B) Bucket back wall (FSA)

(1) Undercarriage (car body + crawler carriers) (6) Boom cylinder

(2) Superstructure (7) Stick cylinder

(3) Boom (8) Bucket cylinder

(4) Stick (9) Clam cylinder (FSA)

(5) Bucket (BHA)

SHOP-10 06279-xD-GB-1 PC3000-6 3 -3

Superstructure Main assembly groups

3.2 SUPERSTRUCTURE

Fig. 3-2 Superstructure top view

3 -4 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups Superstructure

Legend for Fig. 3-2:

(1) Operator’s cab (14) Platform with batteries below floor plates

(2) Cab base (15) Distributor manifold

(3) Fuel tank (16) Main control valve blocks

(4) Hydraulically operated access ladder (17) Hydraulic oil cooler assembly

(5) Exhaust muffler (18) Main hydraulic oil tank

(6) Engine air cleaner (19) Slew gear

(7) Counterweight (20) Hydraulic pumps

(8) Engine coolant radiator (21) PTO (pump distributor gear)

(9) Slew circle (22) Flexible coupling

(10) Guide wheel (Idler) (23) Engine oil reserve tank (optional)

(11) Carrier roller (top roller) (24) Diesel engine

(12) Track roller (bottom roller) (25) Lubrication station (CLS)

(13) Sprocket and travel gear (26) Lubrication station (SLS)

SHOP-10 06279-xD-GB-1 PC3000-6 3 -5

Machine house Main assembly groups

3.3 MACHINE HOUSE

Fig. 3-3 Machine house - side and front view

3 -6 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups Machine house

Legend for Fig. 3-3:

A Side view from main control blocks (front) (9) Diesel engine

B Top view (10) Coolant pump

(1) Main hydraulic pumps (3 tandem pumps) (11) Radiator fan

(2) PTO lubrication pump (12) Coolant radiator

(3) Fan pump (13) Expansion tank for radiator

(4) Suction oil reservoir (14) Engine turbo charger

(5) Control oil pump (pilot oil pump) (15) Engine air cleaner

(6) PTO (pump distributor gear) (16) Exhaust muffler

(7) Engine mounts (elastic) (17) Engine oil reserve tank (optional)

(8) Flexible coupling, oil filled

SHOP-10 06279-xD-GB-1 PC3000-6 3 -7

Hydraulic oil tank Main assembly groups

3.4 HYDRAULIC OIL TANK

Fig. 3-4 Hydraulic oil tank

3 -8 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups Hydraulic oil tank

Legend for Fig. 3-4:

A View from machine center (8) Back pressure valve

B View from pump compartment (9) Leakage oil line connections

C Top view (10) Leakage oil filter

(1) Main hydraulic oil tank (11) Mounting bracket

(2) Location temperature sensors (12) Oil tank outlet (suction pipe)

(3) Oil level sensors [40B004] & [40B050] (13) Main gate valve

(4) Oil level gauge (14) Compensator

(5) Breather filter (15) Access cover

(6) Return oil filter (three pcs.) (16) Oil level switch, service arm maximum filling

(7) Auxiliary return oil connections (17) Refill plug

SHOP-10 06279-xD-GB-1 PC3000-6 3 -9

Hydraulic oil cooler Main assembly groups

3.5 HYDRAULIC OIL COOLER

Fig. 3-5 Hydraulic oil cooler

3 - 10 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups Hydraulic oil cooler

Legend for Fig. 3-5:

A Side view (from machine atrium) (8) PTO cooler outlet

B Front view (9) Oil cooler inlet

C Side view (view from outside) (10) PTO cooler inlet

D Top view (11) PTO cooler

(1) Lower radiator set (12) Swing out cooler look bolt

(2) Lower hydraulic fan motor (13) Hinges for swing out doors (3 pieces)

(3) Lower fan (14) Front swing out door

(4) Upper radiator set (15) Seal (foam rubber)

(5) Upper hydraulic fan motor (16) Elastic cooler mountings

(6) Upper fan (17) Fan cowl

(7) Oil cooler outlet (18) Adapter

SHOP-10 06279-xD-GB-1 PC3000-6 3 - 11

Fuel tank Main assembly groups

3.6 FUEL TANK

Fig. 3-6 Fuel tank (with Wiggins Service System VR310)

3 - 12 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups Fuel tank

Legend for Fig. 3-6:

(1) Fuel tank

(2) Vent valve with filter element

(3) Main shut-off cock

(4) Shut-off cock (for transducer change)

(5) Jet sensor hoses

(6) Main fuel receiver (Wiggins service system VR310)

(7) Jet sensor (Wiggins service system VR310)

[31B063] Pressure transducer for fuel level indication

[31Q599] Fuel shut off solenoid valve

SHOP-10 06279-xD-GB-1 PC3000-6 3 - 13

Counterweight Main assembly groups

3.7 COUNTERWEIGHT

Fig. 3-7 Counterweight

A1/A2 Lifting eye (2) Lifting situation for vertical transport

A3 Lifting eye (3) Lifting situation for horizontal transport

(1) Counterweight (welded box design) (4) Lifting situation for raising up the counter-
weight

NOTE! Make sure that the maximum rope angle depending on the lifting situation (Fig. 3-7, Pos. 2 to 4) is
not exceeded.

DANGER
RISK OF EXPLOSION! (Non-full casting counterweight only)
Failure to properly expel the gases from the counterweight chambers can result in an explosion with
serious personal injury or death.

The chambers of the counterweight are filled with a mixture of concrete, granulated ore and steel pellets.
This mixture can create explosive gases which will accumulate in the chambers of the counterweight.
Before any welding, flame-cutting, grinding or drilling procedures are carried out on the counterweight it
is vital to expel these gases from the counterweight chambers.
Follow the instructions given in PARTS & SERVICE NEWS No. AH04518, latest release, for expelling the
gases from the counterweight chambers.

3 - 14 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups Counterweight

Please continue reading on the next page.

SHOP-10 06279-xD-GB-1 PC3000-6 3 - 15

Cab base Main assembly groups

3.8 CAB BASE

Fig. 3-8 Cab base

3 - 16 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups Cab base

Legend for Fig. 3-8:

A Front view (4) Walk way

B Side view (5) Elastic cab mounts

C Top view (6) Access door

(1) Cab base (7) Mounting brackets

(2) Working light (8) Pilot control frame

(3) Hoist rings / attachment points (9) Main electric switch board, X2-board

The Cab base contains the electronic components of the KOMTRAX Plus system and the electrical switchboards.

SHOP-10 06279-xD-GB-1 PC3000-6 3 - 17

Operator’s cab Main assembly groups

3.9 OPERATOR’S CAB

Fig. 3-9 Operator’s cab

3 - 18 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups Operator’s cab

Legend for Fig. 3-9:

(1) KOMTRAX Plus monitor (20P047) (62) Pilot oil unit: Left track control pedal

(2) Switch panel (71) Pilot oil unit: L.H. control lever

(3) Operator’s seat (72) Pilot oil unit: R.H. control lever

(4) Lock lever (20S105) (73) Pilot oil unit: Clam opening / closing pedal

(5) Heater / A/C unit (74) Pilot oil unit: Right track control pedal

(88) Pilot oil unit: Slew brake control pedal

SHOP-10 06279-xD-GB-1 PC3000-6 3 - 19

Main Control blocks Main assembly groups

3.10 MAIN CONTROL BLOCKS

3.10.1 MAIN CONTROL BLOCKS (FSA)

Fig. 3-10 Main control blocks FSA

3 - 20 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups Main Control blocks

Legend for Fig. 3-10:

Electric components:

[61B158a] Pressure transducer, pump pressure main pump I

[61B158b] Pressure transducer, pump pressure main pump II

[61B158c] Pressure transducer, pump pressure main pump III

[61K632] Solenoid valve - stick floating function

[61K635] Solenoid valve - boom floating function

Hydraulic components:

(9) Main control block I

(10) Main control block II

(11) Main control block III

(131.1) Pilot controlled floating spool valve - stick

(131.2) Pilot controlled floating spool valve - stick

(131.3) Pilot controlled floating spool valve - boom

SHOP-10 06279-xD-GB-1 PC3000-6 3 - 21

Main Control blocks Main assembly groups

3.10.2 MAIN CONTROL BLOCKS (BHA)

Fig. 3-11 Main control blocks BHA

3 - 22 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups Main Control blocks

Legend for Fig. 3-11:

Electric components:

[61B158a] Pressure transducer, pump pressure main pump I

[61B158b] Pressure transducer, pump pressure main pump II

[61B158c] Pressure transducer, pump pressure main pump III

Hydraulic components:

(9) Main control block I

(10) Main control block II

(11) Main control block III

SHOP-10 06279-xD-GB-1 PC3000-6 3 - 23

Slew machinery Main assembly groups

3.11 SLEW MACHINERY

3.11.1 SLEW MACHINERY L&S

Fig. 3-12 Slew machinery L&S

3 - 24 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups Slew machinery

Legend for Fig. 3-12:

(1) Slew gear (60) Slew motor

(2) Drain plug (gearbox) (61) Hydraulic slew brake block

(3) Oil filler plug (gearbox) (102) Multi-disc slew parking brake

(4) Breather filter (gearbox)

(5) Oil dipstick (motor adapter housing)

(6) Breather filter (motor adapter housing)

(7) Oil dipstick (gearbox)

(8) Oil drain plug (motor adapter housing)

(9) Pinion

SHOP-10 06279-xD-GB-1 PC3000-6 3 - 25

Slew machinery Main assembly groups

3.11.2 SLEW MACHINERY SIEBENHAAR

Fig. 3-13 Slew machinery SIEBENHAAR

3 - 26 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups Slew machinery

Legend for Fig. 3-13:

(1) Slew gear (60) Slew motor

(2) Oil drain coupling (61) Hydraulic slew brake block

(3) Compensator oil tank with breather filter (102) Multi-disc slew parking brake

(4) Brake housing

(5) Oil level gauge, motor adapter housing

Oil level gauge and oil drain plug, brake

(6)
housing

Oil drain plug and breather filter, motor

(7)
adapter housing

(8) Breather filter, brake housing

(9) Dipstick, slew machinery housing

SHOP-10 06279-xD-GB-1 PC3000-6 3 - 27

Undercarriage Main assembly groups

3.12 UNDERCARRIAGE

Fig. 3-14 Undercarriage

3 - 28 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups Undercarriage

Legend for Fig. 3-14:

(1) Car body (9) Travel gear

(2) Track tensioning valve block (10) Track group

(3) Carrier roller (11) Track roller

(4) High pressure accumulator (12) Sprocket

(5) Crawler carrier (13) Low pressure accumulator

(6) Travel brake valve block (overspeed valve) (14) Track tensioning cylinder

(7) Rotary joint (15) Guide wheel

(8) Travel motor

SHOP-10 06279-xD-GB-1 PC3000-6 3 - 29

Backhoe attachment (BHA) Main assembly groups

3.13 BACKHOE ATTACHMENT (BHA)

Fig. 3-15 Backhoe attachment (BHA)

(1) Boom (5) Bucket

(2) Boom cylinders (6) Bucket cylinders

(3) Stick (7) Control arm

(4) Stick cylinders (8) Linkage

3 - 30 PC3000-6 SHOP-10 06279-xD-GB-1

Main assembly groups Front shovel attachment (FSA)

3.14 FRONT SHOVEL ATTACHMENT (FSA)

Fig. 3-16 Front shovel attachment (FSA)

(1) Boom (5) Bucket backwall

(2) Boom cylinders (6) Bucket cylinders

(3) Stick (7) Clam

(4) Stick cylinders (8) Clam cylinders

SHOP-10 06279-xD-GB-1 PC3000-6 3 - 31

Front shovel attachment (FSA) Main assembly groups

Please continue reading on the next page.

3 - 32 PC3000-6 SHOP-10 06279-xD-GB-1

Drive

4 DRIVE

SHOP-10 06279-xD-GB-1 PC3000-6 4 -1

Prime drive assembly Drive

4.1 PRIME DRIVE ASSEMBLY

Fig. 4-1 Prime drive assembly

(1) Komatsu engine SDA12V159E-2 (4) Coupling assembly

(2) PTO flange - coupling housing (5) Pump distributor gearbox, PTO

(3) Spacer ring (6) Cover

4 -2 PC3000-6 SHOP-10 06279-xD-GB-1

Drive Prime drive assembly

General description

The drive unit consists of a Komatsu engine SDA12V159E-2 (Fig. 4-1, Pos. 1) bedded on special engine mounts
bolted to the power frame, a flexible coupling (Fig. 4-1, Pos. 4), and a PTO (Fig. 4-1, Pos. 5) distributing the power
to all the pumps installed at the PTO.

Two damping elements, which complement each other, are installed at the prime drive in order to eliminate exces-
sive rotation torques at the crankshaft of the engine.
The damping elements are the front damper at the front and rear side of the engine as well as the flexible coupling
(Fig. 4-1, Pos. 4) which is connected to the PTO.

NOTE! It is very important that both damping elements are working properly.
In case of any damage or wear at either the front damper or at the flexible coupling always check the
damping element at the opposite side of the engine for proper function as well.

For further information about the flexible coupling refer to section 4.3 on page 4-6.

SHOP-10 06279-xD-GB-1 PC3000-6 4 -3

Engine mounts Drive

4.2 ENGINE MOUNTS

Fig. 4-2 Engine mounts

4 -4 PC3000-6 SHOP-10 06279-xD-GB-1

Drive Engine mounts

Legend for Fig. 4-2:

(1) Flexible engine mounts (7) Lock nut

(2) Tie bolt (8) Engine mounting bolt, rear

(3) Self-locking nut (9) Bolt

(4) Rubber-bounded metal bar (10) Engine mounting bolt, front

(5) Stop bolt (11) PTO mounting bolt

(6) Cup springs

General description

Flexible engine mounts (Fig. 4-2, Pos. 1) are installed to absorb the vibrations and torsional forces.
The engine mounts carry the total weight of the engine.

To absorb the torque force, the front engine supports are equipped with stop bolts (Fig. 4-2, Pos. 9) and cup
springs (Fig. 4-2, Pos. 6).

4.2.1 CHECKS AND ADJUSTMENTS

Flexible engine mounts

1. Check all bolts of the engine suspension as well as the flexible engine mounts regularly according to PARTS &
SERVICE NEWS No. "AH01521" (latest edition) and the Operation and Maintenance Manual.

REMARKS: All connections must also be checked after the engine has been replaced.

2. The mounts will show a setting effect (fatigue) with increased lifetime.
Check their overall height/thickness and recorded for the service department, refer to PARTS & SERVICE
NEWS No. "AH01521" (latest edition).

3. In the case of wear or damage of any metal rubber bar inside the engine mounts (Fig. 4-2, Pos. 1), replace all
metal rubber bars and their fastening bolts including nuts.

4. The bolt (Fig. 4-2, Pos. 2) should not have any axial play.
If necessary, re-tighten the nut (Fig. 4-2, Pos. 3) until the rubber is squeezed slightly out of the rubber-bonded
metal bar.

Torque support

1. Check the cup springs (Fig. 4-2, Pos. 6) of all supports for fatigue or damage regularly and replace them, if
necessary.

2. Turn the stop bolt (Fig. 4-2, Pos. 5) down until it slightly pre-stresses the cup springs, and secure it with the
lock nut (Fig. 4-2, Pos. 7).
(Nominal value for the distance "A" between engine torque support and bolt head: 29 mm)

SHOP-10 06279-xD-GB-1 PC3000-6 4 -5

Flexible Coupling Drive

4.3 FLEXIBLE COUPLING

4.3.1 GEISLINGENR COUPLING

Fig. 4-3 Geislingenr coupling

(1) Coupling assembly (7) Output drive flange

(2) Input drive flange (8) Dip stick

(3) Leaf spring assembly (9) Bleeder plug

(4) Spring chamber (10) O-rings

(5) Spring chamber (E) Engine side

(6) Spacers (G) Gearbox (PTO) side

4 -6 PC3000-6 SHOP-10 06279-xD-GB-1

Drive Flexible Coupling

Description

The combination of the high elasticity of the leaf springs together with viscous damping by oil displacement
ensures that the GEISLINGER-COUPLING removes major critical speeds outside the engine speed range and
dampens minor torsional vibrations effectively.

The widest engine speed range free of vibration periods and dangerous resonance is thus obtained.

Furthermore, the employment of this coupling with its highly dampening characteristics generally results in lower
stress in all engine driving shafts and gears as well as in the crankshaft, permitting further power development on
standard components.

In any similar application, a simple vibration damper and/or a pure flexible coupling would not confer the same
advantages.

The springs (Fig. 4-3, Pos. 3) together with the inner driving and outer driven member form the chambers A and B
(Fig. 4-3, Pos. 4 and 5), which are filled with oil.

If the outer member is displaced in relation to the inner member, the deflection of the leaf springs displaces oil from
one chamber to the next. By this action the relative movements of the two members of the coupling are braked and
the vibrations are dampened.

The spacer (Fig. 4-3, Pos. 6) limits the movement of the leaf springs.

SHOP-10 06279-xD-GB-1 PC3000-6 4 -7

Flexible Coupling Drive

4.3.2 CENTAFLEX COUPLING

Fig. 4-4 CentaFlex coupling

4 -8 PC3000-6 SHOP-10 06279-xD-GB-1

Drive Flexible Coupling

Legend for Fig. 4-4:

[A] View onto the PTO side of coupling

[B] View onto the engine side of coupling

(1) Rubber roller (4) Largest outer diameter of rubber roller (1)

(2) Inner part of coupling - pre-assembled com- (5) Deepest point in the bag of the outer part
ponent group (3)

(3) Outer part of coupling (6) Arrows need to be in line with each other

General information

The coupling for heavy duty applications is a highly flexible coupling with progressive characteristics.

Extremely robust and fail-save design with rubber rollers subjected only to compressive stress. Characterized by a
slight stiffness at lower speeds and a moderately increased stiffness at rising torques. For smooth operation and
reliable transmission over the entire high allowable energy loss. Suitable for high ambient temperatures.
HD design includes oil-resistance and even higher temperature resistance.

REMARKS: For the coupling tightening torques refer to the Shop Manual part "50 Disassembly & Assembly".

SHOP-10 06279-xD-GB-1 PC3000-6 4 -9

Flexible Coupling Drive

4.3.2.1 INFORMATION FOR MAINTENANCE

The coupling is mostly maintenance free and it has the same lifetime as the engine.

Maintenance intervals

– Interval A → After 1 month or 250 operating hours after start of operation

– Interval B→ Once per year or after every 3000 operating hours

Maintenance intervals A and B - scope of work

1. Visual inspection as follows:

– Check coupling for crack appearance, chips, or missing parts.

– Replace defective or missing parts.

2. Visual inspection of the rubber rollers:

– Check for crack appearance.

– Check the rubber roller dimension.
– If measurement X is below the specification replace rubber
rollers*.

ØD = 81 mm
X = 75 mm

Legend for Fig. 4-5:

(1) Rubber roller ex factory

(2) Rubber roller wear limit

REMARKS: Deposits of rubber dust are a normal occurrence.

Fig. 4-5 Check rubber roller dimensions

For further information on maintenance refer to the Operation & Maintenance Manual.

NOTICE
* RUBBER ROLLER REPLACEMENT
Replace rubber rollers only as a set.

4 - 10 PC3000-6 SHOP-10 06279-xD-GB-1

Drive Flexible Coupling

4.3.2.2 COUPLING ELEMENTS

Fig. 4-6 Coupling elements

[A] Engine side of coupling

[B] PTO side of coupling

(1) Rubber roller (4) Bag for rubber roller (1)

(2) Inner part of coupling (5) Mounting strap

(3) Outer part of coupling

SHOP-10 06279-xD-GB-1 PC3000-6 4 - 11

Flexible Coupling Drive

4.3.2.3 SEPARATION AND ASSEMBLY OF THE COUPLING INNER AND OUTER

PART
REMARKS: For detailed information regarding the separation and assembly refer to the Shop Manual part "50
Disassembly & Assembly".

Separation

If engine or PTO needs removal, the inner and outer coupling ele-
ments can be separated by sideways sliding.

REMARKS: It is not necessary to remove the coupling from PTO

or engine.

1. When the coupling inner element (Fig. 4-7, Pos. 3) comes out
of the outer element (Fig. 4-7, Pos. 4) fasten the rubber roll-
ers (Fig. 4-7, Pos. 1) with a mounting strap (Fig. 4-7, Pos. 2)
to avoid the rubber rollers to fall out of the coupling.

2. Continue sideways sliding until both coupling parts are sepa-

rated.

Fig. 4-7 Coupling separation

Assembly

1. Clean the coupling before assembly.

2. During coupling assembly make sure that the arrows on inner and outer element are in line with each other
(refer to Fig. 4-4, Pos. 6 on page 4-8).

NOTICE
COUPLING COMPONENTS MAY GET DAMAGED!
Wrong position of inner and outer coupling element may cause damages.

Arrows on inner and outer coupling element must be in line with each other, refer to Fig. 4-4.

REMARKS: For easier assembly wet the roller bags (Fig. 4-6, Pos. 4 on page 4-11) in the outer coupling element
(Fig. 4-7, Pos. 4) with soap solution (10% liquid soap and 90% water) or with silicon spray.

3. Slide both coupling elements together until the rubber rollers (Fig. 4-7, Pos. 1) are held in position and until
they can no longer fall out of the coupling.

4. Remove the mounting strap (Fig. 4-7, Pos. 2).

5. Slide both coupling elements completely together.

6. Fasten the bolts.

7. Perform a test run before continuous machine operation.

4 - 12 PC3000-6 SHOP-10 06279-xD-GB-1

Drive Flexible Coupling

4.3.2.4 OPERATION TROUBLES, CAUSES, AND RECTIFICATION

CAUTION
RISK OF INJURY DUE TO WORN OUT COUPLING PARTS!
Worn out coupling parts may cause injury or damages to the coupling element.

In case of changed running noise and/or if vibration occurs, directly stop the machine.

Trouble Cause Rectification

1. Check tightening torques and correct

Running noise Loose bolts
if necessary

Components over lifetime 1. Stop the machine

Overload
Rubber roller(s) broken 2. Replace rubber rollers

3. Test run

1. Stop the machine

Rubber rollers worn out Normal wear 2. Replace rubber rollers

3. Test run

SHOP-10 06279-xD-GB-1 PC3000-6 4 - 13

Radiator Fan drive Drive

4.4 RADIATOR FAN DRIVE

Fig. 4-8 Fan drive and radiator assembly

4 - 14 PC3000-6 SHOP-10 06279-xD-GB-1

Drive Radiator Fan drive

Legend for Fig. 4-8:

(1) Main bracket (7) Belt tension pulley

(2) Pulley bracket (8) Belt tension assy

(3) Drive belt (9) Belt tension spring

(4) Pulley (10) Radiator fan

(5) Taper roller bearing (11) Retainer

(6) Radial seal ring

Description

The radiator fan (Fig. 4-8, Pos. 10) is driven by the engine via a special drive belt (Fig. 4-8, Pos. 3). The drive belt
is tensioned by a mechanical tensioning system.

The fan draws the outside air through the radiator.

The pulley (Fig. 4-9, Pos. 3) and the bearings (Fig. 4-9, Pos. 2)
are filled with grease.
Due to overheating there may be a loss of grease so the bearings
must be re-lubricated by a hand operated grease gun at the pro-
vided grease nipple (Fig. 4-9, Pos. 5).

For maintenance refer to the refer to the OPERATION AND

MAINTENANCE MANUAL, section RADIATOR FAN BELT AND
AUTOMATIC BELT TENSIONING SYSTEM -MAINTENANCE
CHECK.

NOTICE
PRE-LOADED BEARING!
After a replacement of the pulley bearings make sure that the
floating bearing (Fig. 4-9, Pos. 2) is not pre-loaded.
Between the retainer (Fig. 4-9, Pos. 1) and the bearing must
be a gap of X = 0,05 mm.

Fig. 4-9

SHOP-10 06279-xD-GB-1 PC3000-6 4 - 15

PTO Drive

4.5 PTO

Fig. 4-10 PTO

4 - 16 PC3000-6 SHOP-10 06279-xD-GB-1

Drive PTO

Legend for Fig. 4-10:

(1) Oil filler plug (9) Oil level dip stick

(2) Breather filter (10) Spray nozzle for cooling and lubrication

(3) Power take off for main pump 1 (11) Leak oil inlet from valve block

(4) Power take off for main pump 2 (12) Cooler by-pass inlet

(5) Power take off for main pump 3 (13) Spline shaft housing of main pump

(6) Power take off for pilot oil pump (14) Suction port to PTO lubrication pump

(7) Spline shaft housing of pilot pump (16) Main gear

(8) Main shaft (17) Output gear

(9) Oil level dip stick (18) Drive flange

Description

The pump distribution gear (PTO gear) is a spur gear design and driven by a Diesel engine.

The PTO gear runs in anti-friction bearings and it has been provided with a splash lubrication system.
The oil supply of the bearings and the gearwheels is realized by an injection system.
The gearwheels are made of case-hardened steel.

The hydraulic pumps are directly attached to the gearbox. O-rings included in the supply enable the unit to be reli-
ably sealed statically.

The gearbox housing is a one-piece design and made of grey cast iron.

REMARKS: For arctic environment an optional heating system is available, for further information refer to
section 18.4.2 on page 18-12.

NOTE! PTO gear oil type: CLP 150 (standard oil type).
For the PTO oil filling capacity refer to the OPERATION & MAINTENANCE MANUAL chapter 4, sec-
tion Filling capacities.

SHOP-10 06279-xD-GB-1 PC3000-6 4 - 17

PTO Drive

4.5.1 PTO LUBRICATION AND COOLING

Fig. 4-11 PTO lubrication and cooling

4 - 18 PC3000-6 SHOP-10 06279-xD-GB-1

Drive PTO

Legend for Fig. 4-11:

(1) PTO

(2) Gear pump for PTO gear lubrication

(20) Pressure filter – PTO lubrication

(21) Pressure relief valve block with pressure sensor 57B017

(20) Upper oil cooler set for PTO 1 (rear) - part of the hydraulic oil cooler

(M8-1) Pressure test port (input pressure)

[57B017] Pressure switch – PTO gear lubrication

[57B027] Pressure switch – filter clogging monitoring

[57B049] Temperature sensor - gear oil

[57K553] Solenoid valve

Function

Pump (Fig. 4-11, Pos. 2) forces the gear oil from the gear box oil sump through filter (Fig. 4-11, Pos. 20) to pres-
sure relief valve block (Fig. 4-11, Pos. 21). This pressure relief valve acts as a back pressure valve causing that
most of the oil passes through the gear oil coolers.

The gear oil coolers are a small part of the hydraulic oil coolers, thus the gear oil gets cooled by the same air
stream as the hydraulic oil. From the coolers the oil flows to the ports of the PTO housing and internally via a
system of pipes to the several spray nozzles. The spray nozzles in the PTO housing ensure proper and adequate
distribution of lube oil.
The circuit is monitored by the pressure switch [57B017] at the pressure relief valve block (Fig. 4-11, Pos. 21).
When the lube oil pressure is too low (0.5 bar or less), a fault message will be displayed on the monitor at the
operator’s dashboard.

The gear oil temperature is monitored by the sensor units [57B049] in the PTO housing (Fig. 4-11, Pos. 1).
If the oil temperature gets too high, a fault message will be displayed on the MOMTRAX Plus monitor at the oper-
ator’s dashboard.

If the oil temperature is too low, solenoid valve [57K553] is energized, and port X of the pressure relief valve
(Fig. 4-11, Pos. 20) is opened. This reduces the relief valve pressure setting, most of the gear oil flows directly
back to the PTO to warm up the gear oil as quickly as possible.

SHOP-10 06279-xD-GB-1 PC3000-6 4 - 19

PTO Drive

4.5.1.1 CHECKS AND ADJUSTMENTS - PTO LUBRICATION PRESSURE

Fig. 4-12 PTO lubrication and cooling – adjustment

4 - 20 PC3000-6 SHOP-10 06279-xD-GB-1

Drive PTO

Legend for Fig. 4-12:

(1) Pilot operated relief valve (9) Seal ring

(1a) Protection cap A Pressure port at relief valve block

(1b) Lock nut T Return from relief valve block

(1c) Set screw

(2) Plug screw

(3) Valve piston

(4) Port for pressure switch 570B17-1/-2 [57B017] Pressure switch – PTO gear lubrication

(5) "Y"-port (external return to tank) [57B027] Pressure switch – filter monitoring

"X"-port (external return to tank

(5a) [57K553] Solenoid valve
via solenoid valve 57K553-1/-2)

(6) Port for pressure check stud (20) Pressure filter

(7) Jet bore (21) Pressure relief valve block

(8) Valve spring M8-1 Pressure test port

Checks

NOTICE
GEAR OIL TEMPERATURE TOO HIGH FOR ADJUSTMENT!
The adjustment of the maximum permissible PTO lube pressure has to be carried out with cold oil in order
to avoid serious damages to the coolers.

1. Connect a pressure gauge to pressure test port M8-1.

2. Disconnect the plug of solenoid valve 57K553.

3. Run the engine at high idle.

4. Check the pressure – required: 7.5 bar.

Adjustments

If adjustment is required:

5. Remove the protection cap (Fig. 4-12, Pos. 1a).

6. Loosen the lock nut (Fig. 4-12, Pos. 1b).

7. Set the pressure with set screw (Fig. 4-12, Pos. 1c).

8. Tighten the lock nut (1b) and re-install the protection cap (Fig. 4-12, Pos. 1a).

9. Reconnect the plug of solenoid valve 57K553.

SHOP-10 06279-xD-GB-1 PC3000-6 4 - 21

PTO Drive

4.5.2 PTO GEAR OIL TEMPERATURE CONTROL

In combination with a PT100 sensor temperature converter relays
monitor the adjusted temperature limits. When the adjusted tem-
perature limit is exceeded the corresponding relay immediately
change the switching condition and the LED (Fig. 4-13, Pos 2)
lights up.

The temperature control is done by the following converter relays:

– [11K143] - PTO gear oil temperature too high

(used for KOMTRAX trouble message)
– [11K182] - PTO gear oil temperature too low
(pressure relief via solenoid valve 57K533)

Fig. 4-13 Temperature converter relay

4.5.2.1 TEMPERATURE ADJUSTMENT (OIL VISCOSITY)

1. Adjust the scale drum (Fig. 4-13, Pos. 1) of the concerned converter relay to the standard value according to
the filled PTO gear oil viscosity, refer to Table 4-1.

PTO gear oil temperature charts

Hypoid oil
ISO oil viscosity grade HLP T32 CLP 150
75W-140
11K182 adjust temperature limit value to switching point (TG1)
15°C 48°C 54°C
PTO gear oil temperature too low
11K143 adjust temperature limit value to switching point (TG2)
60°C 95°C 95°C
PTO gear oil temperature too high

Table 4-1 PTO gear oil temperature charts

4 - 22 PC3000-6 SHOP-10 06279-xD-GB-1

Drive PTO

4.5.2.2 ADJUSTMENT OF THE LINE RESISTANCE COMPENSATION

REMARKS: The line resistance compensation is bench adjusted and must only be done in case of replacing the
temperature converter relay, the connected sensor, or after repairs on the sensor wiring.

1. Unplug the concerned temperature sensor (see Table 4-2) and measure the electrical resistance between the
two open ends of the sensor using a multimeter. Use Table 2-11 on page 2-12 to convert the measured resis-
tance into temperature.

2. Adjust the scale drum (Fig. 4-13, Pos. 1) of the converter relay to a higher value as the temperature deter-
mined in step 1. The LED (Fig. 4-13, Pos. 2) is switched OFF.

3. Turn the scale drum slowly to a lower value until the LED is switched ON.
The value at the scale drum should be the same as determined in step 1.

4. If necessary correct with potentiometer (Fig. 4-13, Pos. 3) using a small screw driver.

Converter relays and connected temperature sensors

Converter relay Connected temperature sensor

11K143 57B049

11K182 57B182

Table 4-2

SHOP-10 06279-xD-GB-1 PC3000-6 4 - 23

PTO Drive

4.5.3 PUMP SPLINE LUBRICATION

Fig. 4-14 Pump drive shaft housing

4 - 24 PC3000-6 SHOP-10 06279-xD-GB-1

Drive PTO

Legend for Fig. 4-14:

(1) Oil filler plug with breather pipe (6) Main pump spline shaft

(2) Mounting bore for main pump (7) Shaft seal

(3) Oil level (8) Gear wheel

(4) O-ring (9) Spray nozzle

(5) Main pump

NOTE! The gear oil in the drive shaft housings is different to the gear oil in the pump distributor gear.
For the complete lubricant charts refer to the OPERATION & MAINTENANCE MANUAL,
section FLUIDS AND LUBRICANTS.

Gear oil type only: HLP 32

For the oil filling capacity refer to the OPERATION & MAINTENANCE MANUAL chapter 4,
section Filling capacities.

All drive shaft housings are filled with HLP 32 oil in order to lubricate the multi-spline connections and to prevent
wear and corrosion.

4.5.3.1 OIL LEVEL IN THE MAIN PUMP & GEAR OIL PUMP DRIVE SHAFT HOUSING
If the oil level increases, the oil drops out of the breather pipe (Fig. 4-14, Pos. 1).

Reasons for oil overspill are:

– An unspecified oil viscosity (wrong oil type) was used.

– Overfilling during maintenance.
– The shaft seal of the main pump drive shaft may be leaking.

Inspection method

1. Check the oil level in the concerned drive shaft housing (refer to Fig. 4-10 on page 4-16) at the oil level plug
and drain excessive oil until the specified fill level is reached. Catch the oil in a clean oil pan for further analy-
sis.

2. Verify if the viscosity of the drained oil meets the specification for drive shaft housing oil (oil analysis).

3. If a wrong oil viscosity/type is found, drain the oil from the drive shaft housing and replace it by specified oil.

4. If the oil viscosity/type is correct, check the oil level the next day again. If the oil level is increased again
replace the main pump.

5. If necessary repeat the oil inspection at the other main pump drive shaft housings.

SHOP-10 06279-xD-GB-1 PC3000-6 4 - 25

Hydraulic pumps - arrangement Drive

4.6 HYDRAULIC PUMPS - ARRANGEMENT

Fig. 4-15 Hydraulic pumps

(1) Single main pump 1a (swash plate type) (8) Single main pump 3a (swash plate type)

(2) Single main pump 1b (swash plate type) (9) Charge pump for main pump 3a and 3b

(3) Charge pump for main pump 1a and 1b (10) Pilot oil pump (gear pump)

(4) Single main pump 2a (swash plate type) (11) PTO oil circulating pump (gear pump)

(5) Single main pump 2b (swash plate type) (12) Oil cooler fan pump

(6) Charge pump for main pump 2a and 2b (13) PTO

(7) Single main pump 3a (swash plate type)

4 - 26 PC3000-6 SHOP-10 06279-xD-GB-1

Drive Hydraulic pumps - arrangement

Pump data

Description Model Designation Value Unit

Pump volume Vg 2 x 330 cm³

Theoretical flow rate, each Qmax 910 l/min

Main pump 1, 2, 3 HPV 375+375
Max. outlet pressure pmax 310 bar

Drive speed* n 1378 1/min

Pump volume Vg 56 cm³

Theoretical flow rate Qmax 100 l/min

Pilot oil pump SAR(3) 56
Max. outlet pressure pmax 60 bar

Drive speed* n 1800 1/min

Pump volume Vg 63 cm³

PTO oil circulating Theoretical flow rate Qmax 87 l/min

SAL(2) 63
pump Max. outlet pressure pmax 7.5 bar

Drive speed* n 1378 1/min

Pump volume Vg 125 cm³

Theoretical flow rate Qmax 172 l/min

Oil cooler fan pump HPF 125
Max. outlet pressure pmax 240 bar

Drive speed* n 1378 1/min

Table 4-3 Pump data chart

SHOP-10 06279-xD-GB-1 PC3000-6 4 - 27

Air filter Drive

4.7 AIR FILTER

Fig. 4-16 Air filter

4 - 28 PC3000-6 SHOP-10 06279-xD-GB-1

Drive Air filter

Legend for Fig. 4-16:

(1) Wing nut (6) Safety element

(2) Washer (7) Air intake to the pre-separator tubes

(3) Seal ring (8) Flap for pre-separator

(4) Main filter element [52B018] Pressure switch, engine air filter pressure

(5) Service indicator [52B019] Pressure switch, engine air filter pressure

Description

The air is filtered by a dry air filter with pre-separator for coarse impurities.

One filter housing includes 2 filter sets. Each one consists of a main filter element (Fig. 4-16, Pos. 4) and a safety
element (Fig. 4-16, Pos. 6).

The air cleaner condition is monitored by pressure switches [52B018] & [52B019].
The trouble message "Trouble air cleaner 1“ is displayed at the KOMTRAX Plus display as soon as the air cleaner
restriction is too high.

The mounting parts for the air filter elements contain a service indicator (Fig. 4-16, Pos. 5) for the safety element.

– Green indication = Safety element OK.

– Red indication = safety element requires replacement.

To reset the indicator after air cleaner replacement, blow with your mouth through the nut against the normal air
flow. The indicator should move to the green position.

REMARKS: For service intervals and procedures refer to the OPERATION & MAINTENANCE MANUAL of the
corresponding machine.

SHOP-10 06279-xD-GB-1 PC3000-6 4 - 29

Air filter Drive

Please continue reading on the next page.

4 - 30 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil tank

5 HYDRAULIC OIL TANK

SHOP-10 06279-xD-GB-1 PC3000-6 5 -1

General layout Hydraulic oil tank

5.1 GENERAL LAYOUT

Fig. 5-1 Hydraulic oil tank – overview

5 -2 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil tank General layout

Legend for Fig. 5-1:

A View from machine center (8) Back pressure valve block

B View from pump compartment (9) Leak oil connections

C Top view (10) Leak oil filter (one)

(1) Main oil tank (11) Mounting brackets

(2) Location temperature sensors (see Fig. 5-2) (12) Oil reservoir outlet (suction pipe)

(3) Location level sensors (see Fig. 5-2) (13) Shut-off valve (main gate valve)

(4) Hydraulic oil level gauge (14) Compensator

(5) Breather filter (15) Access cover

(6) Return oil filter (three) (16) Level switch [40B042] (see Fig. 5-2)

(7) Auxiliary return oil connections (17) Refill plug

Description

The hydraulic oil tank (Fig. 5-1, Pos. 1) is a welded sheet-metal construction. The filling capacity is about
3800 litres.

The tank contains three return oil filters (Fig. 5-1, Pos. 6) and one leak oil filter (Fig. 5-1, Pos. 10).
The breather filter (Fig. 5-1, Pos. 5) cleans the air that ventilates the tank.

The back pressure valve and the pressure test port (M4) are located at the at the back pressure valve block
(Fig. 5-1, Pos. 8). The connection to the suction oil manifold can be closed with the shut- off valve (Fig. 5-1,
Pos. 13) to prevent oil flow during repairs on the hydraulic pumps. This unit is monitored by proximity switch
[40B031] to prevent a motor start with closed shut-off valve.

SHOP-10 06279-xD-GB-1 PC3000-6 5 -3

Hydraulic oil tank, location of the electric equipmenT Hydraulic oil tank

5.2 HYDRAULIC OIL TANK, LOCATION OF THE

ELECTRIC EQUIPMENT

Fig. 5-2 Hydraulic Oil Tank - Location of electrical equipment

5 -4 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil tank Hydraulic oil tank, location of the electric equipmenT

Legend for Fig. 5-2:

[40B004] Hydraulic oil level sensor (low level indication)

[40B024] Oil reservoir breather filter clogging switch

[40B025] Pressure switch, leak oil filter monitoring

[40B026] Pressure switch, return oil filter monitoring

[40B031] Proximity switch for shutoff gate valve

[40B040] Temperature sensor, hydraulic oil cooler fan low speed

[40B042] Oil level switch, refilling system maximum filling

[40B050] Hydraulic oil level sensor (refill level indication)

[40B075] Temperature sensor, low hydraulic oil temperature (½ Qmax and back pressure reduction)

[40B165] Pressure switch oil cooler strainer clogged

[40B171] Temperature sensor, hydraulic oil cooler fan medium speed

[40K601] Solenoid valve, Oil cooler preload pressure (controlled by converter relay 11K100)

SHOP-10 06279-xD-GB-1 PC3000-6 5 -5

Suction oil manifold with strainers Hydraulic oil tank

5.3 SUCTION OIL MANIFOLD WITH STRAINERS

Fig. 5-3 Suction oil manifold

5 -6 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil tank Suction oil manifold with strainers

Legend for Fig. 5-3:

(1) Suction oil manifold

(2) Suction strainer – one for each main pump

(3) Oil suction tube

(4) O-ring

(5) Suction strainer – each one for gear oil pump and hydraulic fan pump

(6) Oil suction tube

(7) O-ring

(8) Intermediate pipe

(9) Seal

(10) Main suction oil strainer

(11) Oil drain quick coupling

(12) Adapter

[59B015] Hydraulic oil temperature sensor, suction oil manifold - bucket motion cut-off

[59B032-1] Hydraulic oil temperature sensor, suction oil manifold

The suction oil manifold (Fig. 5-3, Pos. 1) is a welded sheet-metal construction.

The suction lines of all hydraulic pumps are connected to the suction manifold.

NOTICE
RISK OF CAVITATION TO THE PUMPS RESULTING FROM AIR INGRESS.
In case of pump changes or repairs on suction hoses thoroughly clean the flange of the suction tube
(Fig. 5-3, Pos. 3).
Use new suction hoses with silicon fluid gasket between suction tube flange and hose in order to prevent
leaks, and fit new clamps.

SHOP-10 06279-xD-GB-1 PC3000-6 5 -7

Return oil collector manifold with strainer Hydraulic oil tank

5.4 RETURN OIL COLLECTOR MANIFOLD WITH

STRAINER

Fig. 5-4 Return oil collector pipe with strainer

(1) Strainer

(2) Intermediate pipe

(3) Return oil distributor manifold (to oil coolers)

[40B165] Pressure switch - oil cooler strainer clogged

5 -8 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil tank Return oil collector manifold with strainer

Fig. 5-5 Hydraulic diagram section

Task

The strainer (see arrow in Fig. 5-5) is installed to prevent the hydraulic oil coolers from getting clogged up in case
of contamination in the main return oil circuit (return line from the hydraulic cylinders and from the main blocks).

Excessive increase of the hydraulic oil temperature can be an indication for a restricted strainer, i.e. bad cooling
performance due to insufficient oil flow through the coolers.

In case that main components such as cylinders or motors have fragmentary damages inside, the strainer should
be inspected for metal chips.

REMARKS: A strainer inspection is only necessary in case of contamination (safety component).

SHOP-10 06279-xD-GB-1 PC3000-6 5 -9

Back pressure valve Hydraulic oil tank

5.5 BACK PRESSURE VALVE

Fig. 5-6 Back pressure valve

(1) Back pressure valve assembly

[40K601] Solenoid valve, oil cooler preload pressure (controlled by converter relay 11K100)

M4 Pressure test Port

5 - 10 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil tank Back pressure valve

Fig. 5-7 Hydraulic diagram section

Task

The back pressure valve (see arrow in Fig. 5-7) has to perform two functions in the hydraulic system:

1. To ensure a sufficient pressure within the return oil circuit, i.e. to supply oil via the anti-cavitation valves to the
low pressure side of cylinders and motors, respectively.

2. To force the return oil through the coolers, depending on the present hydraulic oil temperature, controlled by
the solenoid valve 40K601 (Fig. 5-6, Pos. 3):

– Below T2  Max. oil volume via filters into the tank (thick broken line [blue])
– Above T2  Max. oil volume directed through the coolers (thick broken line [red])

REMARKS: Temperature value for T2 depends on the used oil viscosity and is set at converter relay 11K100
which controls solenoid valve [40K601].
For further information about converter relay 11K100 and its settings refer to section 9.3.4 on
page 9-22.

SHOP-10 06279-xD-GB-1 PC3000-6 5 - 11

Transfer pump Hydraulic oil tank

5.6 TRANSFER PUMP

Fig. 5-8 Transfer pump

5 - 12 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil tank Transfer pump

Legend for Fig. 5-8:

A View from machine center (6) Shut-off valve (273.1) for suction oil mani-
fold

B Top view (7) Main shut-off valve (main gate valve)

(1) Main oil tank (8) Evacuation line from suction oil manifold

(2) Return line to filter chamber (main oil tank) (9) Suction oil manifold

(3) Transfer pump (40G018) with integrated (10) Operating switch (40S035) for transfer
temperature switch (40B111) pump

(4) Shut-off valve (273.2) for return oil manifold (11) Refill plug

(5) Evacuation line from return oil collector pipe (12) Breather filter

S Shut-off valve position to evacuate the suction oil manifold.

R Shut-off valve position to evacuate the return oil pipes and the oil cooler.

OFF Shut-off valve positions when the transfer pump is not used, machine in working condition

Functions of the transfer pump

– Transfusing oil from the suction oil manifold into the main oil tank.
Necessary for the evacuation of the suction oil manifold (Fig. 5-8, Pos. 9).
In case of repairs on the suction line (e.g. when replacing a pump), the oil has to be drawn off the suction
oil tank.
– Transfusing oil from the return oil manifold (Fig. 5-8, Pos. 5) into the main oil tank.
Necessary when servicing the high pressure filters, the main control valves, or the hydraulic oil cooler
(oil return system).
REMARKS: During normal machine operation all 2 shut-off valves (273.1/2) must be in closed position "C". Refer
to the OPERATION & MAINTENANCE MANUAL to read the operating instructions for the transfer
pump.

CAUTION
OVERFILLING OF THE HYDRAULIC OIL TANK!
Evacuating the suction oil manifold and the return oil manifold at the same time will result in overfilling of
the hydraulic oil tank and in environmental contamination.

Evacuate only one area at the time to prevent overfilling of the main hydraulic tank.

SHOP-10 06279-xD-GB-1 PC3000-6 5 - 13

Return and leak oil filter Hydraulic oil tank

5.7 RETURN AND LEAK OIL FILTER

Fig. 5-9 Return and leak oil filter

5 - 14 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil tank Return and leak oil filter

Legend for Fig. 5-9:

(1) Filter cover retainer

(2) Filter cover with O-ring

(3) Pre-tensioning spring

(4) Retainer

(5) Filter assembly

(6) Filter pot with machined cover

(7) Main filter element (10 micron absolute)

(8) Safety filter element (200 micron strainer)

(9) By-pass valve (2.3 bar)

(9.1) Valve cone

(9.2) Valve spring

(9.3) O-ring

(10) Profile gasket

(11) Seal ring

(12) Self locking nut

(13) Self locking nut

(A) Filter chamber

Function

The return oil flows into the filter chamber (Fig. 5-9, Pos. A) of the hydraulic tank.

The chamber is split into two sections: one section with 3 filter elements for the return oil, and one section with one
filter element for the leak oil. The structure of the five filter assemblies is basically the same.

The hydraulic oil enters the filter at the top and then passes the filter element (Fig. 5-9, Pos. 7) on its way to the
tank ("Inside to outside filtration").

The filter element condition is monitored by pressure switches [40B026] for the return oil filters and [40B025] for
the leak oil filter. As soon as the pressure inside a filter chamber reaches the set threshold value (2.0 bar for
40B026 and 0.5 bar for 40B025) due to restriction of the filter element, the trouble message "Trouble return oil filter
hydraulic oil tank" or ”Trouble leak oil filter hydraulic oil tank" is displayed at the KOMTRAX Plus display. The filter
elements have to be replaced.

For safety precautions the filter elements are equipped with a by-pass valve (Fig. 5-9, Pos. 9). If the filter chamber
pressure increases more and more, the bypass valve opens at 2.3 bar in order to protect the element from burst-
ing.

NOTE! Every time maintenance or repair is carried out at the hydraulic system, the bypass valve section
has to be cleaned, and all lines have to be closed with plugs to prevent foreign material entering
the hydraulic system.

SHOP-10 06279-xD-GB-1 PC3000-6 5 - 15

Breather filter Hydraulic oil tank

5.8 BREATHER FILTER

Fig. 5-10 Breather filter

5 - 16 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil tank Breather filter

Legend for Fig. 5-10:

(1) Nut

(2) Cover

(3) Steel filter element

(4) Filter pot

[40B024] Breather filter pressure switch (filter monitoring)

Function

A breather filter is installed in order to clean the air that streams into the tank any time the oil level decreases while
extending the attachment cylinders.

The filter element condition is monitored by a vacuum type pressure switch (40B024, switch-point: 80 mbar).

NOTE! Only use original filters made of steel.

SHOP-10 06279-xD-GB-1 PC3000-6 5 - 17

Breather filter Hydraulic oil tank

Please continue reading on the next page.

5 - 18 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil cooling

6 HYDRAULIC OIL COOLING

SHOP-10 06279-xD-GB-1 PC3000-6 6 -1

Overall view of the hydraulic oil cooling Hydraulic oil cooling

6.1 OVERALL VIEW OF THE HYDRAULIC OIL

COOLING

Fig. 6-1 Overall view of the hydraulic oil cooling

6 -2 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil cooling Overall view of the hydraulic oil cooling

Legend for Fig. 6-1:

(1) Fan (6) Lines to cooler (hot oil)

(2) Adapter (7) Cooler frame with hinges (swing out door)

(3) Motor bracket (8) Main cooler frame

(4) Fan motor (axial piston motor) (9) Fan guard

(5) Return lines to tank (cold oil) (10) Hydraulic oil cooler (radiator)

General description

The hydraulic oil cooling system keeps the hydraulic oil in the best oil viscosity temperature range.

Design

There are two (ambient temperature range up to 40°C) or four (ambient temperature range up to 55°C) hydraulic
oil coolers (Fig. 6-1, Pos. 10) in front of the hydraulic tank on the R.H. side of the platform.
They are in pairs mounted in one frame (Fig. 6-1, Pos. 7), one above the other.

The air stream needed for the cooling is produced by hydraulic driven fans (Fig. 6-1, Pos. 1). The air flows from
inside to outside through the coolers.

For easy frequently cleaning, the coolers can be opened ("swing out cooler").

Both fans are directly mounted to the hydraulic motor drive shaft without any additional bearing.

SHOP-10 06279-xD-GB-1 PC3000-6 6 -3

Function of the hydraulic oil cooling circuit Hydraulic oil cooling

6.2 FUNCTION OF THE HYDRAULIC OIL COOLING

CIRCUIT

Fig. 6-2 Hydraulic oil cooling circuit

6 -4 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil cooling Function of the hydraulic oil cooling circuit

Legend for Fig. 6-2:

(1) Hydraulic oil cooler Electrical components:

(2) Hydraulic oil tank [40B165] Pressure switch - oil cooler strainer clogged

(3) Restrictors, shock absorbers for the hydrau- [40K601] Solenoid valve – 4/2-directional control
lic oil cooler valve

(4) Back pressure valve

(5) Return oil collector manifold

(6) Strainer

(7) Return oil distributor manifold

Function

The returning oil from the system flows via the lines into the collector manifold (Fig. 6-2, Pos. 5).

The back pressure valve (Fig. 6-2, Pos. 4) causes a back pressure which forces most of the relative hot oil through
the strainer (Fig. 6-2, Pos. 6) and the distributor manifold (Fig. 6-2, Pos. 7) to the cooler (Fig. 6-2, Pos. 1).
The back pressure valve also acts as an return oil flow control valve according to the oil temperature.

The hydraulic oil first passes the restrictors (Fig. 6-2, Pos. 3) before it gets cooled in the cooler elements and then
flows back to the hydraulic oil tank (Fig. 6-2, Pos. 2).

The restrictors are acting like shock absorbers to prevent cooler cracking at pressure peaks.

During the warm up period (1/2 Qmax) the back pressure valve is wide open, because the solenoid valve [40K601]
is energized. The oil flows directly via filters into the tank.

With increasing oil temperature the oil gets thinner, so that the main pumps can be shifted to Qmax position and
simultaneously solenoid valve [40K601] will be de-energized, so that the valve piston of the back pressure valve
will become more closed by the force of the spring thus that more oil passes the cooler.

Between temperatures T2 and T3 the pump regulation is fully activated (Qmax), the fans rotate at medium speed.

Above T3 the fan rotates at maximum speed, the back pressure valve is de-energized and the return oil is directed
through the coolers.

When the temperature of the hydraulic oil rises up to the overheating switching point T4, the bucket cut-off is acti-
vated.

REMARKS: Also refer to the sectional drawing of the back pressure valve in refer to section 6.3 on page 6-6.

SHOP-10 06279-xD-GB-1 PC3000-6 6 -5

Check and Adjustment of the back pressure valve Hydraulic oil cooling

6.3 CHECK AND ADJUSTMENT OF THE BACK PRES-

SURE VALVE

Fig. 6-3 Adjustment of the back pressure valve

6 -6 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil cooling Check and Adjustment of the back pressure valve

Legend for Fig. 6-3:

(1) Control oil port (8) Valve spring

(2) Port "Y" (external return to tank) (9) Valve piston

(2a) Port "X" (external return to tank via sole- (10) Jet bore (small)
noid valve 40K601)

(3) Poppet (11) Plug screw

(4) Valve spring (12) Protective cap

(5) Lock nut B Return to tank (filter chamber)

(6) Set screw A Pressure oil to valve

(7) Jet bore (large) [40K601] Solenoid valve, oil cooler preload pressure
(controlled by converter relay 11K100)

REMARKS: Carry out checks and settings only at normal operating temperature of the hydraulic oil and main
pumps in maximum flow position (Qmax activated via service switch 11S103).

Adjustment procedure

1. Connect a pressure (0 - 25 bar) gauge to test port (M4).

2. Disconnect solenoid valve [40K601].

3. Set service switch 11S103 is switched into ON position.

4. Start Diesel engine and let it run in high idle.

REMARKS: Make sure that the hydraulic oil temperature is higher than T2.
(Temperature value for T2 depends on the used oil viscosity and is set at converter relay 11K100
which controls solenoid valve [40K601]).
For further information about converter relay 11K100 and its settings refer to section 9.3.4 on
page 9-22.

5. Read the pressure gauge; required pressure: 8±1 bar

If adjustment is required, continue with step 6; otherwise jump to step 10.

6. Remove the protective cap (Fig. 6-3, Pos. 12).

7. Loosen the lock nut (Fig. 6-3, Pos. 5).

8. Adjust the pressure with the set screw (Fig. 6-3, Pos. 6).

9. Tighten the lock nut (Fig. 6-3, Pos. 5) and refit the protective cap (Fig. 6-3, Pos. 12).

10. Disconnect the pressure gauge, reconnect the solenoid valve [40K601], and switch off the Qmax function via
service switch 11S103.

REMARKS: Also see description of the pressure relief valves, refer to section 6.4.2 on page 6-12.

SHOP-10 06279-xD-GB-1 PC3000-6 6 -7

Two stage cooler fan RPM control Hydraulic oil cooling

6.4 TWO STAGE COOLER FAN RPM CONTROL

Fig. 6-4 Fan drive shematics

6 -8 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil cooling Two stage cooler fan RPM control

Legend for Fig. 6-4:

(19.2) Check valve [57K506a/b] 4/3 direction flow valve hydraulic

cooler fan speed
(28) Pressure filter, hydraulic fan drive pump (stop, low and high speed)
(29) Pressure reduction valve

(34) Pressure relief valve

(51) Hydraulic oil tank

M6-1 Pressure test port

Function

From the pump the oil flows through the filter (Fig. 6-4, Pos. 28) to the fan motors and then back to the tank.

The check valve (Fig. 6-4, Pos. 19.2) acts as anti-cavitation valve in case the oil flow stops. The check valve is
installed because the fan motors (driven by inertial force) keep on running for a short period after the oil flow is
interrupted by the solenoid valve 57K506a/b.

The hydraulic fan drive circuit is protected by the pilot controlled pressure relief valve (Fig. 6-4, Pos. 34.

The solenoid 57K506a is controlled by the temperature converter relay 11K026 and solenoid 57K506b is con-
trolled by the temperature converter relay 11K0171 depending on the hydraulic oil temperature.

– With de-energized solenoids 57K506a and 57K506b the reduction valve (Fig. 6-4, Pos. 29) is operating and
the fans are running with maximum adjusted speed (1250±50 min-1)
– With solenoid 57K506a energized the reduction valve (Fig. 6-4, Pos. 29) is not operating and the fans are
running with a very low speed caused by the flow resistance only.
– With solenoid 57K506b energized the relief valve (Fig. 6-4, Pos. 34) is controlling the reducing valve
(Fig. 6-4, Pos. 29), the fans are running with medium speed (1000±10 min-1) only.

SHOP-10 06279-xD-GB-1 PC3000-6 6 -9

Two stage cooler fan RPM control Hydraulic oil cooling

6.4.1 SOLENOID VALVE FOR FAN SPEED CONTROL

Fig. 6-5 Fan drive shematics

6 - 10 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil cooling Two stage cooler fan RPM control

Legend for Fig. 6-4:

(1) Control spool (4) Reset springs

(2) Plunger (5) Housing

(3) Solenoids [57K506a/b] (6) Main piston (pressure reducing valve)

(19.2) Check valve [57K506a/b] 4/3 direction flow valve hydraulic

cooler fan speed
(28) Pressure filter, hydraulic fan drive pump (stop, low and high speed)
(29) Pressure reduction valve

(34) Pressure relief valve

(51) Hydraulic oil tank

M6-1 Pressure test port

REMARKS: The solenoid 57K506a is controlled by the temperature converter relay 11K026 and solenoid
57K506b is controlled by the temperature converter relay 11K0171 depending on the hydraulic oil
temperature.

Function

With de-energized solenoids 57K506a and 57K506b the spool (Fig. 6-5, Pos. 1) keeps the "X" connection of
pressure reducing valve 29 and port “B“ to port “P“ closed.
The pressure reducing valve 29 operates normally.
Fan speed: maximum speed.

The energized solenoid 57K506boperates the spool (Fig. 6-5, Pos. 1) and a connection is made between port
“P“ and port “B“ and port "X" of the valves 31.1.
The system pressure now opens the main pistons (Fig. 6-5, Pos. 6) of the pressure reducing valve 29, because
via the solenoid 57K506b (P to B) the oil from the rear side of the piston (Fig. 6-5, Pos. 6) flows from the "X"port to
the “P“ connection of the pressure relief valve 34.
The normal valve function is now remote controlled by the pressure adjusted at the pressure relief valve 34.
Fan speed: medium speed

The energized solenoid 57K506a operates the spool (Fig. 6-5, Pos. 1) and a connection is made between port
“P“ and port “A” and port "X" of the reducing valve 29.
The system pressure now opens the main piston (Fig. 6-5, Pos. 6) of the reducing valve 29 because via the
"X"-port the oil from the rear side of piston (Fig. 6-5, Pos. 6) flows to the tank.
The normal relief valve function is eliminated.
Fan speed: minimum speed

SHOP-10 06279-xD-GB-1 PC3000-6 6 - 11

Two stage cooler fan RPM control Hydraulic oil cooling

6.4.2 PRESSURE REDUCING VALVE (FAN CONTROL VALVE)

Fig. 6-6 Pressure reducing valve

6 - 12 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil cooling Two stage cooler fan RPM control

Legend for Fig. 6-6:

(1) Valve cartridge (7) Main piston

(2) Spring (8) Valve housing

(3) Spring chamber (9) Pilot poppet

(4) Port "X" (A) Pressure port

(5) Jet bore, pilot poppet (B) Return oil port

(6) Jet bore, main piston (Y) External leak oil port

Function

Pressure input (A) affects the main piston (Fig. 6-6, Pos. 7). At the same time pressure acts via the jet bore
(Fig. 6-6, Pos. 6) onto the spring-loaded side of the main piston, and via the jet bore (Fig. 6-6, Pos. 5) onto the
pilot poppet (Fig. 6-6, Pos. 9) of the relief valve cartridge (Fig. 6-6, Pos. 1).

If the system pressure in line (A) exceeds the value which is set at the spring (Fig. 6-6, Pos. 2), the pilot poppet
(Fig. 6-6, Pos. 9) opens. The signal for this action comes from line (A) via the jet bores (Fig. 6-6, Pos. 5 and 6).

The oil on the spring-loaded side of the main piston (Fig. 6-6, Pos. 7) now flows via the jet bore (Fig. 6-6, Pos. 5)
and poppet (Fig. 6-6, Pos. 9) into the spring chamber (Fig. 6-6, Pos. 3).

From here it is fed internally by means of the control line (Fig. 6-6, Pos. Y) to the tank (Fig. 6-6, Pos. B). Due to the
state of equilibrium at the main piston (Fig. 6-6, Pos. 7), the oil flows from line (A) to (B), while the adjusted operat-
ing pressure is maintained.

The pressure reducing valve 29 (fan control valve) can be unloaded (remote controlled) by means of the port "X"
and the function of the solenoid valve 57K506a/b.

SHOP-10 06279-xD-GB-1 PC3000-6 6 - 13

Two stage cooler fan RPM control Hydraulic oil cooling

6.4.3 TEMPERATURE CONVERTER RELAYS

Fig. 6-7 Temperature converter relay

(1) Scale drum (switch point adjustment) (3) Adjustment potentiometer for line resis-
tance compensation
(2) LED, relay active = LED ON

6 - 14 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil cooling Two stage cooler fan RPM control

General

In combination with a PT100 sensor the temperature converter relay monitors the adjusted temperature limits.
When the adjusted temperature limit is exceeded the corresponding relay immediately switches and the LED
(Fig. 6-7, Pos. 2) lights up.

Depending on the connected relay contacts the output switch contacts open or close.

6.4.3.1 FUNCTION CHECK OF COOLER FAN RPM-CONTROL

REMARKS: Carry out checks and settings only after the hydraulic oil has reached the operating temperature
(T3).

1. Adjust the scale drum (Fig. 6-7, Pos. 1) of converter relay 11K026 to a temperature below the actual hydraulic
oil temperature.

2. Start engine (diesel engine run with max. rpm).

3. The cooler fans must run with medium speed 1000±10 min-1.

4. Adjust the scale drum of converter relay 11K117 to a temperature below the actual hydraulic oil temperature.

5. The cooler fans must run with maximum speed 1250±50 min-1.

6. Re-adjust the switching points of 11K026 and 11K117 back to the standard values according to the filled oil vis-
cosity, refer to Table 6-1.

Shell Tellus Shell Tellus

Arctic Arctic
ISO oil viscosity grade VG 22 VG 32 VG 46 VG 68 VG 100
S4VX32 S4VX32
(new) (stabilized)
11K026 adjust temperature limit value
to switching point (T3) 32°C 41°C 50°C 58°C 67°C 46°C 39°C
medium fan speed
11K171 adjust temperature limit value
48°C 59°C 69°C 75°C 75°C 75°C 71°C
to switching point maximum speed

Table 6-1 11K026 - adjustment T3 switching point - cooler fan medium speed
11K171 - adjustment switching point cooler fan maximum speed (>T3)

6.4.3.2 ADJUSTMENT OF THE LINE RESISTANCE COMPENSATION

REMARKS: The line resistance compensation is bench adjusted and must only be done in case of replacing the
temperature converter relay, the connected sensor, or after repairs on the sensor wiring.

1. Unplug the concerned temperature sensor 40B040 / 40B171 and measure the electrical resistance between
the two open ends of the sensor using a multimeter. Use Table 2-11 on page 2-12 to convert the measured
resistance into temperature.

2. Adjust the scale drum (Fig. 6-7, Pos. 1) of the converter relay to a higher value as the temperature determined
in step 1. The LED (Fig. 6-7, Pos. 2) is switched OFF.

3. Turn the scale drum slowly to a lower value until the LED is switched ON.
The value at the scale drum should be the same as determined in step 1.

4. If necessary correct with potentiometer (Fig. 6-7, Pos. 3) using a small screw driver.

SHOP-10 06279-xD-GB-1 PC3000-6 6 - 15

Fan pump Hydraulic oil cooling

6.5 FAN PUMP

Fig. 6-8 Fan pump: HPF125

Description

The fan pump is an axial piston pump. The swash plate displacement is bench adjusted. There is no adjustment
required. The pump is mounted at main pump #2.

The pump is maintenance free.

6 - 16 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil cooling Fan pump

Please continue reading on the next page.

SHOP-10 06279-xD-GB-1 PC3000-6 6 - 17

Checks and Adjustments of the cooler fan drive speeds Hydraulic oil cooling

6.6 CHECKS AND ADJUSTMENTS OF THE COOLER

FAN DRIVE SPEEDS
Check and adjustment – maximum speed

nmax =1250±50 min-1

pmax =200±30 bar

Fig. 6-9 Adjustment of the cooler fan drive speed – maximum speed

6 - 18 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil cooling Checks and Adjustments of the cooler fan drive speeds

Basic adjustment has to be carried out whenever one of the following components has been replaced:

– Pump, or
– reducing valve, or
– relief valve, or
– hydraulic motor.

NOTE! The pump must be bled properly.

Basic adjustment – maximum speed

1. Connect a pressure gauge to the pressure test port M6-1 at the pressure filter (28).

2. Unplug both solenoids 57K506a & 57K506b.

3. Start the engine and let it run at high idle.

REMARKS: Carry out checks and settings only at normal operating temperature (T3) of the hydraulic oil.

WARNING
ROTATING FAN!
Serious injury may occur from contact with the rotating hydraulic cooler fan.

Be careful not to get caught in the fan.

4. Check the fan speed at the lower fan with a non-contact rev. counter. Required fan speed according to
PM-Clinic: 1250±50 min-1 at the lower fan.

5. If adjustment is necessary remove the protection cap (Fig. 6-9, Pos. a) from the reducing valve (29), loosen
the lock nut (Fig. 6-9, Pos. b) and turn the set screw (Fig. 6-9, Pos. c) cw. to increase or ccw. to decrease the
maximum fan speed.

6. Recheck the maximum fan speed adjustment at the lower fan and adjust if necessary.

7. Tighten the lock nut (Fig. 6-9, Pos. b) and reinstall the protection cap (Fig. 6-9, Pos. a).

8. Note down the pressure as reference value (expected 200±30 bar).

REMARKS: Both fans should be checked. A speed difference of 50 min-1 is normal due to the higher resistance
of the air stream for the lower fan, but the lower fan must run at the standard values given in the
PM-Clinic. If the speed difference between both fans is higher than 50 min-1, a possible cause could
be a worn hydraulic motor.

9. Continue with "Check and adjustment – medium speed" on page 6-20.

SHOP-10 06279-xD-GB-1 PC3000-6 6 - 19

Checks and Adjustments of the cooler fan drive speeds Hydraulic oil cooling

Check and adjustment – medium speed

nmed =1000±10 min-1

pmed =130±10 bar

Fig. 6-10 Adjustment of the cooler fan drive speed – medium speed

6 - 20 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic oil cooling Checks and Adjustments of the cooler fan drive speeds

Basic adjustment – medium speed

10. Re-plug the connector of the solenoid valve 57K506b only to activate the function of the pressure relief valve
(34).

WARNING
ROTATING FAN!
Serious injury may occur from contact with the rotating hydraulic cooler fan.

Be careful not to get caught in the fan.

11. Check the fan speed at the lower fan with a non-contact rev. counter. Required fan speed according to
PM-Clinic: 1000±10 min-1 at the lower fan.

12. If adjustment is necessary remove the protection cap (Fig. 6-10, Pos. d) from the relief valve (34), loosen the
lock nut (Fig. 6-10, Pos. e) and turn the set screw (Fig. 6-10, Pos. f) cw. to increase or ccw. to decrease the
maximum fan speed.

13. Recheck the medium fan speed adjustment at the lower fan and adjust if necessary.

14. Tighten the lock nut (Fig. 6-10, Pos. e) and reinstall the protection cap (Fig. 6-10, Pos. d).

15. Note down the pressure as reference value (expected 130±10 bar).

16. Disconnect the pressure gauge from the test port M6-1.

17. Re-plug the connector of the solenoid valve 57K506a.

6.6.1 FUNCTION CHECK OF FAN SPEED CONTROL

REMARKS: Carry out checks only at normal operating temperature (T3) of the hydraulic oil.

1. Unplug/re-plug the solenoids 57K506a/b and check the following fan speeds.:

Solenoid State Required fan speed

57K506a-1 unplugged
nmax = 1250±50 min-1
57K506b-1 unplugged

57K506a-1 unplugged
nmed = 1000±10 min-1
57K506b-1 plugged

57K506a-1 plugged
nmin = 0…50 min-1
57K506b-1 unplugged

Table 6-1 Solenoid conditions

REMARKS: At minimum speed the fan may spin at very low speed or it may stop completely.

2. Re-plug both solenoids 57K506a & 57K506bafter check.

SHOP-10 06279-xD-GB-1 PC3000-6 6 - 21

Checks and Adjustments of the cooler fan drive speeds Hydraulic oil cooling

Please continue reading on the next page.

6 - 22 PC3000-6 SHOP-10 06279-xD-GB-1

Controlling

7 CONTROLLING

SHOP-10 06279-xD-GB-1 PC3000-6 7 -1

General layout Controlling

7.1 GENERAL LAYOUT

Fig. 7-1 Overall view of the control system

7 -2 PC3000-6 SHOP-10 06279-xD-GB-1

Controlling General layout

Legend for Fig. 7-1:

(1) Pilot oil gear pump (26.1) Pressure filter

(2) Control block assembly (62) Pilot oil unit: Left track control pedal

(3) Pilot control frame (71) Pilot oil unit: L.H. control lever

(4) Main control blocks (72) Pilot oil unit: R.H. control lever

(73) Pilot oil unit: Clam opening / closing pedal

(74) Pilot oil unit: Right track control pedal

(88) Pilot oil unit: Slew brake control pedal

(120) Bladder accumulator – 35 liters, 10 bar

(252) Control block - pilot pressure

General

The control circuit is fed by a gear pump (Fig. 7-1, Pos. 1) and split in two pressure lines X4 and X2.

The pump forces the oil through the filter (Fig. 7-1, Pos. 26.1) to the pilot pressure control block. (Fig. 7-1,
Pos. 252) at the control block assembly (Fig. 7-1, Pos. 2).

The pressure accumulator (Fig. 7-1, Pos. 120) ensures that under any circumstances enough pilot pressure oil is
available.
The accumulator also serves as a hydraulic back-up system for a certain time when the engine was shut down, or
to relieve the system pressure for repair works.

The pilot control frame (Fig. 7-1, Pos. 3) is constantly supplied with the pilot pressure X2 (35±3 bar).

When the operator is using his controls (pedal or lever) a hydraulic pressure (0...35 bar) - which is proportional to
the deflection of the used control - is send to the relevant control spool cap at main control blocks via the pilot con-
trol frame.

As a consequence of this, hydraulic oil runs to the corresponding component.

SHOP-10 06279-xD-GB-1 PC3000-6 7 -3

Control and filter plate - location of components Controlling

7.2 CONTROL AND FILTER PLATE - LOCATION OF

COMPONENTS
Hydraulic and electric components

Fig. 7-2 Control and filter plate - location of components

7 -4 PC3000-6 SHOP-10 06279-xD-GB-1

Controlling Control and filter plate - location of components

Legend for Fig. 7-2:

Hydraulic components:

(20) Pressure filter, PTO gear oil (252.1) X2-pressure reducing valve (35±3 bar)

(21) Pressure relief valve, PTO gear lubrication (252.2) X4-pressure relief valve (60±1 bar)

(26.1) Pressure filter, pilot oil (256) Control block - slew brake

(28) Pressure filter, hydraulic fan drive pump (257) Control block - travel parking brake

(29) Pressure reducing valve (257.1) SRV - travel parking brake (50 bar)

(34) Pressure relief valve (258) Control block - access ladder

(120) Bladder accumulator (258.3) SRV - access ladder (70 bar)

(252) Control block - pilot pressure (259) Control block - refilling arm

Electric components:

[57B017] Pressure switch, PTO gear oil pressure

[57B027] Pressure switch, PTO gear oil pressure filter clogged

[57B086] Pressure transducer, X2 pilot pressure

[57K506a/b] Solenoid valve, hydraulic oil cooler fan drive (minimum/medium speed)

[57K553] Solenoid valve, PTO preload pressure

[57Q505] Solenoid valve, slew parking brake control pressure

[57Q516] Solenoid valve, travel parking brake control pressure

[57Q620] Solenoid valve, slew shut-off (emergency)

[57Q623a/b] Solenoid valve, hydraulic access ladder - a) up, b) down

[57Q624a/b] Solenoid valve, refilling arm - a) up, b) down

[57Q624c] Solenoid valve, refilling arm park valve

[57Q625] Solenoid valve, hydraulic access ladder - speed control

SHOP-10 06279-xD-GB-1 PC3000-6 7 -5

Control and filter plate - location of components Controlling

Pressure test ports on control and filter panel

Fig. 7-3 Control and filter plate - location of pressure test ports

7 -6 PC3000-6 SHOP-10 06279-xD-GB-1

Controlling Control and filter plate - location of components

Legend for Fig. 7-3:

Pressure test ports

M1.1 X4 pressure (60±1 bar)

M1.2 X2 pressure – pilot pressure (35±3 bar)

M2 Bladder accumulator, pilot pressure (35±3 bar)

M6-1 Pressure – hydraulic oil cooler fans

M8-1 Pressure – PTO gear lubrication

M9 Travel parking brake operating pressure

M10 Slew parking brake operating pressure

M12 Reserve

M30 X4 pressure (60±1 bar)

M37.1 Hydraulic cylinder access ladder “piston side”

M37.2 Hydraulic cylinder access ladder “rod side”

M38.1 Hydraulic cylinder refilling arm “piston side”

M38.2 Hydraulic cylinder refilling arm “rod side”

M39 Proportional pressure to dynamic slew brake

SHOP-10 06279-xD-GB-1 PC3000-6 7 -7

Pilot control frame - location of components Controlling

7.3 PILOT CONTROL FRAME - LOCATION OF COMPO-

NENTS

Fig. 7-4 Pilot control frame - location of components

7 -8 PC3000-6 SHOP-10 06279-xD-GB-1

Controlling Pilot control frame - location of components

Legend for Fig. 7-4:

[10B037] Pressure switch, motion detection traveling

[10B047] Pressure switch, motion detection slewing

[10B155] FSA only - pressure switch, pressure cut-off, clam closing

[10B156] FSA only (optional) - pressure switch, monitoring pressure cut-off, clam closing (10B155)

[10K040] FSA only - solenoid valve, bucket shut-off

[10K511] FSA only - solenoid valve, pilot control cut-off, clam

[10K511a] Solenoid valve, pilot control cut-off, bucket

[10K511b] Solenoid valve, pilot control cut-off, stick

[10K511c] Solenoid valve, pilot control cut-off, boom

[10K611d] BHA only - solenoid valve, pilot control release

[10K611e] FSA only - solenoid valve, pilot control release

[10Q515] Solenoid valve, pilot control locking slew service brake

SHOP-10 06279-xD-GB-1 PC3000-6 7 -9

Pilot pressure supply and adjustments Controlling

7.4 PILOT PRESSURE SUPPLY AND ADJUSTMENTS

7.4.1 PILOT PRESSURE CIRCUIT

Fig. 7-5 Pilot pressure circuit

7 - 10 PC3000-6 SHOP-10 06279-xD-GB-1

Controlling Pilot pressure supply and adjustments

Legend for Fig. 7-5:

(1) Pilot pressure pump (120) Bladder accumulator – 35 liters, 10 bar

(2) Main hydraulic oil tank (252.1) X2-pressure reducing valve (35±3 bar)

(3) Pilot control frame (252.2) X4-pressure relief valve (60±1 bar)

(26.1) Pressure filter

Function

REMARKS: For further details refer to the hydraulic circuit diagram!

The gear pump (Fig. 7-5, Pos. 1) delivers the oil through the pressure filter (Fig. 7-5, Pos. 26.1) and is splitted in
two pressure lines X4 and X2.

– The pressure relief valve (Fig. 7-5, Pos. 252.2) limits the X4-pressure to 60±1 bar.
– The pressure reducing valve (Fig. 7-5, Pos. 252.1) then reduces the 60±1 bar to X2-pressure of 35±3 bar.

X4-pressure is used to:

– operate the access ladder,

– operate the lubrication systems CLS & SLS.

X2-pressure is used to:

– operate main block spools,

– control travel- and slew parking brakes (spring loaded multi-disk brakes),
– supply the servo valves (pump regulation) at the main pumps,
– operate the refilling arm
– operate the track tensioning system.

The pressure accumulator (Fig. 7-5, Pos. 120) ensures that pilot pressure oil is available after emergency shut off.
The accumulator also serves as a hydraulic back-up system for a certain time when the engine was shut down, or
to relieve the system pressure for repair works.

SHOP-10 06279-xD-GB-1 PC3000-6 7 - 11

Pilot pressure supply and adjustments Controlling

7.4.2 CHECKS AND ADJUSTMENT OF PILOT PRESSURE

Fig. 7-6 Checks and adjustment of pilot pressure

7 - 12 PC3000-6 SHOP-10 06279-xD-GB-1

Controlling Pilot pressure supply and adjustments

Legend for Fig. 7-6:

(1), (3) Lock nut

(2), (4) Set screw, pressure relief valve

(252.1) Pressure reducing valve for pilot pressure X2 (35±3 bar)

(252.2) Pressure relief valve for X4-pressure (60±1 bar)

(120) Bladder accumulator – 35 liters, 10 bar pre-charge pressure

M1.1 Pressure test port X4-pressure (60±1 bar)

M1.2 Pressure test port X2-pressure, pilot pressure (35±3 bar)

M2 Pressure test ports for accumulator

REMARKS: Carry out oil pressure testing and adjustment only at hydraulic oil temperature T3.

X4 pressure (60±1 bar), valve 252.2:

1. Connect a pressure gauge to the appropriate test port (Fig. 7-6, Pos. M1.1).

2. Start the engine, run at high idle.

3. Read pressure, required = 60±1 bar.

If readjustment is required, carry out the following steps 4 to 6:

4. Loosen the lock nut (Fig. 7-6, Pos. 1).

5. Set pressure with the set screw (Fig. 7-6, Pos. 2).

6. Tighten the lock nut (Fig. 7-6, Pos. 1).

X2 pressure (35 bar), valve 252.1:

1. Connect a pressure gauge to the appropriate test port (Fig. 7-6, Pos. M1.2).

2. Start the engine, run at high idle.

3. Read pressure, required = 35±3 bar.

If readjustment is required, carry out the following steps 4 to 6:

4. Loosen lock nut (Fig. 7-6, Pos. 3).

5. Set pressure with the set screw (Fig. 7-6, Pos. 4).

6. Tighten the lock nut (Fig. 7-6, Pos. 3).

Checking the accumulator function:

1. Connect a pressure gauge to the appropriate test port (Fig. 7-6, Pos. M2).

2. Start the engine, run at high idle.

3. After build-up of pressure stop the drive engine, but do not turn the key switch to zero position.

4. Watch the pressure gauge. X2-pressure should remain constant for at least 5 minutes.

REMARKS: If the pressure drops, the system must be checked for leakages. To check the accumulator charging
pressure, refer to the PARTS & SERVICE NEWS “AH01531”, latest edition.

SHOP-10 06279-xD-GB-1 PC3000-6 7 - 13

Pilot pressure supply and adjustments Controlling

Checking the accumulator pre-charge pressure:

5. Start the engine, run at high idle.

6. After build-up of pressure stop the drive engine, but do not turn the key switch to zero position.

7. Activate any control lever function repeatly and observe the pressure gauge at test port M2.
When the accumulator charging pressure is correct the pressure stays stable for a few movements, and then
slowly decrease until the accumulator charging pressure (10 bar) is reached. Then the pressure rapidly drops
to 0 bar.

REMARKS: If the pressure drops rapidly after the first movements the accumulator’s gas filling is probably empty
or to low. To check the accumulator charging pressure, refer to the PARTS & SERVICE NEWS
“AH01531”, latest edition.

8. Remove the pressure gauges.

7 - 14 PC3000-6 SHOP-10 06279-xD-GB-1

Components

8 COMPONENTS

SHOP-10 06279-xD-GB-1 PC3000-6 8 -1

Main control blocks and high pressure filters (FSA) Components

8.1 MAIN CONTROL BLOCKS AND HIGH PRESSURE

FILTERS (FSA)

Fig. 8-7 Main control blocks - location of components I

8 -2 PC3000-6 SHOP-10 06279-xD-GB-1

Components Main control blocks and high pressure filters (FSA)

Legend for Fig. 8-7:

Electric components:

[61B158a] Pressure transducer, pump pressure main pump I

[61B158b] Pressure transducer, pump pressure main pump II

[61B158c] Pressure transducer, pump pressure main pump III

[61K632] Solenoid valve - stick floating function

[61K635] Solenoid valve - boom floating function

Hydraulic components:

(9) Main control block I

(10) Main control block II

(11) Main control block III

(37.1) High pressure filter, main pump I

(37.2) High pressure filter, main pump II

(37.3) High pressure filter, main pump III

(132.1) Pilot controlled floating spool valve - stick

(132.2) Pilot controlled floating spool valve - stick

(132.3) Pilot controlled floating spool valve - boom

SHOP-10 06279-xD-GB-1 PC3000-6 8 -3

Main control blocks and high pressure filters (FSA) Components

Fig. 8-8 Main control blocks - location of components II

8 -4 PC3000-6 SHOP-10 06279-xD-GB-1

Components Main control blocks and high pressure filters (FSA)

Legend for Fig. 8-8:

Control block I

(67) SRV, clam cylinder piston side

(68.1) ACV, clam cylinder rod side

(68.2) ACV, stick cylinder piston side

(68.3) ACV, travel motors left backward

(68.4) ACV, travel motors left forward

Control block II

(66.3*A1) SRV , boom cylinderrod side

(66.4) SRV, bucket cylinder piston side

(66.5) SRV, bucket cylinder rod side

(66.6) SRV, stick cylinder piston side

(66.7) SRV, stick cylinder rod side

(68.6) ACV, stick cylinder piston side

(68.7) ACV, travel motors right forward

(68.8) ACV, travel motors right backward

(66.3*B1) SRV, boom cylinder piston side

Control block III

(66.1) SRV, bucket cylinder rod side

(66.2) SRV , stick cylinder rod side

(68.5) ACV, stick cylinder piston side

*A1 Port A1 at the main control block

*B1 Port B1 at the main control block

REMARKS: There is one main relief valve in each main control block.

SHOP-10 06279-xD-GB-1 PC3000-6 8 -5

Main control blocks and high pressure filters (BHA) Components

8.2 MAIN CONTROL BLOCKS AND HIGH PRESSURE

FILTERS (BHA)

Fig. 8-9 Main control blocks - location of components I

8 -6 PC3000-6 SHOP-10 06279-xD-GB-1

Components Main control blocks and high pressure filters (BHA)

Legend for Fig. 8-9:

Electric components:

[61B158a] Pressure transducer, pump pressure main pump I

[61B158b] Pressure transducer, pump pressure main pump II

[61B158c] Pressure transducer, pump pressure main pump III

Hydraulic components:

(9) Main control block I

(10) Main control block II

(11) Main control block III

(37.1) High pressure filter, main pump I

(37.2) High pressure filter, main pump II

(37.3) High pressure filter, main pump III

SHOP-10 06279-xD-GB-1 PC3000-6 8 -7

Main control blocks and high pressure filters (BHA) Components

Fig. 8-10 Main control blocks - location of components II

8 -8 PC3000-6 SHOP-10 06279-xD-GB-1

Components Main control blocks and high pressure filters (BHA)

Legend for Fig. 8-10:

Control block I

(66.8) SRV, stick cylinder piston side

(68.1) ACV, stick cylinder rod side

(68.2) ACV, bucket cylinder rod side

(68.3) ACV, travel motors left backward

(68.4) ACV, travel motors left forward

Control block II

(66.3) ACV, boom cylinder rod side

(66.7) SRV, stick cylinder piston side

(68.5) ACV, bucket cylinder rod side

(68.10) ACV, stick cylinder rod side

(68.7) ACV, travel motors right forward

(68.8) ACV, travel motors right backward

Control block III

(66.2) SRV, bucket cylinder rod side

(68.9) ACV , stick cylinder piston side

REMARKS: There is one main relief valve in each main control block.

SHOP-10 06279-xD-GB-1 PC3000-6 8 -9

Distributor manifold - location of restrictor blocks and anti cavitation valves (FSA) Components

8.3 DISTRIBUTOR MANIFOLD - LOCATION OF

RESTRICTOR BLOCKS AND ANTI CAVITATION
VALVES (FSA)

Fig. 8-11 Distributor manifold - location of restrictor blocks and anti cavitation valves

FSA manifold

(1) ACV (64.x) (3) SRV with check valve (65.x)

(2) SRV and throttle check valve (63.x) (4) SRV (112.x)

REMARKS: The numbers in brackets behind the components (ACV/SRV) are the component numbers in the
hydraulic diagram. Refer to Table 8-1.

8 - 10 PC3000-6 SHOP-10 06279-xD-GB-1

Components Distributor manifold - location of restrictor blocks and anti cavitation valves (FSA)

Comp. # Section Component Test port

(64.1) Section A ACV, boom cylinder rod side -

(63.8) Section B SRV and throttle check valve, boom cylinder piston side M16.1

(63.2) Section C SRV and throttle check valve, bucket cylinder piston side M16.3

(65.1) Section C SRV and check valve, bucket cylinder piston side M16.2

(64.2) Section D ACV, bucket cylinder rod side -

(63.3) Section E SRV and throttle check valve, clam cylinder rod side M16.4

(64.3) Section F ACV, stick cylinder rod side -

(65.2) Section G SRV and check valve, stick cylinder piston side M16.5

(64.4) Section H ACV, stick cylinde rod side -

(63.5) Section J SRV and throttle check valve, stick cylinder piston side M16.6

(63.6) Section J SRV and throttle check valve, stick cylinder piston side M16.7

(112.1) Section K SRV, clam cylinder piston side M23

(64.5) Section K ACV, clam piston side -

(64.6) Section L ACV, bucket cylinder rod side -

(63.1) Section M SRV and throttle check valve, bucket cylinder piston side M16.9

(64.7) Section M ACV, bucket piston side -

(63.9) Section N SRV and throttle check valve, boom cylinder piston side M16.10

Table 8-1 FSA components an distributor manifold according to the hydraulic diagram

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 11

Distributor manifold - location of restrictor blocks and anti cavitation valves (BHA) Components

8.4 DISTRIBUTOR MANIFOLD - LOCATION OF

RESTRICTOR BLOCKS AND ANTI CAVITATION
VALVES (BHA)

Fig. 8-12 Distributor Manifold - Location of restrictor blocks and anti cavitation valves (BHA)

BHA manifold

(1) ACV (64.x) (3) SRV with check valve (65.x)

(2) SRV and throttle check valve (63.x) (4) SRV (70.x)

REMARKS: The numbers in brackets behind the components (ACV/SRV) are the component numbers in the
hydraulic diagram. Refer to Table 8-2.

8 - 12 PC3000-6 SHOP-10 06279-xD-GB-1

Components Distributor manifold - location of restrictor blocks and anti cavitation valves (BHA)

Comp. # Section Component Test port

(64.1) Section A ACV, boom cylinder rod side -

(63.8) Section B SRV and throttle check valve, boom cylinder piston side M16.1

(64.8) Section C ACV, bucket cylinder piston side -

(70.2) Section C SRV, bucket cylinder piston side M16.11

(63.10) Section D SRV and throttle check valve, boom cylinder piston side M16.13

(63.3) Section E SRV and throttle check valve, stick cylinder rod side M16.4

(64.3) Section F ACV, stick cylinder piston side -

(63.4) Section G SRV and throttle check valve, bucket cylinder rod side M16.5

(64.4) Section H ACV, stick cylinder piston side -

(63.5) Section J SRV and throttle check valve, stick cylinder rod side M16.6

(63.6) Section J SRV and throttle check valve, stick cylinder rod side M16.7

(63.79 Section L SRV and throttle check valve, bucket cylinder rod side M16.15

(64.6) Section L ACV, bucket cylinder rod side -

(70.1) Section M SRV, bucket cylinder piston side M16.9

(64.7) Section M ACV, bucket cylinder piston side -

(63.9) Section N SRV and throttle check valve, boom cylinder piston side M16.10

Table 8-2 BHA components an distributor manifold according to the hydraulic diagram

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 13

Single control blocks (floating) for stick and boom (FSA) Components

8.5 SINGLE CONTROL BLOCKS (FLOATING) FOR

STICK AND BOOM (FSA)

Fig. 8-13 Single control blocks (floating) for stick and boom (FSA)

8 - 14 PC3000-6 SHOP-10 06279-xD-GB-1

Components Single control blocks (floating) for stick and boom (FSA)

Legend for Fig. 8-13:

(132.1) Single control block (pilot controlled floating spool valve) - Stick lowering function

(132.2) Single control block (pilot controlled floating spool valve) - Stick lowering function

(132.3) Single control block (pilot controlled floating spool valve) - Boom lowering function

[61K632] Solenoid valve - stick floating function

[61K635] Solenoid valve - boom floating function

Function (only Front Shovel Attachment)

The additionally installed single control blocks connect the piston side of the cylinders with the rod side and also
with the hydraulic oil tank:

– 132.1 and 132.2 for the stick cylinders

– 132.3 for the boom cylinders
In normal operation mode the pilot pressure oil is directed via 4/2-directional solenoid valves [61K632] and
[61K635] to the single control blocks when lowering the boom or stick.

If a pressurised lowering of the cylinders is required, the pilot pressure oil is directed via the activated 4/2-direc-
tional valves to the main control blocks.

The 4/2-directional control valves are controlled by push buttons located in the control levers (joysticks).

REMARKS: For further information about the 4/2-directional valves refer to section 8.11 on page 8-38.

At deactivated boom floating function the solenoid valve [61K632] holds the single control block 132.3 in neutral
position.

At deactivated stick floating function the solenoid valve [61K635] holds the single control blocks 132.1 and 132.2 in
neutral position.

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 15

Restrictor block with secondary relief valve Components

8.6 RESTRICTOR BLOCK WITH SECONDARY RELIEF

VALVE

Fig. 8-14 Restrictor block with secondary relief valve

8 - 16 PC3000-6 SHOP-10 06279-xD-GB-1

Components Restrictor block with secondary relief valve

Legend for Fig. 8-14:

(1) Adjustment pin (11) Housing

(2) O-ring with back-up ring (12) Return line port (T)

(3) O-ring with back-up ring (13) Secondary relief valve

(4) Retainer (14) Allen key bolt

(5) O-ring with back-up ring (15) Clip ring

(6) O-ring with back-up ring (16) Lock nut

(7) Spring (A) LIne port

(8) Spring cup (B) Line port

(9) Valve poppet (M) Pressure test port

(10) O-ring (Y) Control oil drain port

REMARKS: A restrictor block is used for limiting cylinder lowering speeds.

A secondary relief valve is installed to limit the maximum system pressure due to external forces.

Function

Setting of the maximum permissible cylinder speed (flow B to A) is carried out by the adjustment pin (Fig. 8-14,
Pos. 1). Depending on the setting, the radial holes (Fig. 8-14, Pos. 9.1) in the valve poppet (Fig. 8-14, Pos. 9) will
be partially opened to achieve the required throttling of the oil flow.

The extra holes (fixed throttle Fig. 8-14, Pos. 9.2) prevent the valve from becoming completely closed.

For the lifting operation (flow A to B), the valve poppet (Fig. 8-14, Pos. 9), which is guided by the pin Fig. 8-14,
Pos. 1), is pressed against the spring (Fig. 8-14, Pos. 7) so that the valve will be completely open.

Ex factory the throttle valves are pre-adjusted, refer to PM-Clinic.

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 17

Anti-cavitation valve (ACV) block Components

8.7 ANTI-CAVITATION VALVE (ACV) BLOCK

Fig. 8-15 Anti cavitation valve block

8 - 18 PC3000-6 SHOP-10 06279-xD-GB-1

Components Anti-cavitation valve (ACV) block

Legend for Fig. 8-15:

(1) ACV housing (5) O-ring

(2) Valve cone (6) Valve seat

(3) Valve guide and cover (7) Back pressure port from tank

(4) Valve spring (8) Connecting port to cylinder

REMARKS: ACVs (Anti-Cavitation Valves) are installed to avoid cavitation damages on hydraulic cylinders by
compensating a possible lack of oil when the SRV at the opposite side of the cylinder opens (see cir-
cuit diagram).

Function

The circuit pressure in the connecting port (Fig. 8-15, Pos. 8) to the cylinder hold the valve cone (Fig. 8-15, Pos. 2)
closed.

The pressure at the back pressure port (Fig. 8-15, Pos. 7) allows necessary oil supply into the circuit when the
pressure in the connecting port (Fig. 8-15, Pos. 8) is lower as the pressure at the back pressure port (Fig. 8-15,
Pos. 7).

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 19

High-pressure filter (screen) Components

8.8 HIGH-PRESSURE FILTER (SCREEN)

Fig. 8-16 High pressure filter

(1) Hexagon (6) Filter housing

(2) Drain plug (7) Filter head

(3) Packing ring (8) Back-up ring

(4) Spring (9) O-ring

(5) Filter element (10) Spring

8 - 20 PC3000-6 SHOP-10 06279-xD-GB-1

Components High-pressure filter (screen)

REMARKS: High-pressure filters are installed in each pump line.

Function

The high-pressure in-line screens prevent the hydraulic circuits from contamination (particles > 200 µm) in case of
main pump damage.

The spin-on filters are installed between the main hydraulic pumps and the multi-valve control blocks.

All hydraulic components behind the filters are effectively protected from damage and undue wear.

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 21

Control blocks and valves Components

8.9 CONTROL BLOCKS AND VALVES

Fig. 8-17 Control blocks and valves

8 - 22 PC3000-6 SHOP-10 06279-xD-GB-1

Components Control blocks and valves

Legend for Fig. 8-17:

(1) Main relief valve (MRV) location (8) Short cap ("A" side)

(2) Main relief valve (MRV) (9) "A" side service line ports

(3) Boom lifting / lowering spool (special) (10) Load holding valves

(4) Long cap ("B" side) (11) Pilot oil warm up and flushing grooves

(5) "B" side service line ports (12) Fine controlling grooves

(6) Centering springs (13) Type plate

(7) Solid spool

REMARKS: Principle drawing, showing valve block II and IV.

The control blocks are "Open Center Blocks". Control blocks I and III are 3 spool blocks, control blocks II and IV
are 4 spool blocks. See hydraulic circuit diagram for spool details.

Each spool is provided with "Fine Controlling Grooves", ring grooves for hydraulically centering of the spool and
“Pilot oil warm up and flushing“ grooves.

Pilot pressure between 8 and 19 bar moves the spools in their fine control range.

The spool (Fig. 8-17, Pos. 3) is especially designed to keep the pressure channel connected to the center channel
during the function “Boom lowering“ is selected, so that pump flow is available for other functions.

The Load Holding Valves are installed beneath a plug from the service port side of the control block.

The MRV is a pilot operated pressure relief valve.

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 23

Control blocks and valves Components

Fig. 8-18 Control blocks and valves

8 - 24 PC3000-6 SHOP-10 06279-xD-GB-1

Components Control blocks and valves

Legend for Fig. 8-18:)

(1) Main relief valve (MRV) in control block housing

(2) Check valve (load limiting valve)

(3) Anti-cavitation valve (ACV)

(4) Secondary relief valve (SRV)

Explanation of the schematic drawing of the control block:

The hydraulic oil flows (Qmin = 170 liters/min [375+375 tandem pump]) through the control block from port P to T, if
all spools are in neutral position ("open center“).

– Fig. 8-18, Pos. A:

E.g. the spools pilot pressure is built up in the control pipe line a1. (Imagine the upper symbol box moves to
the center position.)
Now pump oil flows through check valve (Fig. 8-18, Pos. 2) to the user port A1 because the free flow circula-
tion to the hydraulic reservoir is closed. The main relief valve (Fig. 8-18, Pos. 1) limits the maximum operation
pressure in this circuit. Via port B1 the return oil from the user is flowing back to the hydraulic reservoir.
During down hill travelling motion and stopping procedure (e.g. travel motors) the anti cavitation valves
(Fig. 8-18, Pos. 3) prevent cavitation on the hydraulic motors, because during these short periods of time the
hydraulic motor needs a higher oil supply than the pump can deliver.
– Fig. 8-18, Pos. B:
E.g. spool #3 moves up when pilot pressure is built up in the control pipe b3. Now the user port B3 is supplied
with pump pressure. Via port A3 the return oil from the user is flowing back to the hydraulic reservoir.
The secondary relief valve (Fig. 8-18, Pos. 4) is additional installed in this circuit to protect the circuit against
extreme pressure. The short-time extreme pressure also closes the check valve (Fig. 8-18 Pos. 2) which pro-
tects the hydraulic pump against extreme pressure peaks.
The check valves (Fig. 8-18, Pos. 2) also have the function of load holding valves, because during the fine
controlling period all lines are interconnected (negative over-lapping). For a moment, the load pressure is
higher than the pump pressure.

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 25

Control blocks and valves Components

Spool in "neutral position"

Pilot pressure connected to

spool cab "a"

Fig. 8-19 Control blocks and valves

8 - 26 PC3000-6 SHOP-10 06279-xD-GB-1

Components Control blocks and valves

Legend for Fig. 8-19:

(1) Main relief valve (MRV)

(2) Reset springs

(3) Fine control grooves

(4) Spool

Function

Reset springs (Fig. 8-19, Pos. 2) move the spool (Fig. 8-19, Pos. 4) into neutral position.

Fine control grooves (Fig. 8-19, Pos. 3) provide for sensitive controlling, because a motion is always started while
the pressure oil and the return oil first pass these fine control grooves before the spool (Fig. 8-19, Pos. 4) is inter-
connecting the entire groove to the user channel.

In neutral position of spool (Fig. 8-19, Pos. 4) the pump oil is flowing back via port PU to the tank.

Lower Picture

Example: The spool is moved to left position: Port PU is closed and the connection through the check valve RP1 to
the user (port A) is open. In addition, the connection from the other user side (port B return) is connected to the
port T (return line to tank).

The return line of the pressure relief valve MRV (Fig. 8-19, Pos. 1) is also connected to the port T.

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 27

Control blocks and valves Components

8.9.1 SPOOL TYPES

The control blocks are equipped with different spools, depending on function and priority.

Spools without a symbol (standard) are connecting the rod side of

the cylinders with the pump supply line and the piston side with
the tank.

Fig. 8-20 Standard spool (example)

Spools with the symbol "#" (see Fig. 8-21) are connecting the pis-
ton side of the cylinders with the tank only.

(For lowering with free pump circulation, i.e. the pressure channel
is connected to the center channel, so that pump flow is available
for other functions.)

Fig. 8-21 Spool marked "#" (example)

8 - 28 PC3000-6 SHOP-10 06279-xD-GB-1

Components Control blocks and valves

Please continue reading on the next page.

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 29

Control blocks and valves Components

8.9.2 MRV, SRV AND ACV

Fig. 8-22 MRV, SRV and ACVs

8 - 30 PC3000-6 SHOP-10 06279-xD-GB-1

Components Control blocks and valves

Legend for Fig. 8-22:

(1) Secondary relief valve (SRV) (10) Lock nut

(2) Anti-cavitation valve (ACV) (11) Spring, pilot part

(3) Main relief valve (MRV) (12) Poppet

(4) Closing plate (13) Jet bore

(5) Plug screw (14) Spring, main cone

(6) Spring (15) Main valve cone

(7) Valve cone (16) Jet bore

(8) Dust cap (17) Pilot oil dump line to tank

(9) Set screw

MRVs and SRVs

MRVs (Fig. 8-22, Pos. 3) and SRVs (Fig. 8-22, Pos. 1) are pilot operated relief valves. The MRV limits the max.
pump supply line pressure. The SRV limits the max. possible pressure peak in the service-line.

The valves have an „opening characteristic“. That means, that in case of contamination after the response proce-
dure no further pressure increase is possible and damages are avoided.

Function:
The circuit pressure P pushes the piston surface A of the main valve cone (Fig. 8-22, Pos. 15) with the force F1.
Because there is the same pressure on the back side of the main cone via the jet bore (Fig. 8-22, Pos. 16), this,
together with the spring (Fig. 8-22, Pos. 14) force, results in a force F2 that keeps the main cone closed.
Via the jet bore (Fig. 8-22, Pos. 13) the circuit pressure is in front of the poppet (Fig. 8-22, Pos. 12).
When the circuit pressure exceeds the setting value of the spring (Fig. 8-22, Pos. 11), the poppet opens against
the force of the spring (Fig. 8-22, Pos. 11).
As a result, force F2 decreases and there is no more balance condition between F1 and F2.
The valve cone (Fig. 8-22, Pos. 15) is moved upwards by the greater force F1. That means now there is a direct
connection from port P to T (tank).

ACVs

ACVs (Fig. 8-22, Pos. 2) serve for compensating a possible lack of oil when the SRV at the opposite port is actu-
ated (see circuit diagram) and for avoiding cavitation damages. In addition, they serve to supply a user in case it is
continuously moved by acceleration forces at zero position of the control spool.

Function:
The circuit pressure inside the spring chamber closes the valve cone (Fig. 8-22, Pos. 7). The back pressure of the
return line acts on the surface of the valve cone (Fig. 8-22, Pos. 7).
Whenever the pressure in the service-line is lower than the springs force, the valve cone opens by the force of the
back pressure and hydraulic oil is additionally supplied.

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 31

Control blocks and valves Components

8.9.3 LOAD HOLDING VALVE

Fig. 8-23 Load holding valves

8 - 32 PC3000-6 SHOP-10 06279-xD-GB-1

Components Control blocks and valves

Legend for Fig. 8-23:

(1) Valve cone guide

(2) Valve spring

(3) Valve cone

(4) Valve block housing

(5) Passage from pump (P)

(6) Passage to control block spool A/B

Control blocks II and IV (4 spool blocks)

The load holding valves are fitted into separate spaces of the control block housing, one valve for each spool.

The load holding valves have three tasks:

– When the circuit pressure is higher than pump pressure due to the attachment weight, these valves prevent
dropping of the attachment, within their sensitive (fine controlling) range.
– Due to sudden pressure peaks in the service-lines the valves also protect the pump.
– When two pump flows are used for one user, the valves ensure that at least the flow of one pump reaches the
user in case one MRV is defect or no longer properly adjusted.
That means: Up to the max. pressure of the defective valve, both load holding valves are open allowing the flow of
both pumps to the user. Then one valve will be closed by the higher pressure and the flow of one pump only flows
to the user.

Function

The system pressure pushes onto the front area of the valve cone (Fig. 8-23, Pos. 1). This force moves the valve
cone against the spring (Fig. 8-23, Pos. 2) and allows the oil to flow from the pump to the spool.

In neutral position of the spool no further flow is possible (see circuit diagram).

If the spool is no longer in neutral position, the flow continues to the user.

If, due to an external force, the pressure directed to the pump overcomes the pump line pressure, this pressure
forces the valve onto its seat (closed position).

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 33

Control blocks and valves Components

Fig. 8-24 Load holding valves

8 - 34 PC3000-6 SHOP-10 06279-xD-GB-1

Components Control blocks and valves

Legend for Fig. 8-24 (load holding valve):

(1) Spool

(2) Valve cone

(3) Valve spring

(4) Passage from P to A

(5) Passage from B to T

NOTE: This is a principle drawing only, showing the location of load holding valves in valve block I and III.

Control blocks I and III (3 spool blocks)

The load holding valves are directly fitted into the spools (one on each side).

The load holding valves have three tasks:

When circuit pressure is higher than pump pressure due to attachment weight, these valves prevent dropping of
the attachment, within their sensitive (fine controlling) range.

Due to sudden pressure peaks in the service lines, the valves also protect the pump.

When two pump flows are used for one user, the load holding valves ensure that at least the flow of one pump
reaches the user in case one MRV is defect or no longer properly adjusted.

That means: Up to the max. pressure of the defective valve, both load holding valves are open allowing the flow of
both pumps to the user. Then one valve will be closed by the higher pressure and the flow of one pump only flows
to the user.

Function

In neutral position (upper picture) of the spool (Fig. 8-24, Pos. 1) both valve cones (Fig. 8-24, Pos. 2) are closed
by the springs (Fig. 8-24, Pos. 3).

In a switched position (lower picture), the circuit pressure pushes onto the front area of the valve piston (Fig. 8-24,
Pos. 2).

This force moves the piston against the spring (Fig. 8-24, Pos. 3) and allows the oil to flow from the pump supply
(Fig. 8-24, Pos. 4) to the user port (A) and from port B via boring (Fig. 8-24, Pos. 5) to the return oil passage.

If, due to an external force, the pressure directed to the pump overcomes the pressure in the pump line, this pres-
sure/force closes the valve (direction P to A).

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 35

Travel brake valve Components

8.10 TRAVEL BRAKE VALVE

Fig. 8-25 Travel brake valve

8 - 36 PC3000-6 SHOP-10 06279-xD-GB-1

Components Travel brake valve

Legend for Fig. 8-25:

(1) Valve spool

(2) Spring

(3) Check valve

Task

Travel brake valves control the oil flow from the hydraulic motor to the tank depending on the operating pressure.
This braking action prevents the motors from overspeeding.

Function

Spring force keeps the spool in the lowest flow position. With increasing operating pressure the opening for the
return oil flow becomes larger.

On its way to the hydraulic motor the oil flows from A to A1 or B to B1, depending on the selected travel motion.

Example

The operating pressure at port A moves the spool (Fig. 8-25, Pos. 1) against the force of the spring (Fig. 8-25,
Pos. 2) and opens the way for the return oil (Fig. 8-25, Pos. B1 to B).

The check valve (Fig. 8-25, Pos. 3) prevents a direct oil flow from B1 to B.

If the operating pressure decreases to such an extend that the spring force overcomes the pressure, the flow to
the tank becomes restricted, resulting in braking of the machine.

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 37

4/2 Directional solenoid valves Components

8.11 4/2 DIRECTIONAL SOLENOID VALVES

Fig. 8-26 Directional solenoid valves

8 - 38 PC3000-6 SHOP-10 06279-xD-GB-1

Components 4/2 Directional solenoid valves

Legend for Fig. 8-26:

(1) Housing (4) Solenoid

(2) Control spool (5) Dust cap with stem for manual operation

(3) Plunger (6) Return spring

When there is no flow through the valve, the control spool (Fig. 8-26, Pos. 2) is held in neutral or output position by
means of the return springs (Fig. 8-26, Pos. 6). The control spool (Fig. 8-26, Pos. 2) is operated by means of oil
immersed solenoid (Fig. 8-26, Pos. 4).

The force of the solenoid (Fig. 8-26, Pos. 4) effects the control spool (Fig. 8-26, Pos. 2) by means of the plunger
(Fig. 8-26, Pos. 3) and pushes it from its resting position to the required end position.
This results in free flow from or P to B and A to T.

When the solenoid (Fig. 8-26, Pos. 4) is de-energized, the control spool (Fig. 8-26, Pos. 2) is moved back to its
resting position by means of return springs (Fig. 8-26, Pos. 6).

An optional emergency operating device for manual operation (Fig. 8-26, Pos. 5) allows movement of the control
spool (Fig. 8-26, Pos. 2) without energizing the solenoid.

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 39

4/3 Directional solenoid valves Components

8.12 4/3 DIRECTIONAL SOLENOID VALVES

Fig. 8-27 4/3 Directional solenoid valve

8 - 40 PC3000-6 SHOP-10 06279-xD-GB-1

Components 4/3 Directional solenoid valves

Legend for Fig. 8-27:

(1) Control spool

(2) Plunger

(3) Solenoids

(4) Reset springs

(5) Housing

These solenoid operated directional spool valves are installed to control the start, stop and direction of an oil flow.

Function

In un-operated condition the control spool (Fig. 8-27, Pos. 1) is held in the neutral position by the reset springs
(Fig. 8-27, Pos. 4). Operation of the control spool takes place by means of oil immersed solenoids (Fig. 8-27,
Pos. 3).

The force of the solenoid (Fig. 8-27, Pos. 3) acts via the plunger (Fig. 8-27, Pos. 2) on the control spool (Fig. 8-27,
Pos. 1) and pushes it from its neutral position into the required end position. This results in the required flow from
P to A and B to T, or from P to B and A to T.

When the solenoid (Fig. 8-27, Pos. 3) is de-energized, the control spool (Fig. 8-27, Pos. 1) is returned to its origi-
nal position by the reset springs (Fig. 8-27, Pos. 4).

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 41

Pressure double stage valve Components

8.13 PRESSURE DOUBLE STAGE VALVE

Fig. 8-28 Pressure double stage valve

8 - 42 PC3000-6 SHOP-10 06279-xD-GB-1

Components Pressure double stage valve

Legend for Fig. 8-28:

(1) Pilot valve with valve seat (8) Set screw

(2) Valve poppet (9) Piston

(3) Compression spring (10) Pin

(4) Main valve with sleeve (11) Jet bore

(5) Main piston (12) Jet bore

(6) Closing spring (13) Lock nut

(7) Set screw (14) Lock nut

Function

The valve poppet (Fig. 8-28, Pos. 2) is connected via the jet bores (Fig. 8-28, Pos. 11 and 12) with port P.

If static pressure increases above the set pressure value, the valve poppet (Fig. 8-28, Pos. 2) opens and allows oil
to flow freely to tank (T1). This oil generates a pressure drop in the spring chamber of the main spool, the closing
force of the spring (Fig. 8-28, Pos. 6) is cancelled, and the main piston (Fig. 8-28, Pos. 5) opens to allow the pump
flow to tank (T2).

Damped opening and closing is obtained by the throttled volumetric change.

By applying external pressure of Pst max = 35 bar to the main spool (Fig. 8-28, Pos. 9) via port X, the pre-tension-
ing of the pressure spring (Fig. 8-28, Pos. 3) is increased by the amount of the piston stroke "S", and system pres-
sure is increased correspondingly.

The setting is fixed by means of the set screw (Fig. 8-28, Pos. 7) and lock nut (Fig. 8-28, Pos. 13); 1 turn of the
screw = 150 bar.

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 43

Hydraulic cylinder Components

8.14 HYDRAULIC CYLINDER

Fig. 8-29 Hydraulic cylinder, layout

8 - 44 PC3000-6 SHOP-10 06279-xD-GB-1

Components Hydraulic cylinder

Legend for Fig. 8-29:

(1) Bushing (17) Back up ring

(2) Grease fitting (18) O-ring

(3) Cylinder head with rod guide and rod seal (19) Hydraulic port to rod side

(4) Snap ring (20) Cylinder head seal to barrel

(5) Piston rod (21) O-ring

(6) Piston seal (22) Back up ring

(7) Cylinder barrel (23) Buffer ring

(8) Main piston seal (24) Rod seal

(9) Back up ring (25) Back up ring for rod buffer ring

(10) Piston (26) Rod packing

(11) Piston nut (27) Rod seal

(12) Bushing (28) Back up ring

(13) Hydraulic port to piston side (29) Dust seal

(14) Set screw connection of piston nut and pis- (30) Dust seal
ton

(15) Set screw secured with a prick-punch (31) Snap ring

(according to work standard)

(16) Rod seal to piston

Function

Hydraulic cylinders (also called linear hydraulic motors) are actuators which convert fluid power into mechanical
power. The cylinders get their power from pressurized hydraulic fluid, typically oil.

Hydraulic cylinders are used at high pressures to produce large forces and precise movements. Therefore they
are constructed of strong materials and designed to withstand large forces.

The hydraulic cylinder is the actuator or "motor" side of the system. The "generator"side of the system is the
hydraulic pump which brings in a regulated flow of oil to the bottom side of the cylinder to move the piston rod out-
wards. The oil in the chamber on the rod side is pushed back to the oil tank.

The force of the cylinder depends on the hydraulic oil pressure and the piston face. The force F is given by the for-
mula F = p A, where p is the pressure (in N/m²) and A is the face (in m²) of the piston the pressure acts on.

That means, that the force of the hydraulic oil can be multiplied as needed, the maximum force is only limited by
the dimension of the piston face.

Structure

The layout of the hydraulic cylinder is shown in Fig. 8-29.

The piston (Fig. 8-29, Pos. 10) separates the two sides of the cylinder barrel internally. To prevent leakage from
one side to the other, the piston is fitted with the piston seal (Fig. 8-29, Pos. 6) and the rod seal (Fig. 8-29,
Pos. 16).

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 45

Hydraulic cylinder Components

At the other side of the cylinder, there are 4 different seal packages:

– a dust seal (Fig. 8-29, Pos. 29) the prevent dirt being drawn into the cylinder
– a rod packing (Fig. 8-29, Pos. 26) as the main seal to the outside
– a buffer ring (Fig. 8-29, Pos. 23) to prevent leakage between the cylinder head and the piston rod
– a cylinder head seal (Fig. 8-29, Pos. 20) to prevent the leakage from the fit between cylinder head and barrel.
The cylinder head (Fig. 8-29, Pos. 10) is bolted to the cylinder barrel (Fig. 8-29, Pos. 7).

NOTE! During commissioning and when new hydraulic cylinders are installed, first of all, the air has to be
bled from the cylinders, refer to the ’air bleeding’ procedure described in 40 TROUBLESHOOTING.

REMARKS: In case abnormal movements of the hydraulic cylinder are noticed, carry out a cylinder bypass test,
refer to 40 TROUBLESHOOTING.

8 - 46 PC3000-6 SHOP-10 06279-xD-GB-1

Components Hydraulic cylinder

Cylinder data markings

Cylinder data markings, with the following information, are located at the retainer flange of the cylinder.

Fig. 8-30

(1) Piston diameter [mm] (7) Last two digits of production year (10=2010)

(2) Piston rod diameter [mm] (8) Cylinder Part No.

(3) Piston stroke [mm] (9) Index letter (optional)

(4) Manufacturer symbol (10) Retainer flange over size (REMAN cyl. only)

(5) Annual counting number of the cylinder (11) Piston oversize (REMAN cyl. only)

(6) Production month (06 = June)

SHOP-10 06279-xD-GB-1 PC3000-6 8 - 47

Auxiliary gear pumps Components

8.15 AUXILIARY GEAR PUMPS

Fig. 8-31 Auxiliary gear pump

(1) Drive shaft (5) Driven gear

(2) Mounting flange (6) Side plate

(3) Pump housing (7) Suction port S

(4) Cover (8) Pressure outlet port P

Function

The auxiliary gear pumps are used for the pilot pressure circuit and PTO gear lubrication.

– SAL 63 - PTO lubrication with a delivery rate of of 63 cm³/rev.

– SAR 56 - pilot oil pump with a delivery rate of of 56 cm³/rev.

NOTE! Make sure to bleed the pump at the suction side for the first start after oil or pump exchange.

REMARKS: All gear pumps are free from maintenance and adjustment.

8 - 48 PC3000-6 SHOP-10 06279-xD-GB-1

Main hydraulic pumps and pump regulation

9 MAIN HYDRAULIC PUMPS

AND PUMP REGULATION

SHOP-10 06279-xD-GB-1 PC3000-6 9 -1

General Main hydraulic pumps and pump regulation

9.1 GENERAL

Fig. 9-1 Hydraulic pumps and suction oil tank

(1) Main pump 1 assembly (5) Cooler fan drive pump (auxiliary pump)

(2) Main pump 2 assembly (6) Pilot oil pump (auxiliary pump)

(3) Main pump 3 assembly (7) PTO

(4) PTO oil circulation pump (auxiliary pump) (8) Suction oil tank

9 -2 PC3000-6 SHOP-10 06279-xD-GB-1

Main hydraulic pumps and pump regulation General

Description

The rotative energy from Diesel engine drives the gears in the PTO (Fig. 9-1, Pos. 7) via a coupling. The gearbox
drives the main pump assemblies (Fig. 9-1, Pos. 1...3) and the auxiliary pumps (Fig. 9-1, Pos. 4...6).
The pumps generate the hydraulic oil flow for the hydraulic system.

Each main pump assembly (tandem pump) consists of two single pumps and one impeller pump. The impeller
pump at the pump suction side supports the main pump with oil from the suction oil tank (Fig. 9-1, Pos. 9).

Each main pump has a drive through shaft, so auxiliary pumps can be flanged directly onto the main pump head.

– Main pump 1 has no auxiliary pump.

– Main pump 2 is equipped with an auxiliary pump for the oil cooler fan.
– Main pump 3 is equipped with an auxiliary pump for the PTO lubrication.

SHOP-10 06279-xD-GB-1 PC3000-6 9 -3

General Main hydraulic pumps and pump regulation

9.1.1 PUMP LOCATIONS AND PUMP DATA

Fig. 9-2 Hydraulic pump locations

(1) Single main pump 1a (swash plate type) (8) Single main pump 3a (swash plate type)

(2) Single main pump 1b (swash plate type) (9) Charge pump for main pump 3a and 3b

(3) Charge pump for main pump 1a and 1b (10) Pilot oil pump (gear pump)

(4) Single main pump 2a (swash plate type) (11) PTO oil circulating pump (gear pump)

(5) Single main pump 2b (swash plate type) (12) Oil cooler fan pump

(6) Charge pump for main pump 2a and 2b (13) PTO

(7) Single main pump 3a (swash plate type)

9 -4 PC3000-6 SHOP-10 06279-xD-GB-1

Main hydraulic pumps and pump regulation General

Pump data

Description Model Designation Value Unit

Pump volume Vg 2 x 330 cm³

Theoretical flow rate, each Qmax 910 l/min

Main pump 1, 2, 3 HPV 375+375
Max. outlet pressure pmax 310 bar

Drive speed* n 1378 1/min

Pump volume Vg 56 cm³

Theoretical flow rate Qmax 100 l/min

Pilot oil pump SAR(3) 56
Max. outlet pressure pmax 60 bar

Drive speed* n 1800 1/min

Pump volume Vg 63 cm³

PTO oil circulating Theoretical flow rate Qmax 87 l/min

SAL(2) 63
pump Max. outlet pressure pmax 7.5 bar

Drive speed* n 1378 1/min

Pump volume Vg 125 cm³

Theoretical flow rate Qmax 172 l/min

Oil cooler fan pump HPF 125
Max. outlet pressure pmax 240 bar

Drive speed* n 1378 1/min

Table 9-1 Pump data chart

Pump type / designation:

– HPV375+375 tandem pump:

High Pressure pump Variable with 375 cm³ capacity each, at front and rear pump
– SAL(2) 63:
SAL = Model type, (3) = SAE size standard, 63 cm³ capacity
– SAR(3) 56:
SAL = Model type, (3) = SAE size standard, 56 cm³ capacity
– HPF 125:
High Pressure pump Fixed with 125 cm³ capacity

SHOP-10 06279-xD-GB-1 PC3000-6 9 -5

Main pumps Main hydraulic pumps and pump regulation

9.2 MAIN PUMPS

9.2.1 HYDRAULIC PUMP TYPE HPV375+375

Fig. 9-3 Main pump (tandem pump) overview

(1) Front pump (swash plate type) (5r) VC valve for rear (r) single pump

(2) Rear pump (swash plate type) (6) Swash plate angle indicator - front pump

(3) Servo valve (7) Swash plate angle indicator - rear pump

(4f) EPC valve for front (f) single pump (8) Cover for drive through shaft flange

(4r) EPC valve for rear (r) single pump (9) Discharge port - front pump

(5f) VC valve for front (f) single pump (10) Discharge port - rear pump

9 -6 PC3000-6 SHOP-10 06279-xD-GB-1

Main hydraulic pumps and pump regulation Main pumps

General

The hydraulic drive consists of 3 tandem pumps (each 910 l/min, total volume 2730 l/min). The hydraulic system
consists of work equipment, slew circuit, and travel drive. The sub-circuits are fed by the auxiliary pumps.

Description

Each main pump consist of two separate swash plate pumps (Fig. 9-3, Pos. 1 & 2) which are assembled in line
and one impeller pump on the suction side.

Both single pumps in each main pump are individually regulated by a servo valve (Fig. 9-3, Pos. 3) with integrated
EPC valves (Fig. 9-3, Pos. 4f / 4r) and VC valves (Fig. 9-3, Pos. 5f / 5r).
The servo valve controls the swash plate angle.

SHOP-10 06279-xD-GB-1 PC3000-6 9 -7

Main pumps Main hydraulic pumps and pump regulation

9.2.1.1 MAIN PUMP SECTIONAL DRAWINGS

Fig. 9-4 Main pump (tandem pump) sectional drawings

9 -8 PC3000-6 SHOP-10 06279-xD-GB-1

Main hydraulic pumps and pump regulation Main pumps

Legend for Fig. 9-4:

A Main pump (tandem pump) top view (11) Main drive shaft bearing

B Main pump (tandem pump) side view (12) Pump valve plate

(1) Main spline shaft (13) Inner pump bearing

(2) Qmin stop bolt (14) Coupling sleeve

(3) Swash plate - front pump (15) Bevel gear for impeller pump

(4) Slipper pad (16) Drive shaft coupling for auxiliary pump

(5) Swash plate governor (17) Case drain (leak oil)

(6) Servo piston (18) Pump outlet, high pressure

(7) Qmax stop bolt (19) Impeller pump

(8) Pump barrel (20) Pump intake, suction chamber

(9) Pump cylinder (Ph) Controlled shuttle valve output pressure

(10) Swash plate - rear pump (Ps) VC valve output pressure

Function

The engine speed and torque are transmitted to the shaft (Fig. 9-4, Pos. 1) of the main pump.

The suction chamber (Fig. 9-4, Pos. 20) between the pumps is equipped with an impeller pump (Fig. 9-4, Pos. 19)
acting as charge pump. The impeller pump is driven from the drive shaft (Fig. 9-4, Pos. 1) via bevel gears
(Fig. 9-4, Pos. 15).

The swash plate angle is changed by the servo piston (Fig. 9-4, Pos. 6).
This servo piston is moved by an attached servo valve (Fig. 9-3, Pos. 3) according to the signals from the
EPC valve.

REMARKS: For further information relating the servo valve refer to refer to section 9.2.2 on page 9-10.

The piston motion is transmitted to the swash plate (Fig. 9-4, Pos. 3 / 10) by means of the swash plate governor
(Fig. 9-4, Pos. 5). The swash plate governor also gives a feedback to the servo valve.

When the swash plate angle becomes larger, the pump delivery (Q) increases.

The servo piston (Fig. 9-4, Pos. 6), has different diameters at both sides.
The controlled shuttle valve output pressure (Ph) from the servo valve is constantly led to the pressure chamber of
the small diameter piston end.

The pressure chamber of the large diameter piston end is supplied with the pump control pressure (Ps) from the
VC valve.

The dependency of Ph-pressure and Ps-pressure, and the ratio between the servo piston’s diameters controls the
movement of the servo piston.

SHOP-10 06279-xD-GB-1 PC3000-6 9 -9

Main pumps Main hydraulic pumps and pump regulation

9.2.2 SERVO VALVE

Fig. 9-5 Servo valve

(1) Servo valve (load sensing valve block) (8) Servo basic pressure port

(2) EPC valve (9) Servo piston

(3) VC valve [10K032] Pump controller CR710

(4) Shuttle valve (Ph) Controlled shuttle valve output pressure

(5) Spring (Pp) Pilot pressure X2 (35±3 bar)

(6) Sleeve (Ps) VC valve output pressure

(7) Spool

9 - 10 PC3000-6 SHOP-10 06279-xD-GB-1

Main hydraulic pumps and pump regulation Main pumps

General

The servo valve consists of the following components which are important for the pump regulation:

– Shuttle valve
– VC valve
– EPC valve

The pump’s swash plate angle is changed with the servo piston (Fig. 9-5, Pos. 10).
This servo piston is moved by a servo valve (Fig. 9-5, Pos. 1) according to the signal (mA) from the pump
controller.

Therefore the servo valve needs external pilot oil supply (X2-pressure). The pilot oil (35±3 bar) keeps the swash
plate in Qmin position until the pump’s output pressure is high enough to support the regulation system.

9.2.2.1 VC VALVE ⇔ SERVO PISTON

REMARKS: VC valve means: Volume Control valve.

General

The VC valve is included in the servo valve (Fig. 9-5, Pos. 1).
It is used to position the servo piston (Fig. 9-5, Pos. 10) according to the output pressure from the EPC valve
(Fig. 9-5, Pos. 2).

Function

The sleeve (Fig. 9-5, Pos. 6) moves to a position where the EPC valve output pressure and the force of spring
(Fig. 9-5, Pos. 5) are balanced.

The movement of the servo piston is fed back to the VC valve (Fig. 9-5, Pos. 3) by the spool (Fig. 9-5, Pos. 7).

The movement of the servo piston changes the opening space of the notch (throttle) between spool and sleeve,
changing the VC valve output (Ps).

REMARKS: For further information about the VC valve operation principle see the following sections on
page 9-12 - 9-14.

NOTICE
FAULTY ADJUSTMENT!
A faulty adjustment causes improper pump regulation.

All adjustment screws are bench tested. Do not change these adjustments.

SHOP-10 06279-xD-GB-1 PC3000-6 9 - 11

Main pumps Main hydraulic pumps and pump regulation

VC valve moving the servo piston into Qmax position

EPC valve
output pressure

Shuttle valve
output pressure

Fig. 9-6 VC valve moving the servo piston to Qmax position

As the EPC valve output pressure increases, the sleeve (Fig. 9-6, Pos. 3) moves upward against the spring
(Fig. 9-6, Pos. 2).

An opening (Fig. 9-6, Pos. A) in the sleeve gets closed, thus closing the VC valve input port.
Oil from the shuttle valve flows directly to the small diameter end of the servo piston (Fig. 9-6, Pos. 5).
At the same time another opening (Fig. 9-6, Pos. B) opens the return line to the tank inside the VC valve
(Fig. 9-6, Pos. 1). Oil from the large diameter end of the servo piston flows via the VC valve back to the tank.

As a result the servo piston is moved toward the Qmax position (Ph > Ps).

REMARKS: As long as the swash plate angle is set to maximum by the servo valve, the shuttle valve output
pressure keeps on moving the servo piston into Qmax position until it reaches the Qmax stop bolt
(Fig. 9-6, Pos. 6).

9 - 12 PC3000-6 SHOP-10 06279-xD-GB-1

Main hydraulic pumps and pump regulation Main pumps

VC valve moving the servo piston into Qmin position

EPC valve
output pressure

Shuttle valve
output pressure

Fig. 9-7 VC valve moving the servo piston to Qmin position

As the EPC valve output pressure decreases, the sleeve (Fig. 9-7, Pos. 3) moves downward by the force of the
spring (Fig. 9-7, Pos. 2).

An opening (Fig. 9-7, Pos. A) in the sleeve opens the VC valve input port.
At the same time another opening (Fig. 9-7, Pos. B) gets closed, thus closing the return line to the tank.
Oil from the shuttle valve flows via the VC valve (Fig. 9-7, Pos. 1) to the large diameter end of the servo piston
(Fig. 9-7, Pos. 5).

As a result the servo piston is moved toward the Qmin position by the different pressure from the VC valve until
it reaches the Qmin stop bolt (Fig. 9-7, Pos. 6).

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Main pumps Main hydraulic pumps and pump regulation

Balance of the servo piston between Qmax and Qmin movement

The movement of the servo piston (Fig. 9-7, Pos. 5) is fed back to the VC valve (Fig. 9-7, Pos. 1) by the spool
(Fig. 9-7, Pos. 4).

The movement of the servo piston changes the opening space of the notch (throttle) between spool (Fig. 9-7,
Pos. 4) and sleeve (Fig. 9-7, Pos. 3), changing the pump control pressure (Ps).

The servo piston stops as soon as the pump discharge pressure is two times higher than the pump control
pressure (ratio Ph: Ps = 2 : 1).

REMARKS: Ratio of pressure receiving areas between small diameter piston and large diameter piston = 1 : 2

When the EPC valve is not activated (Qmin)

The sleeve (Fig. 9-7, Pos. 3) of the VC valve (Fig. 9-7, Pos. 1) does not move if pilot pressure from the EPC valve
is not present.

In this case, the ports (Ph) and (Ps) are connected and the connection between port (Ps) and tank is closed.

Since the pressure at the ports (Ph) and (Ps) is set to the same level, the servo piston (Fig. 9-7, Pos. 5) is moved
toward the Qmin position by the difference in the force resulting from the difference in the pressure receiving areas
until it reaches the Qmin stop bolt (Fig. 9-7, Pos. 6).

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Main hydraulic pumps and pump regulation Main pumps

Please continue reading on the next page.

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Main pumps Main hydraulic pumps and pump regulation

9.2.2.2 EPC VALVE

REMARKS: EPC valve means: Electromagnetic Proportional Control valve.

Fig. 9-8 EPC valve

(1) Valve body (6) Plunger

(2) Spool (7) Auxiliary port (plugged)

(3) Spring (C) Output pressure port (to VC valve)

(4) Rod (P) Pilot pressure port X2 (35±3 bar)

(5) Coil (T) Return oil port to hydraulic tank

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Main hydraulic pumps and pump regulation Main pumps

Function

When the EPC valve receives min~max signal current from the pump controller, it generates the EPC output
pressure proportional to the signal, and outputs it to the VC valve.

– EPC valve signal current decreasing to min:

The spool (Fig. 9-8, Pos. 2) is pushed to the right by spring (Fig. 9-8, Pos. 3).
The pilot pressure port (Fig. 9-8, Pos. P) gets closed, so the pilot oil does not flow to the VC valve.
The pressurized oil from the VC valve at port (Fig. 9-8, Pos. C) is drained to the tank through the return oil port
(Fig. 9-8, Pos. T).
– EPC valve signal current increasing to max:
When a signal current flows to the coil (Fig. 9-8, Pos. 5), the spool (Fig. 9-8, Pos. 2) is moved to the left in
proportion to the signal current.
So the spool begins to open the pilot pressure port (Fig. 9-8, Pos. P) and the output pressure port (Fig. 9-8,
Pos. C), but the return oil port (Fig. 9-8, Pos. T) begins to close.
With increasing signal current this effect on the spool also increases. Thus the pressure on port (C) increases
proportional to the signal current.

At maximum signal current the pilot pressure port (Fig. 9-8, Pos. P) and the output pressure port (Fig. 9-8,
Pos. C) are completely opened. Since the return oil port (Fig. 9-8, Pos. T) is closed, pressurized oil does not
flow to the tank.

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Electronic pump regulation system Main hydraulic pumps and pump regulation

9.3 ELECTRONIC PUMP REGULATION SYSTEM

Fig. 9-9 Pump regulation overview

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Main hydraulic pumps and pump regulation Electronic pump regulation system

Legend for Fig. 9-9:

(1) Main pump (tandem pump) 1

(2) Main pump (tandem pump) 2

(3) Main pump (tandem pump) 3

(4) Pilot oil pump

(5f) VC-valve for front (f) single pump (part of servo valve)

(5r) VC-valve for rear (r) single pump (part of servo valve)

(252.1) Pressure reducing valve X2-pressure (35±3 bar)

[10K032] Pump controller CR710

[52B064] Engine speed sensor

[57K658f] Main pump 1 - EPC valve for front (f) & rear (r) single pump (part of servo valve)
[57K658r]

[57K659f] Main pump 2 - EPC valve for front (f) & rear (r) single pump (part of servo valve)
[57K659r]

[57K660f] Main pump 3 - EPC valve for front (f) & rear (r) single pump (part of servo valve)
[57K660r]

[61B158a~c] Pressure transducer at main control blocks I ~ III (MRV pressure) - for main pump 1 ~ 3

General

The pump regulation is working as an engine load limiting system which ensures optimum use of the power
required for the excavator under varying operating conditions. Also it avoids overload of the engine.
If an unwanted engine overload occurs, the engine speed drops below the maximum engine output speed
(max. power at 1800 1/min) and results in bad excavator performance up to engine problems.

With increasing load the engine torque will rise and the engine speed will drop.

The main engine load indicator is the engine speed. It is indicated by the engine speed sensor 52B064 at the
engine fly wheel. The sensor is directly connected to the pump controller CR710.

The pump’s swash plate angle is changed with a servo piston according to the pressure from the EPC valves.
The EPC valves are directly connected to pump controller.
When it receives signal current from the pump controller it generates the EPC output pressure, proportional to
the signal, and outputs it to the VC valve which moves the servo piston between Qmin and Qmax position.

If the engine speed is stalled to 1800 1/min, the pump controller reduces the pump output volume via the
EPC valves to limit the pump power in order to keep the engine at 1800 1/min (maximum engine power).

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Electronic pump regulation system Main hydraulic pumps and pump regulation

The electronic pump regulation system also includes the following functions:

– Cut-off
– Slew control (volume reduction)
– Diagnostics and monitoring
– Temperature control (by converter relays)

9.3.1 CUT-OFF FUNCTION

Dependent on the engine load the pump controller CR710
reduces the pump output volume to Qmin via the EPC valves
if the pump pressure increases to 312-16 bar.

The pump output pressure signal comes from the pressure

transducer at the high pressure filter.

This function prevents too high oil flow through the main relief
valves (MRV) when the oil flow is restricted or blocked as e.g.
by a cylinder in final stop position.

Cut-off for clam close (FSA only)

The secondary relief valve (SRV) of the clam close circuit

is reduced to a lower pressure as the normal main relief valve
(MRV) pressure.

To protect the SRV against to high oil flow the pump controller
CR710 reduces the cut-off setting for main pump #2 to Fig. 9-10
150±30 bar.

The pump output pressure signal comes from the pressure transducer [51B158a] at the high pressure filter (main
control block 1).

Dependent on the engine load the pump controller CR710 reduces the main pump #2 output volume to Qmin
via the EPC valves 57K659f & 57K659r.

The cut-off function can be checked at the swash plate angle

indicator (Fig. 9-11).

At cut-off the pump angle indicator shows Qmin position.

Fig. 9-11 Swash plate angle indicator

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Main hydraulic pumps and pump regulation Electronic pump regulation system

9.3.2 SLEW CONTROL (VOLUME REDUCTION)

Any slewing motion is monitored by pressure switch 10B047 in
the pilot control frame.
If pilot pressure for slewing is present relay 10K073 gets ener-
gized via pressure switch 10B047.
The energized relay 10K073 switches the input of the pump con-
troller CR710 active (24 V).
Thus, during slewing the pump controller CR710 sets main pump
#3 to Qswing position via the EPC valves 57K660f & 57K660r.
So only a reduced oil flow from main pump #3 is available for
the slewing to prevent overspeeding of the slew motor.

The respective pump is out of the regular regulation (torque prior-

ity) so that the slew system operates with fixed pump volume.

Fig. 9-12

9.3.3 DIAGNOSTICS AND MONITORING

The pump regulation system has its own diagnostics and monitoring system called Multimonitor.

For further information refer to section 9.5 on page 9-30.

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Electronic pump regulation system Main hydraulic pumps and pump regulation

9.3.4 TEMPERATURE CONTROL

In combination with a PT100 sensor temperature converter relays
monitor the adjusted temperature limits. When the adjusted tem-
perature limit is exceeded the corresponding relay immediately
change the switching condition and the LED (Fig. 9-13, Pos 2)
lights up.

The temperature control is done by the following converter relays:

– [11K100] switching point T2

reduction preload pressure - ½Qmax

– [11K026] switching point T3 - hydraulic cooler fan speed

medium fan speed
– [11K171] switching point hydraulic cooler fan speed
maximum fan speed
– [11K039] switching point T4
bucket cut-off
Fig. 9-13 Temperature converter relay

REMARKS: As long as the temperature is below "T2" (depending on the hydraulic oil type shown in Table 9-2
main pumps #1–3 are in ½Qmax position for warm up.

9.3.4.1 TEMPERATURE ADJUSTMENT (HYDRAULIC OIL VISCOSITY)

1. Adjust the scale drum (Fig. 9-13, Pos. 1) of the concerned converter relay to the standard values according to
the filled oil viscosity, refer to Table 9-2.

Hydraulic oil temperature charts

Shell Tellus Shell Tellus

Arctic Arctic
ISO oil viscosity grade VG 22 VG 32 VG 46 VG 68 VG 100
S4VX32 S4VX32
(new) (stabilized)
11K100 adjust temperature limit value
to switching point (T2) 9°C 16°C 25°C 32°C 39°C 10°C 5°C
reduction preload pressure - ½Qmax
11K026 adjust temperature limit value
to switching point (T3) 32°C 41°C 50°C 58°C 67°C 46°C 39°C
medium fan speed
11K171 adjust temperature limit value
to switching point 48°C 59°C 69°C 75°C 75°C 75°C 71°C
maximum fan speed
11K039 adjust temperature limit value
to switching point (T4) 58°C 69°C 79°C 85°C 85°C 85°C 81°C
bucket cut-off

Table 9-2 Hydraulic oil temperature charts

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Main hydraulic pumps and pump regulation Electronic pump regulation system

9.3.4.2 ADJUSTMENT OF THE LINE RESISTANCE COMPENSATION

REMARKS: The line resistance compensation is bench adjusted and must only be done in case of replacing the
temperature converter relay, the connected sensor, or after repairs on the sensor wiring.

1. Unplug the concerned temperature sensor (see Table 9-3) and measure the electrical resistance between the
two open ends of the sensor using a multimeter. Use Table 2-11 on page 2-12 to convert the measured resis-
tance into temperature.

2. Adjust the scale drum (Fig. 9-13, Pos. 1) of the converter relay to a higher value as the temperature deter-
mined in step 1. The LED (Fig. 9-13, Pos. 2) is switched OFF.

3. Turn the scale drum slowly to a lower value until the LED is switched ON.
The value at the scale drum should be the same as determined in step 1.

4. If necessary correct with potentiometer (Fig. 9-13, Pos. 3) using a small screw driver.

Converter relays and connected temperature sensors

Converter relay Connected temperature sensor

11K100 40B075

11K026 40B040

11K171 40B171

11K039 59B015

Table 9-3

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Pump controller CR710 Main hydraulic pumps and pump regulation

9.4 PUMP CONTROLLER CR710

Fig. 9-14 Pump controller CR710

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Main hydraulic pumps and pump regulation Pump controller CR710

Legend for Fig. 9-14:

(1) X2 switch board

(2) Pump controller CR710 [10K032]

(3) Two LEDs (red & green)

[11P046] Multimonitor MH801

CN1~CN3 Sockets at the pump controller

General

The three main pumps (tandem pumps) are controlled and regulated by the pump controller CR710 (Fig. 9-14,
Pos. 2). All six single pumps of the three tandem pumps are individually regulated via servo valves.
Controller and Multimonitor [11P046] are connected by CAN bus.
The Multimonitor is used for diagnostic and adjusting purposes.

The pump controller is mounted at the R.H. side wall in the cab base and the Multimonitor is mounted at the X2
board (Fig. 9-14, Pos. 1).

The pump controller uses digital and analog input signals to regulate the output signals to the EPC valves
of each main pump. At the bottom side there are three connectors CN1, CN2 and CN3.

The CR710 includes a self diagnostics via LEDs (Fig. 9-14, Pos. 3):

– If the red LED is switched on, the processor is not in operation.

– If the green LED is switched on, the controller is in normal operation mode.
– If the green LED is blinking, some trouble occurred, e.g. a disconnection to an EPC valve.
In addition a trouble code is generated and stored in the Multimonitor.
Also this trouble code is displayed on the K+ display in the operator’s cab.

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Pump controller CR710 Main hydraulic pumps and pump regulation

9.4.1 CONNECTOR AND PIN ARRANGEMENT AT CR710 (10K032)

REMARKS: Refer to Fig. 9-14.

Pin Nomination in Wiring Diagram Connection

CN1.1 Adjustment mode 11R096 - potentiometer

CN1.3 Pump pressure 2 61B158b - pressure sensor for tandem pump 2

CN1.5 CLS refill grease barrel 62B108b - digital sensor

CN1.5 CLS end line switch pres. 80B043 - pressure switch

CN1.7 Adjustment power 11R097 - potentiometer

CN1.9 Pump pressure 1 61B158a - pressure sensor for tandem pump 1

CN1.11 SLS refill grease barrel 62B109b - digital sensor

CN1.12 SLS end line switch pres. 62B046 - pressure switch

CN1.13 Adjustment primary P-factor 11R098 - potentiometer

11F21b - circuit breaker

CN1.18 Refill hydr. oil
via 11K011a - relay

CN1.20 Pump pressure 3 61B158c - pressure sensor for tandem pump 3

GND for potentiometers 11R096~98 and

CN1.21 Analog GND
pump pressure sensors 61B158a~c

Supply voltage for potentiometers 11R096~98 and

CN1.22 +5V/80mA max
pump pressure sensors 61B158a~c

11F21b - circuit breaker

CN1.23 Slew
via 11K073 - relay

11F21b - circuit breaker

CN1.24 Clam close
via 11K191 - relay

Table 9-4 Socket CN1

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Pin Nomination in Wiring Diagram Connection

CN2.3 Machine 11 GND

CN2.5 DIGITAL INPUT 20S036 - Emergency stop operator’s cab

CN2.6 DIGITAL INPUT Fire extinguishing system cab base

CN2.7 Memory 11S104 - service switch "Primary P-factor"

CN2.12 CAN0_SH CAN line_Shield

CN2.15 DIGITAL INPUT 51S033d - emergency stop switch engine

CN2.17 Memory 11S100 - service switch "Adjustment Mode"

CN2.22 CAN0_L CAN line_Low

CN2.24 PWR CTR EXT 11X336 - diagnostic connector WAKE INPUT signal

CN2.25 DIGITAL INPUT 51S033e - emergency stop switch engine room / ladder

CN2.27 Down 11S101 - adjustment switch "down"

CN2.32 CAN0_H CAN line_High

CN2.35 DIGITAL INPUT 51S058 - safety switch

CN2.37 Up 11S102 - adjustment switch "up"

CN2.39 Engine speed 52B064 - pick up (engine speed sensor)

CN2.40 Engine speed 52B064 - pick up (engine speed sensor)

Table 9-5 Socket CN2

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Pump controller CR710 Main hydraulic pumps and pump regulation

Pin Nomination in Wiring Diagram Connection

CN3.1 ECM-Power (Power for controller) 11F041 - circuit breaker

CN3.2 Sol. Drive Power 11F061 - circuit breaker

CN3.3 SOL COM 1 GND for EPC valves 57K658f and 57K658r

57K660f - EPC valve

CN3.5 Pump swash plate 5
(tandem pump 3, front pump)

57K658f - EPC valve

CN3.6 Pump swash plate 1
(tandem pump 1, front pump)

CN3.10 DIGITAL INPUT 10B156 - pressure sensor 22 bar clam cut-off

CN3.11 ECM-Power (Power for controller) 11F041 - circuit breaker

CN3.12 Sol. Drive Power 11F061 - circuit breaker

CN3.13 SOL COM 2 GND for EPC valves 57K659f and 57K659r

CN3.14 Key signal 11F061a - circuit breaker

57K660r - EPC valve

CN3.15 Pump swash plate 6
(tandem pump 3, rear pump)

57K658r - EPC valve

CN3.16 Pump swash plate 2
(tandem pump 1, rear pump)

45S051 / 052 - emergency stop switch

CN3.20 DIGITAL INPUT
engine stop from ground (option)

CN3.21 Power GND 11 GND

CN3.22 Sol. Drive Power 11F061 - circuit breaker

CN3.23 SOL COM 3 GND for EPC valves 57K660f and 57K660r

CN3.24 Key signal 11F061a - circuit breaker

57K659f - EPC valve

CN3.26 Pump swash plate 3
(tandem pump 2, front pump)

CN3.29 DIGITAL INPUT 61S033b - emergency stop switch at valve blocks

11K100a - relay
CN3.30 Q 1/2
via 11K079 - relay

CN3.31 Power GND 11 GND

CN3.32 Power GND 11 GND

CN3.33 Power GND 11 GND

CN3.36 Pump swash plate 4 57K659r - EPC valve - tandem pump 2, rear pump

11S150 - Qmin service switch

CN3.40 Q min
11K079 - relay

Table 9-6 Socket CN3

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Please continue reading on the next page.

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Multimonitor Main hydraulic pumps and pump regulation

9.5 MULTIMONITOR

Fig. 9-15 Multimonitor

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Main hydraulic pumps and pump regulation Multimonitor

Legend for Fig. 9-15:

(1) X2 switch board

(2) Multimonitor MH801 [11P046]

(3) Initialization screen

(4) Softkeys for: Return - Enter - movements on the screen

(5) Key pad for entering data

General

The Multimonitor is used for:

– Monitoring the actual individual main pump data from the pump controller CR710,
e.g.: pump pressure, engine speed, VC valve current, refer to section 9.5.2 on page 9-34.
– Recording and displaying fault messages from the pump controller CR710, refer to section 9.5.3 on
page 9-38.
– Adjustment of the pump controller parameters, refer to section 9.5.5 on page 9-43.

The Multimonitor is mounted at the X2 board in order to protect the unit against dust and humidity.
Via CAN bus it is connected to the pump controller CR710.

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Multimonitor Main hydraulic pumps and pump regulation

Multimonitor main control - flow chart

Fig. 9-16 Multimonitor main control - flow chart

Start screen

When the main key is switched ON the start screen is

displayed on the Multimonitor.

Fig. 9-17 Start screen

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Main hydraulic pumps and pump regulation Multimonitor

9.5.1 SERVICE MENU SCREEN

Entering Key code for Service Menu access

1. Keep key 4 of the key pad pressed.

2. Simultaneously enter the digits 1, 2, 3.

3. Then release key 4.

Fig. 9-18 Key code

Service menu

Function of control keys in the Service Menu:

– F3 - Scroll down
– F4 - Scroll up
– F5 - Quit screen
– F6 - Confirm selection

Fig. 9-19 Service menu screen

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Multimonitor Main hydraulic pumps and pump regulation

9.5.2 SERVICE MENU, OPTION: 01 MONITORING

1. Press F3 or F4 to move up or down in the menu.

2. Select menu option 01 Monitoring and press softkey F6.

REMARKS: All monitoring items of PC3000 (Diesel & Electric)

are then shown on the screen.

Fig. 9-20 Service menu screen

3. Press F1 or F2 to toggle the screens.

Fig. 9-21 Monitoring, screens 1 - 7

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Main hydraulic pumps and pump regulation Multimonitor

All data of the pump controller CR710 can be displayed in the Multimonitor.

4. Press F3 or F4 to move up or down in the list.

5. To select an item from the list press softkey F6 or enter the

item number on the key pad.

It is possible to select up to six items at the same time (Fig. 9-22).

After selecting an item the select box turns red and the next select
box is activated.

REMARKS: Selecting a binary (ON/OFF) type item,

e.g. 03810 Torque distribute sig(1), may reduce the
number of selectable items from the list due to its Fig. 9-22 Multi selection
multiline output (refer to Fig. 9-24).

6. Double press or hold softkey F6 or enter 99999 on the key pad to start monitoring.

Examples for monitoring:

Fig. 9-23 shows 6 selected exemplary items.

Fig. 9-23 Example screen

Fig. 9-24 shows 4 selected exemplary items including binary

(ON/OFF) type items.

Due to multiline output of the binary type items, there is only

space for 4 items on the screen.

Fig. 9-24 Example screen with binary

items

REMARKS: All monitoring items (Fig. 9-21) of PC3000 (Diesel & electric) can be selected but only the items
that are relevant for your machine will be displayed, refer to Table 9-7 on page 9-36 for further
information.

If the CAN-bus between pump controller and Multimonitor is faulty (e.g. disconnection) the displayed
values will be blank.

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Multimonitor Main hydraulic pumps and pump regulation

Relevant monitoring items

Item number Monitoring item Remarks

00200 Controller Model Select

13100 P1 Absorption Torque

13101 P2 Absorption Torque

13102 P3 Absorption Torque

13103 P4 Absorption Torque

13104 P5 Absorption Torque

13105 P6 Absorption Torque

13116 All Real Absorption Torque

01100 Pump1_2 pressure

01102 Pump3_4 pressure

01104 Pump5_ 6pressure

01304 P1 EPC Sol. Curr.

01305 P2 EPC Sol. Curr.

01306 P3 EPC Sol. Curr.

01307 P4 EPC Sol. Curr.

01308 P5 EPC Sol. Curr.

01309 P6 EPC Sol. Curr.

01006 Engine speed

03809 Engine derate sig. Binary (multiline output)

03810 Torque distribute sig(1) Binary (multiline output)

03811 Torque distribute sig(2) Binary (multiline output)

03812 Cut off sig. Binary (multiline output)

03813 Adjustment input Binary (multiline output)

03814 Machine select input Binary (multiline output)

03815 Flow regulation sig(1) Binary (multiline output)

03816 Flow regulation sig(2) Binary (multiline output)

03817 Output sig Binary (multiline output)

13400 Adjusting Item

13401 Adjusting Item name

13402 Adjusting Memory

13403 Adjusting Parameter

13404 Adjusting unit name

13500 Prim P-factor saved

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Item number Monitoring item Remarks

13501 Prim P-factor Potentio

20229 Pump Con. Ass'y P/N

20403 Pump Con. Serial No

20230 Pump Con. Prog. P/N

20212 Pump Con. Prog. Version

20227 Monitor Ass'y P/N

20402 Monitor Serial No

20228 Monitor Prog. P/N

20200 Monitor Prog. Version

Table 9-7 Relevant monitoring items

9.5.2.1 HOLD FUNCTION

1. If you want to freeze the data, press softkey F4. The yellow
mark moves to Hold, at the bottom of the display.

2. To show the current monitoring data again, press softkey F3.

The yellow mark moves to Monitoring again.

Fig. 9-25 Monitoring - Hold activated

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Multimonitor Main hydraulic pumps and pump regulation

9.5.3 SERVICE MENU, OPTION: 02 ABNORMALITY RECORD

1. Press F3 or F4 to move up or down in the menu.

2. Select menu option 02 Abnormality Record and press

softkey F6.

Fig. 9-26 Service menu screen

3. Press F1 or F2 to toggle the screens.

The FAILURE HISTORY is displayed in the reverse order of the

failure occurrence.
The failure message which was saved lastly, is shown at the top
of the displayed chart.

The internal memory records max. 20 failure messages.

As long as a failure code is still active the letter "E" is displayed

between the failure message’s code number and text.

Fig. 9-27 Failure history

9.5.3.1 TROUBLESHOOTING PROCEDURES

For the pump controller troubleshooting procedures refer to chapter 40 TROUBLESHOOTING,
section 9 Troubleshooting by pump controller codes.

To delete any failure record from the display:

1. Keep key 4 of the key pad pressed.

2. Simultaneously enter the digits 1, 2, 3.

3. Then release key 4.

Selection now becomes possible.

4. Press softkey F3 or F4 to move up or down in failure history

then press F6 to select the failure record to delete.
Or press softkey F2 to delete all inactive (without "E")
failure records.
Fig. 9-28

REMARKS: It is only possible to delete inactive failure records.

5. In the upcoming window for deletion (Fig. 9-29) confirm by pressing softkey F6, or quit the delete action by
pressing softkey F5.

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Main hydraulic pumps and pump regulation Multimonitor

Fig. 9-29 Window for deletion

SHOP-10 06279-xD-GB-1 PC3000-6 9 - 39

Multimonitor Main hydraulic pumps and pump regulation

9.5.3.2 TABLE OF PUMP-CONTROLLER-CODES (MULTI MONITOR)

Trouble messages of the pump controller are displayed on the KOMTRAX Plus display and on the Multimonitor in
the cab base.

Explanation of the columns in the following Trouble Code chart

Column 1 Trouble Code Code number

1 = displayed once
Column 2 Display 2 = displayed at each occurrence
0 = NOT displayed

Column 3 Acoustic Signal 1 = an acoustic signal sounds if the relating trouble occurs

Column 4 7 segments LED Short-code of the displayed Trouble Code

0 = Red
Colour Code of
1 = Yellow
Column 5 Top Message
2 = Green
(K+ display only)
3 = Blue

Instruction Number of the Instruction Message, which is displayed together with

Column 6
Message No. the Trouble Code (numbers 1 - 58)

The error/message is saved in a History Memory:

1 = Service & Operator History
Column 7 Memory 2 = Service History
3 = Operator History
4 = KOMTRAX Plus History

Column 8 Message Displayed text of the Trouble Code

Table of Pump-Controller-Codes:
Color on (K+ only)
7 segments LED
Acoustic Signal

Message No.
Instruction

Memory
Display

Trouble-
Message
Code

DXAAKA 1 1 1 40 2 Solenoid-1(Pump-1) open circuit

DXAAKB 1 1 1 40 2 Solenoid-1(Pump-1) short circuit
DXABKA 1 1 1 40 2 Solenoid-2(Pump-2) open circuit
DXABKB 1 1 1 40 2 Solenoid-2(Pump-2) short circuit
DXACKA 1 1 1 40 2 Solenoid-3(Pump-3) open circuit
DXACKB 1 1 1 40 2 Solenoid-3(Pump-3) short circuit
DXADKA 1 1 1 40 2 Solenoid-4(Pump-4) open circuit
DXADKB 1 1 1 40 2 Solenoid-4(Pump-4) short circuit
DXAEKA 1 1 1 40 2 Solenoid-5(Pump-5) open circuit
DXAEKB 1 1 1 40 2 Solenoid-5(Pump-5) short circuit
DXAFKA 1 1 1 40 2 Solenoid-6(Pump-6) open circuit

9 - 40 PC3000-6 SHOP-10 06279-xD-GB-1

Main hydraulic pumps and pump regulation Multimonitor

Color on (K+ only)

7 segments LED
Acoustic Signal

Message No.
Instruction

Memory
Display
Trouble-
Message
Code

DXAFKB 1 1 1 40 2 Solenoid-6(Pump-6) short circuit

DHPEMA 1 1 1 40 2 Pump-1/2 pressure sensor abnormality
DHPGMA 1 1 1 40 2 Pump-3/4 pressure sensor abnormality
DHPJMA 1 1 1 40 2 Pump-5/6 pressure sensor abnormality
DLE2MA 1 1 1 40 2 Engine speed sensor abnormality
DA25KP 1 1 1 40 2 5V sensor1 power abnormality
DA22KK 1 1 1 40 2 Pump Solenoid Power Low Error
DA29KQ 1 1 1 40 2 Model Selection Abnormality

SHOP-10 06279-xD-GB-1 PC3000-6 9 - 41

Multimonitor Main hydraulic pumps and pump regulation

9.5.4 SERVICE MENU, OPTION: 03 DEFAULT

1. Press F3 or F4 to move up or down in the menu.

2. Select menu option 03 Default and press softkey F6.

Fig. 9-30 Service menu screen

1. Press F3 or F4 to move up or down in the menu.

2. Select the desired unit system for monitoring and press

softkey F6.

Fig. 9-31 Unit menu screen

Unit system Item Unit

Pressure MPa

Torque Nm

SI Current mA

Temperature °C

Voltage V

Pressure psi

Torque lbft

Imperial Current mA

Temperature °F

Voltage V

Pressure bar

Torque kgm

Metric Current mA

Temperature °C

Voltage V

Table 9-8 Unit systems

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Main hydraulic pumps and pump regulation Multimonitor

9.5.5 SERVICE MENU, OPTION: 04 ADJUSTMENT

All electronically controlled pump parameters like regulation values can be selected, checked and adjusted in this
menu.

The adjustment of the pump regulation system in this menu must be done via the switches [11S100], [11S101],
[11S102], and [11S104] (Fig. 9-32) and via the potentiometers [11R096] & [11R098] (Fig. 9-33) at the X2 board.

[11S100] Memory (except Primary P-factor)

[11S101] Down

[11S102] Up

[11S104] Memory Primary P-factor

Fig. 9-32 Adjustment switches

[11R096] Adjustment (except Primary P-factor)

[11R098] Adjustment Primary P-factor

Fig. 9-33 Adjustment potentiometers

SHOP-10 06279-xD-GB-1 PC3000-6 9 - 43

Multimonitor Main hydraulic pumps and pump regulation

1. Press F3 or F4 to move up or down in the menu.

2. Select menu option 04 Adjustment and press softkey F6.

Fig. 9-34 Service menu screen

The first parameter to be shown is a dummy entry with item No. 0.

3. Press 11S101 or 11S102 (Fig. 9-32) to toggle Item No. and

Item Name.

4. Select a parameter from Table 9-9 on page 9-45 and press

softkey F6.

– Record Data is the data set stored in the pump controller.

– Current Data is the adjustment value via 11R096 / 11R098.

Fig. 9-35 Parameter (0) screen

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Main hydraulic pumps and pump regulation Multimonitor

9.5.6 ADJUSTABLE PARAMETERS

NOTICE
FAULTY PARAMETER SETTING!
A faulty setting results in improper controlling function and it may cause bad excavator performance and
machine operation in the emergency mode (performance approx. 75%).

Other parameters than the parameters shown in Table 9-9 must not be changed.

Item Item
Item name Item name
No. No.

1 Primary P-factor 39 Sol_adj_max_P1

23 Sol_adj_min_P1 40 Sol_adj_max_P2

24 Sol_adj_min_P2 41 Sol_adj_max_P3

25 Sol_adj_min_P3 42 Sol_adj_max_P4

26 Sol_adj_min_P4 43 Sol_adj_max_P5

27 Sol_adj_min_P5 44 Sol_adj_max_P6

28 Sol_adj_min_P6

Table 9-9 Adjustable parameters

9.5.7 EMERGENCY MODE

In the emergency mode the pump controller automatically uses the internal data (default values). When these
default values are used for regulation, the machine performance is approx. 75% of the standard performance.

To leave the emergency mode:

Pressing switches 11S100, 11S101 and 11S102 simultaneously for 5 seconds will reset all values to the default
factory settings.

NOTE! After such a reset the values of the above table (except Primary P-factor) need new adjustment.

For the Primary P-factor refer to next section.

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Multimonitor Main hydraulic pumps and pump regulation

9.5.8 DESCRIPTION OF THE PRIMARY P-FACTOR

Primary P-factor is equivalent to PID-control.

PID-control: Balances the "hydraulic torque" in dependency on the "drive torque" (Diesel engine).

General

The drive torque must always be higher than the hydraulic torque.

Otherwise the following effects occur:

– Engine hunting
– Hydraulic system jerking
If one or both of the above effects occur, fine-tuning with the Primary P-factor is necessary, in order to find a rem-
edy.

Fine-tuning

If engine hunting - The internal fixed value of the Primary P-factor is 100%
- Use potentiometer 11R098 for adjustment
- Adjust down to a value below 100%

If hydraulic system jerking - The internal fixed value of the Primary P-factor is 100%
- Use potentiometer 11R098 for adjustment
- Adjust up to a value above 100%

Procedure for fine-tuning of Primary P-factor

Step 1 Hydraulic oil temperature at T3 (shovel in operation condition).

Step 2 Shovel in loading mode (loaded bucket).

Step 3 In shovel loading mode adjust the Primary P-factor up or down via potentiometer 11R098.

NOTE! Adjust gradually in steps of 2% until the problem of "engine hunting" or "hydraulic system
jerking" is solved.

9.5.8.1 ADJUSTMENT, ITEM 1: PRIMARY P-FACTOR

1. In menu 04 Adjustment press 11S101 or 11S102 (Fig. 9-32)
to toggle Item No. and Item Name.

2. Select Item No. 1 and press softkey F6.

3. Adjust current data at the potentiometer 11R098 (Fig. 9-32).

Effective range: 60...120%
Nominal value: 100%

4. Press 11S104 (Fig. 9-32) to save the adjusted data in the

controller.

Fig. 9-36 Parameter screen 1

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Main hydraulic pumps and pump regulation Multimonitor

9.5.9 ADJUSTMENT, ITEMS 23...28:

SOL_ADJ_MIN_P1...SOL_ADJ_MIN_P6
After installation of new or repaired Komatsu pumps it is necessary to adjust the EPC current from every single
pump of the tandem pump with individual Qmin values belonging to them.

REMARKS: Also refer to the Parts & Service News AH12503 latest edition.

1. Check the data plate (Fig. 9-37, Pos. 1) on the main pump.

Example:

608 - 613 <- Front pump

622 - 631 <- Rear pump

^
Code for Qmin values (refer to Table 9-10)

Fig. 9-37 Data plate

2. Select adjustment value from the below table.

mA 253 258 263 268 273 278 283 288 293 298 303 308 313 318 323
- - - - - - - - - - - - - - -
258 263 268 273 278 283 288 293 298 303 308 313 318 323 328

Code E D C B A 9 8 7 6 5 4 3 2 1 0

Value 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Table 9-10 Qmin current values for EPC valves

3. In menu 04 Adjustment press 11S101 or 11S102 (Fig. 9-32)

to toggle Item No. and Item Name.

4. Select Item No. 23...30 and press softkey F6.

5. Adjust current data at the potentiometer 11R096 (Fig. 9-32).

In the adjustment mode an integer from 0...14 is displayed on
the adjustment screen (refer to Fig. 9-38).

6. Press 11S100 (Fig. 9-32) to save the adjusted data in the

controller.

Fig. 9-38 Parameter screen 23 (example)

SHOP-10 06279-xD-GB-1 PC3000-6 9 - 47

Multimonitor Main hydraulic pumps and pump regulation

9.5.10 ADJUSTMENT, ITEMS 39...44:

SOL_ADJ_MAX_P1...SOL_ADJ_MAX_P6
After installation of new or repaired Komatsu pumps it is necessary to adjust the EPC current from every single
pump of the tandem pump with individual Qmax values belonging to them.

REMARKS: Also refer to the Parts & Service News AH12503 latest edition.

1. Check the data plate (Fig. 9-39, Pos. 1) on the main pump.

Example:

608 - 613 <- Front pump

622 - 631 <- Rear pump

^
Code for Qmax values (refer to Table 9-11)

Fig. 9-39 Data plate

2. Select adjustment value from the below table.

mA 560 571.5 576.5 581.5 586.5 591.5 596.5 601.5 606.5 611.5 616.5 621.5 626.5 631.5 636.5
- - - - - - - - - - - - - - -
571.5 576.5 581.5 586.5 591.5 596.5 601.5 606.5 611.5 616.5 621.5 626.5 631.5 636.5 641.5

Code E D C B A 9 8 7 6 5 4 3 2 1 0

Value 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Table 9-11 Qmax current values for EPC valves

3. In menu 04 Adjustment press 11S101 or 11S102 (Fig. 9-32)

to toggle Item No. and Item Name.

4. Select Item No. 39...46 and press softkey F6.

5. Adjust current data at the potentiometer 11R096 (Fig. 9-32).

In the adjustment mode an integer from 0...14 is displayed on
the adjustment screen (refer to Fig. 9-40).

6. Press 11S100 (Fig. 9-32) to save the adjusted data in the

controller.

Fig. 9-40 Parameter screen 39 (example)

9 - 48 PC3000-6 SHOP-10 06279-xD-GB-1

Main hydraulic pumps and pump regulation Multimonitor

9.5.11 AVAILABLE PARAMETERS LIST

NOTICE
FAULTY PARAMETER SETTING!
A faulty setting results in improper controlling function and it may cause bad excavator performance and
machine operation in the emergency mode (performance approx. 75%).

Other parameters than the parameters shown in Table 9-9 must not be changed.

Item No. Item name SI unit Adjustment Inner

range Nominal
Data

0 No select

1 Primary P-factor % 60...120 100

2 P_tm 1…5000 225

3 I_tm 1…3000 1172

4 D_tm 1…2000 1

5 n'set rpm 1…2100 1800

6 T_match Nm 1…20000 5830

7 Sol_ofs_P1 % 80…120 100

8 Sol_ofs_P2 % 80...120 100

9 Sol_ofs_P3 % 80...120 100

10 Sol_ofs_P4 % 80...120 100

11 Sol_ofs_P5 % 80...120 100

12 Sol_ofs_P6 % 80...120 100

23 Sol_adj_min_P1 - 0…14 7

24 Sol_adj_min_P2 - 0…14 7

25 Sol_adj_min_P3 - 0…14 7

26 Sol_adj_min_P4 - 0…14 7

27 Sol_adj_min_P5 - 0…14 7

28 Sol_adj_min_P6 - 0…14 7

39 Sol_adj_max_P1 - 0…14 7

40 Sol_adj_max_P2 - 0…14 7

41 Sol_adj_max_P3 - 0…14 7

42 Sol_adj_max_P4 - 0…14 7

43 Sol_adj_max_P5 - 0…14 7

44 Sol_adj_max_P6 - 0…14 7

55 Pres_adj_CO1[1] bar 1…350 312

SHOP-10 06279-xD-GB-1 PC3000-6 9 - 49

Multimonitor Main hydraulic pumps and pump regulation

Item No. Item name SI unit Adjustment Inner

range Nominal
Data

56 Pres_adj_CO1[2] bar 1…350 312

57 Pres_adj_CO1[3] bar 1…350 312

58 Pres_adj_CO1[4] bar 1…350 312

59 Pres_adj_CO1[5] bar 1…350 312

60 Pres_adj_CO1[6] bar 1…350 312

Table 9-12 Pump controlling parameters

REMARKS: After all adjustments are done: Main key switch OFF for approx. 10 seconds.

9 - 50 PC3000-6 SHOP-10 06279-xD-GB-1

Main hydraulic pumps and pump regulation Multimonitor

9.5.12 SERVICE MENU, OPTION: 05 DISPLAY SETUP

1. Press F3 or F4 to move up or down in the menu.

2. Select menu option 05 Display Setup and press softkey F6.

Fig. 9-41 Service menu screen

(1) Brightness adjustment

In the first display of the screen the brightness field is highlighted

yellow.

1. For adjusting the brightness press softkey F3 or F4 until the

desired condition is obtained.

2. Press softkey F6 in order to save the selected brightness

adjustment and to change over to the contrast adjustment.

Fig. 9-42 Screen adjustment

(2) Contrast adjustment

The contrast field is now highlighted yellow.

1. For increasing the contrast press softkey F3 or F4 until the desired condition is obtained.

2. Press softkey F6 in order to save the selected contrast adjustment and to change over to the back light
adjustment.

(3) Back Light adjustment

The back light field is now highlighted yellow.

1. For increasing the back light press softkey F3 or F4 until the desired condition is obtained.

2. Press softkey F6 in order to save the selected back light adjustment and to return to the brightness
adjustment.

3. To return to the default values (yellow arrow, Fig. 9-42, Pos. 4) for brightness, contrast, and back light
press softkey F2.

4. To leave the above adjustment screens without saving any adjustment, press softkey F5 and return to
the Service menu screen.

SHOP-10 06279-xD-GB-1 PC3000-6 9 - 51

Checks and adjustments Main hydraulic pumps and pump regulation

9.6 CHECKS AND ADJUSTMENTS

9.6.1 ENGINE POWER CHECK

Fig. 9-43 Test ports and pressure gauges & MRV adjustment

9 - 52 PC3000-6 SHOP-10 06279-xD-GB-1

Main hydraulic pumps and pump regulation Checks and adjustments

REMARKS: Carry out checks and settings only at normal operating temperature (T3).

Reason for Power Check

Check the basic necessary drive power / engine performance to exclude engine or hydraulic problems in case
of troubleshooting, e.g. when the loading performance is bad or movements are slow.

How to perform the Power Check

1. To prevent overheating during Power Check, it is necessary to unplug the solenoid valves 57K506a and
57K506b in order to run the fans (hydraulic oil cooler) at max. speed.

2. Connect pressure gauges (0~400 bar) to the test ports M11.1 - M11.3 (Fig. 9-43).

REMARKS: The pressure gauges must be certified,

max. bias ±2 bar,
or use digital pressure gauges.

3. Turn the main relieve valves (MRV) of the three main control blocks two turns counterclockwise.

4. Start the engine and let it run at high idle (operating temperature T3 is reached).

5. Switch 11S103 to Qmax ON (position 2).

6. Stall the engine with all three pumps simultaneously pressur-

ized e.g.:
FSA = curl bucket to final stop
BHA = raise boom & bucket to final stop

Keep the lever in final position.

Fig. 9-44

7. Keep pressurized and adjust all three MRV simultaneously to 155±5 bar, see "Adjusting the MRV" on
page 9-55.

REMARKS: The pressure at all three MRV must be equal.

NOTE! Do not keep up the pressure for more than 1 minute.

8. Now the max. load of all three pumps should stall the engine to 1800 ± 5 rpm.

Evaluation of the engine Power Check:

If the stall speed (1800 rpm) is reached with this pressure adjustment  engine OK
If the stall speed is far below 1800 rpm  insufficient engine power

a) In this case first check fuel and air filters for clogging.
b) Then check the engine blow-by pressure - standard: 5~10 mbar.
c) If any problem is found, clean, repair or replace as necessary.
d) After repair repeat the Power Check.

SHOP-10 06279-xD-GB-1 PC3000-6 9 - 53

Checks and adjustments Main hydraulic pumps and pump regulation

Fig. 9-45 Test ports and pressure gauges & MRV adjustment

9 - 54 PC3000-6 SHOP-10 06279-xD-GB-1

Main hydraulic pumps and pump regulation Checks and adjustments

9. Release the control levers to neutral.

10. After test re-adjust the MRV of the control blocks to the nominal value (315+5 bar), see "Adjusting the MRV"
below.

11. Switch 11S103 to Qmax OFF (position 1).

12. Stop the engine.

13. Remove the pressure gauges.

14. Reconnect the solenoid valves 57K506a and 57K506b.

Adjusting the MRV

1. Remove protective cap (Fig. 9-45, Pos. 1).

2. Loosen lock nut (Fig. 9-45, Pos. 2).

3. Turn set screw (Fig. 9-45, Pos. 3) clockwise to increase the pressure, or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

9.6.2 CUT-OFF FUNCTION CHECK

Dependent of the engine load the pump controller CR710 reduces the pump output volume to Qmin via the
EPC valves. The cut-off pressure range is fix-programmed in the pump controller (CR710). These values can not
be changed (312-16 bar = 296 bar).

296 bar  Start of cut-off function

(312-16 bar) Pump moves to Qmin

312 bar  Cut-off function completed

Pump is kept in Qmin

The cut-off function check is performed e.g. in case of trouble-

shooting.

Fig. 9-46 Cut-off diagram

1. Connect pressure gauges (0~400 bar) to the test ports M11.1 - M11.3 (Fig. 9-45).

2. Start the engine and let it run at high idle (operating temperature T3 is reached).

SHOP-10 06279-xD-GB-1 PC3000-6 9 - 55

Checks and adjustments Main hydraulic pumps and pump regulation

3. Apply max. load to all pumps e.g.:

FSA: curl bucket to final stop
BHA: raise boom & bucket to final stop until the hydraulic system stalls
Keep the lever in final position.

4. Set the main pressure at the respective MRV to 312 -16 bar, see "Adjusting the MRV" on page 9-55.

5. Check the pump angle indicator (Fig. 9-47).

At cut-off pressure (312 bar) the swash plate angle indicator
must show Qmin position.

REMARKS: The engine speed is an additional indicator for the

cut-off function:
At cut-off pressure (312 bar) the engine speed
increases to approx. 1870 rpm.

6. Re-adjust the MRV of the control blocks to the nominal value

(310+5 bar), see "Adjusting the MRV" on page 9-55.

7. Release the control levers and stop the engine.

8. Remove the pressure gauges.

Fig. 9-47 Swash plate angle indicator

9.6.2.1 CUT-OFF FOR CLAM CLOSE (FSA ONLY)

1. Connect a (digital) pressure gauge (0 - 400 bar) to the test port M11.1 (Fig. 9-45).

2. Start the engine and let it run at high idle (operating temperature T3 is reached).

3. Close the clam and keep the pedal fully pressed.

4. Set the main pressure at MRV on control block I to 150±30 bar, see "Adjusting the MRV" on page 9-55.

5. Check the pump angle indicator (Fig. 9-47) at main pump #1.
At cut-off pressure (150±30 bar) the pump angle indicator must show Qmin position.

6. Re-adjust the MRV of the control block I to the nominal value (315+5 bar), see "Adjusting the MRV" on
page 9-55.

7. Release the pedal and stop the engine.

8. Remove the pressure gauge.

9 - 56 PC3000-6 SHOP-10 06279-xD-GB-1

Main hydraulic pumps and pump regulation Checks and adjustments

Please continue reading on the next page.

SHOP-10 06279-xD-GB-1 PC3000-6 9 - 57

Engine speed sensor (pick-up) Main hydraulic pumps and pump regulation

9.7 ENGINE SPEED SENSOR (PICK-UP)

Fig. 9-48 Engine speed sensor

9 - 58 PC3000-6 SHOP-10 06279-xD-GB-1

Main hydraulic pumps and pump regulation Engine speed sensor (pick-up)

Legend for Fig. 9-48:

(1) Speed sensor (pick-up)

(2) Flywheel housing

(3) Flywheel

(4) Lock nut

9.7.1 GENERAL
The engine speed sensor [52B064] (pick-up) uses the flywheel teeth to count RPM. With running engine, each
tooth induces a voltage in the pick-up coil. That causes an alternative voltage at the pick-up coil wire. With engine
at stand still, there is no voltage at the pick-up wire.
The frequency of this alternative voltage will increase or decrease proportional to the engine RPM.

9.7.2 ENGINE SPEED SENSOR (PICK-UP) ADJUSTMENT

NOTICE
SENSOR DAMAGE!
The sensor gets damaged when it comes in contact with the flywheel while engine is running.

Do not adjust the sensor while engine is running.

1. Stop the engine.

2. Disconnect the harness connector at the pick-up wire.

3. Loosen the lock nut (Fig. 9-48, Pos. 4).

4. Turn out the pick-up (Fig. 9-48, Pos. 1) completely ccw.

5. Check front end of the pick-up and clean it from magnetic chips and dirt.

6. Turn the pick-up completely in (cw) until it touches the flywheel (Fig. 9-48, Pos. A).

7. Turn the pick-up ¾ turn out (ccw) (Fig. 9-48, Pos. B).

8. Secure the pick-up with lock nut.

9. Measure the resistance of the speed sensor [52B064] at the sensor connector (Fig. 9-48, Pos. C).
Nominal Value: 850 ± 50Ω

10. Re-connect the harness connector.

SHOP-10 06279-xD-GB-1 PC3000-6 9 - 59

Engine speed sensor (pick-up) Main hydraulic pumps and pump regulation

Fig. 9-49 Wiring Diagram - engine RPM signal (52B064) to pump controller

Final Check

11. Start the engine.

12. Check the REAL TIME MONITOR 01 Engine 1, screen 1 of 5.

The displayed engine speed monitored by the Quantum engine control should be the same as for the speed
sendor [52B064].

1. Stop the engine.

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Operating hydraulics

10 OPERATING
HYDRAULICS

SHOP-10 06279-xD-GB-1 PC3000-6 10 - 1

General Operating hydraulics

10.1 GENERAL

Fig. 10-1 Overall view of the operating hydraulic

10 - 2 PC3000-6 SHOP-10 06279-xD-GB-1

Operating hydraulics General

Legend for Fig. 10-1:

(1) Main pump 1 (6) Attachment cylinders

(2) Main pump 2 (7) Slew motor

(3) Main pump 3 (8) Rotary joint

(4) Main control blocks (9) Travel motors

(5) Distributor manifold

General Information

The control main block (Fig. 10-1, Pos. 4), the piping to the distributor manifold (Fig. 10-1, Pos. 5) and the con-
necting hoses to the attachment are different between the backhoe attachment (BHA) and the front shovel attach-
ment (FSA).

REMARKS: If a conversion is required, contact the service department for further information.

Function:

REMARKS: Also refer to the hydraulic circuit diagram.

Each main pump (Fig. 10-1, Pos. 1 to 3) delivers oil trough the high pressure filter to port P of the main control
blocks I to III. This results in three main circuits.

If all spools of the control blocks are in neutral position, the oil leaves the blocks at port T and returns via return oil
manifold, back pressure valve (depend on oil temperature) and return oil filters into the tank.

The function of the back pressure valve ensures that, depending on the temperature, an appropriate amount of oil
is forced through the coolers.

If a control lever or pedal is actuated, pilot pressure oil moves the spools of the control blocks, directing the oil flow
from the main control blocks to one side of the cylinders or motors.
From the other side of the cylinders or motors the oil returns to the control block and from there via the return oil
circuit back into the tank.

Each circuit is equipped with a MRV in the main control blocks and with one or more SRV and at least one flow
restrictor for the lowering function.

SHOP-10 06279-xD-GB-1 PC3000-6 10 - 3

General Operating hydraulics

10.1.1 FLOATING SYSTEM (FSA)

Fig. 10-2 Floating function of boom and stick cylinders (FSA)

10 - 4 PC3000-6 SHOP-10 06279-xD-GB-1

Operating hydraulics General

Legend for Fig. 10-2:

(132.1) Single control block (pilot controlled floating spool valve) - Stick lowering function

(132.2) Single control block (pilot controlled floating spool valve) - Stick lowering function

(132.3) Single control block (pilot controlled floating spool valve) - Boom lowering function

[61K632] Solenoid valve - stick floating function

[61K635] Solenoid valve - boom floating function

General

Normally, the excavator is operated with activated float function for boom down and stick in. That means that when
lowering boom or stick, these components are in "floating position".
For deactivation of the floating position, two push-buttons are installed:

– 20S095 in the right control lever for the boom down function,
– 20S098 in the left control lever for the stick in function.
Press the respective button and keep it depressed as long as the floating position shall be deactivated.
When releasing the button, the floating position is activated again.

Function:

The additionally installed single control blocks connect the piston side of the cylinders with the rod side and also
with the hydraulic oil tank:

– 132.1 and 132.2 for the stick cylinders

– 132.3 for the boom cylinders
In normal operation mode the pilot pressure oil is directed via 4/2-directional solenoid valves [61K632] and
[61K635] to the single control blocks when lowering the boom or stick.

If a pressurised lowering of the cylinders is required, the pilot pressure oil is directed via the activated 4/2-direc-
tional valves to the main control blocks.

The 4/2-directional control valves are controlled by push buttons located in the control levers (joysticks).

Boom 20S095 ON  61K635 ON  Floating position deactivated

20S095 OFF  61K635 OFF  Floating position activated

Stick 20S098 ON  60K632 ON  Floating position deactivated

20S098 OFF  60K632 OFF  Floating position activated

Table 10-1 Float function ON/OFF, FSA

REMARKS: Due to the two different operation modes for lowering, the lowering speed of boom and stick cylinder
must be adjusted twice - floating position deactivated and floating position activated.

At deactivated boom floating function the solenoid valve [61K632] holds the single control block 132.3 in neutral
position.

At deactivated stick floating function the solenoid valve [61K635] holds the single control blocks 132.1 and 132.2 in
neutral position.

SHOP-10 06279-xD-GB-1 PC3000-6 10 - 5

Checks and adjustments of the main relief valve (MRV) Operating hydraulics

10.2 CHECKS AND ADJUSTMENTS OF THE MAIN

RELIEF VALVE (MRV)

Fig. 10-3 Checks and adjustments of the main relief valves (MRV)

10 - 6 PC3000-6 SHOP-10 06279-xD-GB-1

Operating hydraulics Checks and adjustments of the main relief valve (MRV)

There are three main relief valves (MRV) installed, one in each main control block, to limit the maximum pump
supply pressure (operating pressure).

MRV in Test port Functions FSA

control block

Pump circuit I I M11.1 Boom Clam Bucket filling Travel

Stick extend

Pump circuit II II M11.2 Boom Stick Bucket Travel

Pump circuit III III M11.3 Slew Bucket Stick

Table 10-2 Pump circuits, FSA

MRV in Test port Functions BHA

control block

Pump circuit I I M11.1 Boom Stick Bucket Travel

Pump circuit II II M11.2 Boom Stick Bucket Travel

Pump circuit III III M11.3 Slew Bucket Stick

Table 10-3 Pump circuits, BHA

Each pump circuit can be checked or adjusted individually by selecting one function of the required pump circuit.

Checking:

1. Connect pressure gauges (0~400 bar) to the test ports M11.1 - M11.3 (Fig. 10-3).

REMARKS: The pressure gauges must be certified,

max. bias ±2 bar,
or use digital pressure gauges.

2. Start the engine and let it run at high idle (operating temperature T3 is reached).

3. Stall the engine with all three pumps simultaneously pressurized e.g.:
FSA = curl bucket to final stop
BHA = raise boom & bucket to final stop

Keep the lever in final position.

4. Read the pressure. Nominal value: 315+5 bar.

5. If necessary, adjust the MRV of the control blocks to the nominal value, refer to "Adjusting:" on page 10-8.
Release and stall the system a few times and check if the pressure is in balance.
Correct the adjustment if necessary.

6. Release the control levers and stop the engine.

7. Remove the pressure gauges.

SHOP-10 06279-xD-GB-1 PC3000-6 10 - 7

Checks and adjustments of the main relief valve (MRV) Operating hydraulics

Adjusting:

1. Remove protective cap (Fig. 10-3, Pos. 1).

2. Loosen lock nut (Fig. 10-3, Pos. 2).

3. Turn set screw (Fig. 10-3, Pos. 3) clockwise to increase the pressure, or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

REMARKS: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm).
Otherwise internal leaks could occur, resulting in loud flow noises and wrong adjustments.

10 - 8 PC3000-6 SHOP-10 06279-xD-GB-1

Operating hydraulics Checks and adjustments of the main relief valve (MRV)

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SHOP-10 06279-xD-GB-1 PC3000-6 10 - 9

Hydraulics for the attachment cylinders Operating hydraulics

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 & FSA), BOOM UP

Fig. 10-4 Checks and adjustments of the SRVs, boom cylinders piston side (BHA & FSA)

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Operating hydraulics Hydraulics for the attachment cylinders

There are 3 secondary relief valves (SRV) installed, 2 at the distributor manifold and 1 in main control block II to
limit the maximum possible pressure peaks in the lines.

Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs) it is necessary
to increase the main relief pressure for testing and adjusting purposes.

Valve FSA Valve BHA Pressure Test Port Location

MRV circuit I M11.1 (High pressure filter) Control block I

SRV 66.3*A1 MRV circuit II M11.2 (High pressure filter) Control block II
MRV circuit II

SRV 63.8 M16.1 Manifold section B

SRV 63.9 M16.10 Manifold section N

Table 10-4 Relief valves, locations and designations

*A1 Port
A1 at the main control block

REMARKS: Fig. 10-4 shows an FSA-manifold, the location of the respective SRVs at the BHA-manifold is analo-
gously identical.
For further information relating the manifold refer to section 8.3 on page 8-10 (FSA) or refer to
section 8.4 on page 8-12 (BHA).

Checking

1. Connect pressure gauges (0 - 400 bar) to all test ports listed in Table 10-4.

2. Start the engine and let it run at high idle (operating temperature T3 is reached).

3. Switch pumps to Qmin via switch 11S150 at the X2-switch board.

4. Extend the boom cylinders (boom up) to the final stop position until the hydraulic system stalls.

5. Slowly increase the pump supply line pressure by turning in set screws (Fig. 10-4, Pos. 3) of both MRVs in
control block I and II while observing the pressure gauges. Stop as soon as the pressure does not rise any fur-
ther, see "Adjusting of the MRV" on page 10-12.
The gauges should show: 350±5 bar.

REMARKS: Since the piston sides of the boom cylinders are protected by several SRVs, the pressure gauges
show the pressure of the valve with the lowest setting. Even when the gauges show the required
pressure, it is possible that one or more valves have a higher setting.
To ensure that only the SRVs open during checks and adjustments, it is necessary to further
increase the setting of the MRVs to 360 - 370 bar.

6. Turn set screw (Fig. 10-4, Pos. 3) of the MRVs ½ turn further in. The pressure will remain at the value shown
in step 5.

Adjusting

7. Adjust all SRVs equally until all gauges show a pressure of 350±5 bar, see "Adjusting of the SRV" on
page 10-12.
Adjust in steps of ¼ turn regarding the following sequence: 63.8  63.9  63.3*A1

8. Reduce the pressure at SRV 63.8 at first to a value below the required value, then increase the pressure to the
required value of 350±5 bar while observing all gauges, see "Adjusting of the SRV" on page 10-12.

REMARKS: Now all gauges will show the same value of 350±5 bar, but only SRV 63.8 has the correct setting.

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Hydraulics for the attachment cylinders Operating hydraulics

9. Proceed with the other SRVs in the same manner in the following sequence: 63.9  63.3*A1

NOTICE
STRONG PULSATION OF THE RETURN LINE HOSES!
Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be
avoided.

Repeat the adjusting procedure until the oil returns well-balanced via all involved secondary relief valves.

10. After the check / adjustment is finished reset the MRV at control block(s) to 315+5 bar, see "Adjusting of the
MRV" below.

11. Stop the engine.

12. Switch pumps back to operation mode (Qmin OFF) via switch 11S150 at the X2-switch board.

13. Remove the pressure gauges.

REMARKS: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm).
Otherwise internal leaks could occur, resulting in loud flow noises and wrong adjustments.

Adjusting of the SRV

1. Remove protective cap (Fig. 10-4, Pos. 4) of the SRVs.

2. Loosen lock nut (Fig. 10-4, Pos. 5).

3. Turn set screw (Fig. 10-4, Pos. 6) clockwise to increase the pressure or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

Adjusting of the MRV

1. Remove protective cap (Fig. 10-4, Pos. 1).

2. Loosen lock nut (Fig. 10-4, Pos. 2).

3. Turn set screw (Fig. 10-4, Pos. 3) clockwise to increase the pressure, or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

10 - 12 PC3000-6 SHOP-10 06279-xD-GB-1

Operating hydraulics Hydraulics for the attachment cylinders

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SHOP-10 06279-xD-GB-1 PC3000-6 10 - 13

Hydraulics for the attachment cylinders Operating hydraulics

10.3.1.2 BOOM CYLINDER, PISTON ROD SIDE (BHA & FSA), BOOM DOWN

Fig. 10-5 Checks and adjustments of the SRVs, boom cylinders piston rod side (BHA & FSA)

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Operating hydraulics Hydraulics for the attachment cylinders

There is 1 secondary relief valve (SRV) installed in the main control block II, to limit the maximum possible pres-
sure peaks in the lines.

Since the opening pressure of the SRV is higher than the setting of the main relief valves (MRVs), it is necessary
to increase the main relief pressure for testing and adjusting purposes.

Valve FSA Valve BHA Pressure Test Port Location

MRV circuit I M11.1 (High pressure filter) Control block I

SRV 66.3*B1 SRV 66.3

M11.2 (High pressure filter) Control block II
MRV circuit II MRV circuit II

Table 10-5 Relief valves, locations and designations

*B1 Port
B1 at the main control block

Checking

1. Connect pressure gauges (0 - 400 bar) to all test ports listed in Table 10-5.

2. Start the engine and let it run at high idle (operating temperature T3 is reached).

3. Switch pumps to Qmin via switch 11S150 at the X2-switch board.

4. FSA only:
With button 20S095 in R.H. joystick activated (floating function OFF), retract the boom cylinders (boom down)
to the final stop position until the hydraulic system stalls.

BHA only:
Retract the boom cylinders (boom down) to the final stop position until the hydraulic system stalls.

5. Slowly increase the pump supply line pressure by turning in set screws (Fig. 10-5, Pos. 3) of both MRVs in
control block I and II while observing the pressure gauges. Stop as soon as the pressure does not rise any fur-
ther, see "Adjusting of the MRV" on page 10-16.
The gauges should show: 350±5 bar.

REMARKS: To ensure that only the SRV opens during checks and adjustments, it is necessary to further
increase the setting of the MRVs to 360 - 370 bar.

6. Turn set screw (Fig. 10-5, Pos. 3) of the MRVs ½ turn further in. The pressure will remain at the value shown
in step 5.

Adjusting

7. Adjust the pressure at the SRV to the required value of 350±5 bar while observing all gauges, see "Adjusting
of the SRV" on page 10-16.
Adjust in steps of ¼ turn.

NOTICE
STRONG PULSATION OF THE RETURN LINE HOSES!
Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be
avoided.

Repeat the adjusting procedure until the oil returns well-balanced via all involved secondary relief valves.

8. After the check / adjustment is finished reset the MRVs at control blocks to 315+5 bar, see "Adjusting of the
MRV" on page 10-16.

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Hydraulics for the attachment cylinders Operating hydraulics

9. Stop the engine.

10. Switch pumps back to operation mode (Qmin OFF) via switch 11S150 at the X2-switch board.

11. Remove the pressure gauges.

REMARKS: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm).
Otherwise internal leaks could occur, resulting in loud flow noises and wrong adjustments.

Adjusting of the SRV

1. Remove protective cap (Fig. 10-5, Pos. 4) of the SRVs.

2. Loosen lock nut (Fig. 10-5, Pos. 5).

3. Turn set screw (Fig. 10-5, Pos. 6) clockwise to increase the pressure or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

Adjusting of the MRV

1. Remove protective cap (Fig. 10-5, Pos. 1).

2. Loosen lock nut (Fig. 10-5, Pos. 2).

3. Turn set screw (Fig. 10-5, Pos. 3) clockwise to increase the pressure, or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

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SHOP-10 06279-xD-GB-1 PC3000-6 10 - 17

Hydraulics for the attachment cylinders Operating hydraulics

10.3.1.3 STICK CYLINDERS, PISTON SIDE (FSA), STICK OUT

Fig. 10-6 Checks and adjustments of the SRVs, stick cylinders piston side (FSA)

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Operating hydraulics Hydraulics for the attachment cylinders

There are 4 secondary relief valves (SRV) installed, 3 at the distributor manifold and 1 in main control block III, to
limit the maximum possible pressure peaks in the lines.

Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs) it is necessary
to increase the main relief pressure for testing and adjusting purposes.

Valve Press. test port Location

MRV circuit I M11.1 (High pressure filter) Control block I

MRV circuit II M11.2 (High pressure filter) Control block II

SRV 66.6
M11.3 (High pressure filter) Control block III
MRV circuit III

SRV 65.2 M16.5 Manifold section G

SRV 63.5 M16.6 Manifold section J

SRV 63.6 M16.7 Manifold section J

Table 10-6 Relief valves, locations and designations

Checking

1. Connect pressure gauges (0 - 400 bar) to all test ports listed in Table 10-6.

2. Start the engine and let it run at high idle (operating temperature T3 is reached).

3. Switch pumps to Qmin via switch 11S150 at the X2-switch board.

4. Extend the stick cylinders (stick out) to the final stop position until the hydraulic system stalls.

5. Slowly increase the pump supply line pressure by turning in set screws (Fig. 10-6, Pos. 3) of the MRVs in con-
trol blocks while observing the pressure gauges. Stop as soon as the pressure does not rise any further, see
"Adjusting of the MRV" on page 10-20.
The gauges should show: 350±5 bar.

REMARKS: Since the piston sides of the stick cylinders are protected by several SRVs, the pressure gauges
show the pressure of the valve with the lowest setting. Even when the gauges show the required
pressure, it is possible that one or more valves have a higher setting.
To ensure that only the SRVs open during checks and adjustments, it is necessary to further
increase the setting of the MRV to 360 - 370 bar.

6. Turn set screw (Fig. 10-6, Pos. 3) of the MRVs ½ turn further in. The pressure will remain at the value shown
in step 5.

Adjusting

7. Adjust all SRVs equally until all gauges show a pressure of 350±5 bar, see "Adjusting of the SRV" on
page 10-20.
Adjust in steps of ¼ turn regarding the following sequence: 65.2  63.5  63.6  66.6

8. Reduce the pressure at SRV 65.2 at first to a value below the required value, then increase the pressure to the
required value of 350±5 bar while observing all gauges, see "Adjusting of the SRV" on page 10-20.

REMARKS: Now all gauges will show the same value of 350±5 bar, but only SRV 65.2 has the correct setting.

9. Proceed with the other SRVs in the same manner in the following sequence: 63.5  63.6  66.6

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Hydraulics for the attachment cylinders Operating hydraulics

NOTICE
STRONG PULSATION OF THE RETURN LINE HOSES!
Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be
avoided.

Repeat the adjusting procedure until the oil returns well-balanced via all involved secondary relief valves.

10. After the check / adjustment is finished reset the MRV at control block(s) to 315+5 bar, see "Adjusting of the
MRV" below.

11. Stop the engine.

12. Switch pumps back to operation mode (Qmin OFF) via switch 11S150 at the X2-switch board.

13. Remove the pressure gauges.

REMARKS: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm).
Otherwise internal leaks could occur, resulting in loud flow noises and wrong adjustments.

Adjusting of the SRV

1. Remove protective cap (Fig. 10-6, Pos. 4) of the SRVs.

2. Loosen lock nut (Fig. 10-6, Pos. 5).

3. Turn set screw (Fig. 10-6, Pos. 6) clockwise to increase the pressure or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

Adjusting of the MRV

1. Remove protective cap (Fig. 10-6, Pos. 1).

2. Loosen lock nut (Fig. 10-6, Pos. 2).

3. Turn set screw (Fig. 10-6, Pos. 3) clockwise to increase the pressure, or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

10 - 20 PC3000-6 SHOP-10 06279-xD-GB-1

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Hydraulics for the attachment cylinders Operating hydraulics

10.3.1.4 STICK CYLINDERS, PISTON SIDE (BHA), STICK IN

Fig. 10-7 Checks and adjustments of the SRVs, stick cylinders piston side (BHA)

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Operating hydraulics Hydraulics for the attachment cylinders

There is one secondary relief valves (SRV) installed in main control blocks II to limit the maximum possible pres-
sure peaks in the lines.

Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs) it is necessary
to increase the main relief pressure for testing and adjusting purposes.

Valve Press. test port Location

SRV 66.7
M11.2 (High pressure filter) Control block II
MRV circuit II

MRV circuit III M11.3 (High pressure filter) Control block III

Table 10-7 Relief valves, locations and designations

Checking

1. Connect pressure gauges (0 - 400 bar) to all test ports listed in Table 10-7.

2. Start the engine and let it run at high idle (operating temperature T3 is reached).

3. Switch pumps to Qmin via switch 11S150 at the X2-switch board.

4. Extend the stick cylinders (stick in) to the final stop position until the hydraulic system stalls.

5. Slowly increase the pump supply line pressure by turning in set screws (Fig. 10-7, Pos. 3) of both MRVs in
control block II and III while observing the pressure gauges. Stop as soon as the pressure does not rise any
further, see "Adjusting of the MRV" on page 10-24.
The gauges should show: 350±5 bar.

REMARKS: Since the piston sides of the stick cylinders are protected by several SRVs, the pressure gauges
show the pressure of the valve with the lowest setting. Even when the gauges show the required
pressure, it is possible that one or more valves have a higher setting.
To ensure that only the SRVs open during checks and adjustments, it is necessary to further
increase the setting of the MRVs to 360 - 370 bar.

6. Turn set screw (Fig. 10-7, Pos. 3) of the MRVs ½ turn further in. The pressure will remain at the value shown
in step 5.

Adjusting

7. Adjust the pressure at the SRV to the required value of 350±5 bar while observing all gauges, see "Adjusting
of the SRV" on page 10-16.
Adjust in steps of ¼ turn.

NOTICE
STRONG PULSATION OF THE RETURN LINE HOSES!
Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be
avoided.

Repeat the adjusting procedure until the oil returns well-balanced via all involved secondary relief valves.

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Hydraulics for the attachment cylinders Operating hydraulics

8. After the check / adjustment is finished reset the MRV at control blocks to 315+5 bar, see "Adjusting of the
MRV" below.

9. Stop the engine.

10. Switch pumps back to operation mode (Qmin OFF) via switch 11S150 at the X2-switch board.

11. Remove the pressure gauges.

REMARKS: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm).
Otherwise internal leaks could occur, resulting in loud flow noises and wrong adjustments.

Adjusting of the SRV

1. Remove protective cap (Fig. 10-7, Pos. 4) of the SRVs.

2. Loosen lock nut (Fig. 10-7, Pos. 5).

3. Turn set screw (Fig. 10-7, Pos. 6) clockwise to increase the pressure or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

Adjusting of the MRV

1. Remove protective cap (Fig. 10-7, Pos. 1).

2. Loosen lock nut (Fig. 10-7, Pos. 2).

3. Turn set screw (Fig. 10-7, Pos. 3) clockwise to increase the pressure, or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

10 - 24 PC3000-6 SHOP-10 06279-xD-GB-1

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Hydraulics for the attachment cylinders Operating hydraulics

10.3.1.5 STICK CYLINDERS, PISTON ROD SIDE (FSA), STICK IN

Fig. 10-8 Checks and adjustments of the SRVs, stick cylinders piston rod side (FSA)

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Operating hydraulics Hydraulics for the attachment cylinders

There are 2 secondary relief valves (SRVs) installed in main control blocks II and II to limit the maximum possible
pressure peaks in the lines.

Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs) it is necessary
to increase the main relief pressure for testing and adjusting purposes.

Valve Press. test port Location

SRV 66.7
M11.2 (High pressure filter) Control block II
MRV circuit II

SRV 66.2
M11.3 (High pressure filter) Control block III
MRV circuit III

Table 10-8 Relief valves, locations and designations

Checking

1. Connect pressure gauges (0 - 400 bar) to all test ports listed in Table 10-8.

2. Start the engine and let it run at high idle (operating temperature T3 is reached).

3. Switch pumps to Qmin via switch 11S150 at the X2-switch board.

4. With button (20S098) in L.H. joystick activated (floating function OFF), retract the stick cylinders (stick in) to
the final stop position until the hydraulic system stalls.

5. Slowly increase the pump supply line pressure by turning in set screws (Fig. 10-8, Pos. 3) of both MRVs in
control block II and III while observing the pressure gauges. Stop as soon as the pressure does not rise any
further, see "Adjusting of the MRV" on page 10-28.
The gauges should show: 350±5 bar.

REMARKS: Since the piston rod sides of the stick cylinders are protected by several SRVs, the pressure gauges
show the pressure of the valve with the lowest setting. Even when the gauges show the required
pressure, it is possible that one or more valves have a higher setting.
To ensure that only the SRVs open during checks and adjustments, it is necessary to further
increase the setting of the MRVs to 360 - 370 bar.

6. Turn set screw (Fig. 10-8, Pos. 3) of the MRVs ½ turn further in. The pressure will remain at the value shown
in step 5.

Adjusting

7. Adjust all SRVs equally until all gauges show a pressure of 350±5 bar, see "Adjusting of the SRV" on
page 10-28.
Adjust in steps of ¼ turn regarding the following sequence: 66.2  66.7

8. Reduce the pressure at SRV 66.2 at first to a value below the required value, then increase the pressure to the
required value of 350±5 bar while observing all gauges, see "Adjusting of the SRV" on page 10-28.

REMARKS: Now all gauges will show the same value of 350±5 bar, but only SRV 66.2 has the correct setting.

9. Proceed with the other SRV 66.7 in the same manner.

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Hydraulics for the attachment cylinders Operating hydraulics

NOTICE
STRONG PULSATION OF THE RETURN LINE HOSES!
Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be
avoided.

Repeat the adjusting procedure until the oil returns well-balanced via all involved secondary relief valves.

10. After the check / adjustment is finished reset the MRV at control block(s) to 315+5 bar, see "Adjusting of the
MRV" below.

11. Stop the engine.

12. Switch pumps back to operation mode (Qmin OFF) via switch 11S150 at the X2-switch board.

13. Remove the pressure gauges.

REMARKS: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm).
Otherwise internal leaks could occur, resulting in loud flow noises and wrong adjustments.

Adjusting of the SRV

1. Remove protective cap (Fig. 10-8, Pos. 4) of the SRVs.

2. Loosen lock nut (Fig. 10-8, Pos. 5).

3. Turn set screw (Fig. 10-8, Pos. 6) clockwise to increase the pressure or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

Adjusting of the MRV

1. Remove protective cap (Fig. 10-8, Pos. 1).

2. Loosen lock nut (Fig. 10-8, Pos. 2).

3. Turn set screw (Fig. 10-8, Pos. 3) clockwise to increase the pressure, or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

10 - 28 PC3000-6 SHOP-10 06279-xD-GB-1

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10.3.1.6 STICK CYLINDERS, PISTON ROD SIDE (BHA), STICK OUT

Fig. 10-9 Checks and adjustments of the SRVs, stick cylinders piston rod side (BHA)

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Operating hydraulics Hydraulics for the attachment cylinders

There are 3 secondary relief valves (SRVs) installed at the distributor manifold to limit the maximum possible pres-
sure peaks in the lines.

Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs) it is necessary
to increase the main relief pressure for testing and adjusting purposes.

Valve Pressure Test Port Location

SRV 63.3 M16.4 Manifold section E

SRV 63.5 M16.6 Manifold section J

SRV 63.6 M16.7 Manifold section J

MRV circuit I M11.1 (High pressure filter) Control block I

MRV circuit II M11.2 (High pressure filter) Control block II

MRV circuit III M11.3 (High pressure filter) Control block III

Table 10-9 Relief valves, locations and designations

Checking

1. Connect pressure gauges (0 - 400 bar) to all test ports listed in Table 10-9.

2. Start the engine and let it run at high idle (operating temperature T3 is reached).

3. Switch pumps to Qmin via switch 11S150 at the X2-switch board.

4. Retract the stick cylinders (stick out) to the final stop position until the hydraulic system stalls.

5. Slowly increase the pump supply line pressure by turning in set screws (Fig. 10-9, Pos. 3) of the MRVs in the
control blocks I, II and III while observing the pressure gauges. Stop as soon as the pressure does not rise any
further, see "Adjusting of the MRV" on page 10-32.
The gauge should show: 350±5 bar.

REMARKS: Since the piston rod sides of the stick cylinders are protected by several SRVs, the pressure gauges
show the pressure of the valve with the lowest setting. Even when the gauges show the required
pressure, it is possible that one or more valves have a higher setting.
To ensure that only the SRVs open during checks and adjustments, it is necessary to further
increase the setting of the MRV to 360 - 370 bar.

6. Turn set screw (Fig. 10-9, Pos. 3) of the MRV ½ turn further in. The pressure will remain at the value shown in
step 5.

Adjusting

7. Adjust all SRVs equally until all gauges show a pressure of 350±5 bar, see "Adjusting of the SRV" on
page 10-32.
Adjust in steps of ¼ turn regarding the following sequence: 63.3  63.5  63.6

8. Reduce the pressure at SRV 63.3 at first to a value below the required value, then increase the pressure to the
required value of 350±5 bar while observing all gauges, see "Adjusting of the SRV" on page 10-32.

REMARKS: Now all gauges will show the same value of 350±5 bar, but only SRV 63.3 has the correct setting.

9. Proceed with the other SRV in the same manner in the following sequence: 63.5  63.6

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Hydraulics for the attachment cylinders Operating hydraulics

NOTICE
STRONG PULSATION OF THE RETURN LINE HOSES!
Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be
avoided.

Repeat the adjusting procedure until the oil returns well-balanced via all involved secondary relief valves.

10. After the check / adjustment is finished reset the MRV at control block(s) to 315+5 bar, see "Adjusting of the
MRV" below.

11. Stop the engine.

12. Switch pumps back to operation mode (Qmin OFF) via switch 11S150 at the X2-switch board.

13. Remove the pressure gauges.

REMARKS: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm).
Otherwise internal leaks could occur, resulting in loud flow noises and wrong adjustments.

Adjusting of the SRV

1. Remove protective cap (Fig. 10-9, Pos. 4) of the SRVs.

2. Loosen lock nut (Fig. 10-9, Pos. 5).

3. Turn set screw (Fig. 10-9, Pos. 6) clockwise to increase the pressure or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

Adjusting of the MRV

1. Remove protective cap (Fig. 10-9, Pos. 1).

2. Loosen lock nut (Fig. 10-9, Pos. 2).

3. Turn set screw (Fig. 10-9, Pos. 3) clockwise to increase the pressure, or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

10 - 32 PC3000-6 SHOP-10 06279-xD-GB-1

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Hydraulics for the attachment cylinders Operating hydraulics

10.3.1.7 BUCKET CYLINDERS, PISTON SIDE (FSA), BUCKET FILL

Fig. 10-10 Checks and adjustments of the SRVs, bucket cylinders piston side (FSA)

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Operating hydraulics Hydraulics for the attachment cylinders

There are 4 secondary relief valves (SRVs) installed, 3 at the distributor manifold and 1 in main control block II to
limit the maximum possible pressure peaks in the lines.

Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs) it is necessary
to increase the main relief pressure for testing and adjusting purposes.

Valve Pressure Test Port Location

SRV 66.4
M11.2 (High pressure filter) Control block II
MRV circuit II

MRV circuit III M11.3 (High pressure filter) Control block III

SRV 65.1 M16.2 Manifold section C

SRV 63.2 M16.3 Manifold section C

SRV 63.1 M16.9 Manifold section M

Table 10-10 Relief valves, locations and designations

Checking

1. Connect pressure gauges (0 - 400 bar) to all test ports listed in Table 10-10.

2. Start the engine and let it run at high idle (operating temperature T3 is reached).

3. Switch pumps to Qmin via switch 11S150 at the X2-switch board.

4. Extend the bucket cylinders (bucket fill) to the final stop position until the hydraulic system stalls.

5. Slowly increase the pump supply line pressure by turning in set screws (Fig. 10-10, Pos. 3) of both MRVs in
control block II and III while observing the pressure gauges. Stop as soon as the pressure does not rise any
further, see "Adjusting of the MRV" on page 10-36.
The gauges should show: 350±5 bar.

REMARKS: Since the piston sides of the bucket cylinders are protected by several SRVs, the pressure gauges
show the pressure of the valve with the lowest setting. Even when the gauges show the required
pressure, it is possible that one or more valves have a higher setting.
To ensure that only the SRVs open during checks and adjustments, it is necessary to further
increase the setting of the MRVs to 360 - 370 bar.

6. Turn set screw (Fig. 10-10, Pos. 3) of the MRVs ½ turn further in. The pressure will remain at the value shown
in step 5.

Adjusting

7. Adjust all SRVs equally until all gauges show a pressure of 350±5 bar, see "Adjusting of the SRV" on
page 10-36.
Adjust in steps of ¼ turn regarding the following sequence: 65.1  63.2  63.1  66.4

8. Reduce the pressure at SRV 65.1 at first to a value below the required value, then increase the pressure to the
required value of 350±5 bar while observing all gauges, see "Adjusting of the SRV" on page 10-36.

REMARKS: Now all gauges will show the same value of 350±5 bar, but only SRV 65.1 has the correct setting.

9. Proceed with the other SRV in the same manner in the following sequence: 63.2  63.1  66.4

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Hydraulics for the attachment cylinders Operating hydraulics

NOTICE
STRONG PULSATION OF THE RETURN LINE HOSES!
Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be
avoided.

Repeat the adjusting procedure until the oil returns well-balanced via all involved secondary relief valves.

10. After the check / adjustment is finished reset the MRV at control block(s) to 315+5 bar, see "Adjusting of the
MRV" below.

11. Stop the engine.

12. Switch pumps back to operation mode (Qmin OFF) via switch 11S150 at the X2-switch board.

13. Remove the pressure gauges.

REMARKS: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm).
Otherwise internal leaks could occur, resulting in loud flow noises and wrong adjustments.

Adjusting of the SRV

1. Remove protective cap (Fig. 10-10, Pos. 4) of the SRVs.

2. Loosen lock nut (Fig. 10-10, Pos. 5).

3. Turn set screw (Fig. 10-10, Pos. 6) clockwise to increase the pressure or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

Adjusting of the MRV

1. Remove protective cap (Fig. 10-10, Pos. 1).

2. Loosen lock nut (Fig. 10-10, Pos. 2).

3. Turn set screw (Fig. 10-10, Pos. 3) clockwise to increase the pressure, or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

10 - 36 PC3000-6 SHOP-10 06279-xD-GB-1

Operating hydraulics Hydraulics for the attachment cylinders

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Hydraulics for the attachment cylinders Operating hydraulics

10.3.1.8 BUCKET CYLINDERS, PISTON SIDE (BHA), BUCKET FILL

Fig. 10-11 Checks and adjustments of the SRVs, bucket cylinders piston side (BHA)

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Operating hydraulics Hydraulics for the attachment cylinders

There are 2 secondary relief valves (SRVs) installed at the distributor manifold to limit the maximum possible pres-
sure peaks in the lines.

Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs) it is necessary
to increase the main relief pressure for testing and adjusting purposes.

Valve Pressure Test Port Location

SRV 70.2 M16.11 Manifold section C

SRV 70.1 M16.9 Manifold section M

MRV circuit I M11.1 (High pressure filter) Control block I

MRV circuit II M11.2 (High pressure filter) Control block II

Table 10-11 Relief valves, locations and designations

Checking

1. Connect pressure gauges (0 - 400 bar) to all test ports listed in Table 10-11.

2. Start the engine and let it run at high idle (operating temperature T3 is reached).

3. Switch pumps to Qmin via switch 11S150 at the X2-switch board.

4. Extend the bucket cylinders (bucket fill) to the final stop position until the hydraulic system stalls.

5. Slowly increase the pump supply line pressure by turning in set screws (Fig. 10-11, Pos. 3) of both MRVs in
control block I and II while observing the pressure gauges. Stop as soon as the pressure does not rise any fur-
ther, see "Adjusting of the MRV" on page 10-40.
The gauges should show: 350±5 bar.

REMARKS: Since the piston sides of the bucket cylinders are protected by several SRVs, the pressure gauges
show the pressure of the valve with the lowest setting. Even when the gauges show the required
pressure, it is possible that one or more valves have a higher setting.
To ensure that only the SRVs open during checks and adjustments, it is necessary to further
increase the setting of the MRV to 360 - 370 bar.

6. Turn set screw (Fig. 10-11, Pos. 3) of the MRV ½ turn further in. The pressure will remain at the value shown
in step 5.

Adjusting

7. Adjust all SRVs equally until all gauges show a pressure of 350±5 bar, see "Adjusting of the SRV" on
page 10-40.
Adjust in steps of ¼ turn regarding the following sequence: 70.1  70.2

8. Reduce the pressure at SRV 70.1 at first to a value below the required value, then increase the pressure to the
required value of 350±5 bar while observing all gauges, see "Adjusting of the SRV" on page 10-40.

REMARKS: Now all gauges will show the same value of 350±5 bar, but only SRV 70.1 has the correct setting.

9. Proceed with the other SRV 70.2 in the same manner.

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Hydraulics for the attachment cylinders Operating hydraulics

NOTICE
STRONG PULSATION OF THE RETURN LINE HOSES!
Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be
avoided.

Repeat the adjusting procedure until the oil returns well-balanced via all involved secondary relief valves.

10. After the check / adjustment is finished reset the MRV at control block(s) to 315+5 bar, see "Adjusting of the
MRV" below.

11. Stop the engine.

12. Switch pumps back to operation mode (Qmin OFF) via switch 11S150 at the X2-switch board.

13. Remove the pressure gauges.

REMARKS: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm).
Otherwise internal leaks could occur, resulting in loud flow noises and wrong adjustments.

Adjusting of the SRV

1. Remove protective cap (Fig. 10-11, Pos. 4) of the SRVs.

2. Loosen lock nut (Fig. 10-11, Pos. 5).

3. Turn set screw (Fig. 10-11, Pos. 6) clockwise to increase the pressure or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

Adjusting of the MRV

1. Remove protective cap (Fig. 10-11, Pos. 1).

2. Loosen lock nut (Fig. 10-11, Pos. 2).

3. Turn set screw (Fig. 10-11, Pos. 3) clockwise to increase the pressure, or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

10 - 40 PC3000-6 SHOP-10 06279-xD-GB-1

Operating hydraulics Hydraulics for the attachment cylinders

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Hydraulics for the attachment cylinders Operating hydraulics

10.3.1.9 BUCKET CYLINDERS, PISTON ROD SIDE (FSA), BUCKET DUMP

Fig. 10-12 Checks and adjustments of the SRVs, bucket cylinders piston rod side (FSA)

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Operating hydraulics Hydraulics for the attachment cylinders

There are 2 secondary relief valves (SRVs) installed, 1 in main control block II and 1 in block III, to limit the maxi-
mum possible pressure peaks in the lines.

Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs) it is necessary
to increase the main relief pressure for testing and adjusting purposes.

Valve Pressure Test Port Location

SRV 66.5
M11.2 (High pressure filter) Control block II
MRV circuit II

SRV 66.1
M11.3 (High pressure filter) Control block III
MRV circuit III

Table 10-12 Relief valves, locations and designations

Checking

1. Connect pressure gauges (0 - 400 bar) to all test ports listed in Table 10-12.

2. Start the engine and let it run at high idle (operating temperature T3 is reached).

3. Switch pumps to Qmin via switch 11S150 at the X2-switch board.

4. Retract the bucket cylinders (bucket dump) to the final stop position until the hydraulic system stalls.

5. Slowly increase the pump supply line pressure by turning in set screws (Fig. 10-12, Pos. 3) of both MRVs in
control block III and IV while observing the pressure gauges. Stop as soon as the pressure does not rise any
further, see "Adjusting of the MRV" on page 10-44.
The gauges should show: 350±5 bar.

REMARKS: Since the piston rod sides of the bucket cylinders are protected by several SRVs, the pressure
gauges show the pressure of the valve with the lowest setting. Even when the gauges show the
required pressure, it is possible that one or more valves have a higher setting.
To ensure that only the SRVs open during checks and adjustments, it is necessary to further
increase the setting of the MRVs to 360 - 370 bar.

6. Turn set screw (Fig. 10-12, Pos. 3) of the MRVs ½ turn further in. The pressure will remain at the value shown
in step 5.

Adjusting

7. Adjust all SRVs equally until all gauges show a pressure of 350±5 bar, see "Adjusting of the SRV" on
page 10-44.
Adjust in steps of ¼ turn regarding the following sequence: 66.1  66.5

8. Reduce the pressure at SRV 66.1 at first to a value below the required value, then increase the pressure to the
required value of 350±5 bar while observing all gauges, see "Adjusting of the SRV" on page 10-44.

REMARKS: Now all gauges will show the same value of 350±5 bar, but only SRV 66.1 has the correct setting.

9. Proceed with the other SRV 66.5 in the same manner.

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Hydraulics for the attachment cylinders Operating hydraulics

NOTICE
STRONG PULSATION OF THE RETURN LINE HOSES!
Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be
avoided.

Repeat the adjusting procedure until the oil returns well-balanced via all involved secondary relief valves.

10. After the check / adjustment is finished reset the MRV at control block(s) to 315+5 bar, see "Adjusting of the
MRV" below.

11. Stop the engine.

12. Switch pumps back to operation mode (Qmin OFF) via switch 11S150 at the X2-switch board.

13. Remove the pressure gauges.

REMARKS: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm).
Otherwise internal leaks could occur, resulting in loud flow noises and wrong adjustments.

Adjusting of the SRV

1. Remove protective cap (Fig. 10-12, Pos. 4) of the SRVs.

2. Loosen lock nut (Fig. 10-12, Pos. 5).

3. Turn set screw (Fig. 10-12, Pos. 6) clockwise to increase the pressure or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

Adjusting of the MRV

1. Remove protective cap (Fig. 10-12, Pos. 1).

2. Loosen lock nut (Fig. 10-12, Pos. 2).

3. Turn set screw (Fig. 10-12, Pos. 3) clockwise to increase the pressure, or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

10 - 44 PC3000-6 SHOP-10 06279-xD-GB-1

Operating hydraulics Hydraulics for the attachment cylinders

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Hydraulics for the attachment cylinders Operating hydraulics

10.3.1.10 BUCKET CYLINDERS, PISTON ROD SIDE (BHA), BUCKET DUMP

Fig. 10-13 Checks and adjustments of the SRVs, bucket cylinders piston rod side (BHA)

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Operating hydraulics Hydraulics for the attachment cylinders

There are 2 secondary relief valves (SRVs) installed at the distributor manifold to limit the maximum possible pres-
sure peaks in the lines.

Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs) it is necessary
to increase the main relief pressure for testing and adjusting purposes.

Valve Pressure Test Port Location

SRV 65.2 M16.5 Manifold section G

SRV 63.7 M16.15 Manifold section L

MRV circuit I M11.1 (High pressure filter) Control block I

MRV circuit II M11.2 (High pressure filter) Control block II

Table 10-13 Relief valves, locations and designations

Checking

1. Connect pressure gauges (0 - 400 bar) to all test ports listed in Table 10-13.

2. Start the engine and let it run at high idle (operating temperature T3 is reached).

3. Switch pumps to Qmin via switch 11S150 at the X2-switch board.

4. Retract the bucket cylinders (bucket dump) to the final stop position until the hydraulic system stalls.

5. Slowly increase the pump supply line pressure by turning in set screws (Fig. 10-13, Pos. 3) of both MRVs in
control block I and II while observing the pressure gauges. Stop as soon as the pressure does not rise any fur-
ther, see "Adjusting of the MRV" on page 10-48.
The gauge should show: 350±5 bar.

REMARKS: Since the piston rod sides of the bucket cylinders are protected by several SRVs, the pressure
gauges show the pressure of the valve with the lowest setting. Even when the gauges show the
required pressure, it is possible that one or more valves have a higher setting.
To ensure that only the SRVs open during checks and adjustments, it is necessary to further
increase the setting of the MRV to 360 - 370 bar.

6. Turn set screw (Fig. 10-13, Pos. 3) of the MRV ½ turn further in. The pressure will remain at the value shown
in step 5.

Adjusting

7. Adjust all SRVs equally until all gauges show a pressure of 350±5 bar, see "Adjusting of the SRV" on
page 10-48.
Adjust in steps of ¼ turn regarding the following sequence: 65.2  63.7

8. Reduce the pressure at SRV 65.2 at first to a value below the required value, then increase the pressure to the
required value of 350±5 bar while observing all gauges, see "Adjusting of the SRV" on page 10-48.

REMARKS: Now all gauges will show the same value of 350±5 bar, but only SRV 65.2 has the correct setting.

9. Proceed with the other SRV 63.7 in the same manner.

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Hydraulics for the attachment cylinders Operating hydraulics

NOTICE
STRONG PULSATION OF THE RETURN LINE HOSES!
Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be
avoided.

Repeat the adjusting procedure until the oil returns well-balanced via all involved secondary relief valves.

10. After the check / adjustment is finished reset the MRV at control block(s) to 315+5 bar, see "Adjusting of the
MRV" below.

11. Stop the engine.

12. Switch pumps back to operation mode (Qmin OFF) via switch 11S150 at the X2-switch board.

13. Remove the pressure gauges.

REMARKS: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm).
Otherwise internal leaks could occur, resulting in loud flow noises and wrong adjustments.

Adjusting of the SRV

1. Remove protective cap (Fig. 10-13, Pos. 4) of the SRVs.

2. Loosen lock nut (Fig. 10-13, Pos. 5).

3. Turn set screw (Fig. 10-13, Pos. 6) clockwise to increase the pressure or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

Adjusting of the MRV

1. Remove protective cap (Fig. 10-13, Pos. 1).

2. Loosen lock nut (Fig. 10-13, Pos. 2).

3. Turn set screw (Fig. 10-13, Pos. 3) clockwise to increase the pressure, or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

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Operating hydraulics Hydraulics for the attachment cylinders

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Hydraulics for the attachment cylinders Operating hydraulics

10.3.1.11 CLAM CYLINDERS, PISTON ROD SIDE (FSA), CLAM OPEN

Fig. 10-14 Checks and adjustments of the SRVs, clam cylinders piston rod side (FSA)

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Operating hydraulics Hydraulics for the attachment cylinders

There is one secondary relief valve (SRV) installed at the distributor manifold to limit the maximum possible pres-
sure peaks in the lines.

Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs) it is necessary
to increase the main relief pressure for testing and adjusting purposes.

Valve Pressure Test Port Location

SRV 63.3 M16.3 Manifold section E

MRV circuit I M11.1 (High pressure filter) Control block I

Table 10-14 Relief valves, locations and designations

Checking

1. Connect pressure gauges (0 - 400 bar) to all test ports listed in Table 10-14.

2. Start the engine and let it run at high idle (operating temperature T3 is reached).

3. Switch pumps to Qmin via switch 11S150 at the X2-switch board.

4. Retract the clam cylinders (clam open) to the final stop position until the hydraulic system stalls.

5. Slowly increase the pump supply line pressure by turning in set screws (Fig. 10-14, Pos. 3) of the MRV in con-
trol block II while observing the pressure gauges. Stop as soon as the pressure does not rise any further, see
"Adjusting of the MRV" on page 10-52.
The gauge should show: 350±5 bar.

REMARKS: Since the piston rod sides of the clam cylinders are protected by a SRV, the pressure gauges show
the pressure of the valve with the lowest setting. Even when the gauges show the required pressure,
it is possible that the SRV has a higher setting.
To ensure that only the SRV opens during checks and adjustments, it is necessary to further
increase the setting of the MRV to 360 - 370 bar.

6. Turn set screw (Fig. 10-14, Pos. 3) of the MRV ½ turn further in. The pressure will remain at the value shown
in step 5.

Adjusting

7. Adjust the SRV until all gauges show a pressure of 350±5 bar, see "Adjusting of the SRV" on page 10-52.
Adjust in steps of ¼ turn.

8. Reduce the pressure at SRV 63.3 to a value below the required value, then increase the pressure to the
required value of 350±5 bar while observing all gauges, see "Adjusting of the SRV" on page 10-52.

9. After the check / adjustment is finished reset the MRV at control block to 315+5 bar, see "Adjusting of the
MRV" on page 10-52.

10. Stop the engine.

11. Switch pumps back to operation mode (Qmin OFF) via switch 11S150 at the X2-switch board.

12. Remove the pressure gauges.

REMARKS: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm).
Otherwise internal leaks could occur, resulting in loud flow noises and wrong adjustments.

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Hydraulics for the attachment cylinders Operating hydraulics

Adjusting of the SRV

1. Remove protective cap (Fig. 10-14, Pos. 4) of the SRV.

2. Loosen lock nut (Fig. 10-14, Pos. 5).

3. Turn set screw (Fig. 10-14, Pos. 6) clockwise to increase the pressure or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

Adjusting of the MRV

1. Remove protective cap (Fig. 10-14, Pos. 1).

2. Loosen lock nut (Fig. 10-14, Pos. 2).

3. Turn set screw (Fig. 10-14, Pos. 3) clockwise to increase the pressure, or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

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10.3.1.12 CLAM CYLINDERS, PISTON SIDE (FSA), CLAM CLOSE

Fig. 10-15 Checks and adjustments of the SRVs, clam cylinders piston rod side (FSA)

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Operating hydraulics Hydraulics for the attachment cylinders

There are 2 secondary relief valves (SRVs) installed, 1 at distributor manifold, and 1 in main control block I, to limit
the maximum possible pressure in the lines when closing the bucket.

Since the opening pressure of the SRVs is higher than the setting of the main relief valves (MRVs) it is necessary
to increase the main relief pressure for testing and adjusting purposes.

Valve Pressure Test Port Location

SRV 121.1 M23 Manifold section K

SRV 67
M11.1 (High pressure filter) Control block I
MRV circuit I

Table 10-15 Relief valves, locations and designations

Checking

1. Connect pressure gauges (0 - 400 bar) to all test ports listed in Table 10-15.

2. Start the engine and let it run at high idle (operating temperature T3 is reached).

3. Switch pumps to Qmin via switch 11S150 at the X2-switch board.

4. Raise the attachment and bring the back wall of the bucket in a horizontal position (bucket dump).

5. Depress pedal "Bucket close" until the hydraulic system stalls. Release the pedal (bring it back into neutral
position). The bucket must stay closed, that means the clam cylinders may not be retracted by the force
(weight) of the clam.

REMARKS: Since the piston sides of the clam cylinders are protected by several SRVs, the pressure gauges
show the pressure of the valve with the lowest setting. Even when the gauges show the required
pressure, it is possible that one or more valves have a higher setting.

Adjusting

6. Adjust both SRVs until all gauges show a pressure of 150±30 bar, see "Adjusting of the SRV" on page 10-56.
Adjust in steps of ¼ turn.

NOTICE
STRONG PULSATION OF THE RETURN LINE HOSES!
Strong pulsation of the return line hoses indicates deviation in opening pressure of SRVs and must be
avoided.

Repeat the adjusting procedure until the oil returns well-balanced via all involved secondary relief valves.

7. Now reduce the pressure at the SRVs equally in steps of 5 bar until the bucket opens by gravity (check with
released pedal).
Read the pressure and increase the setting by 10% to compensate the weight of material stuck at the clam
shell.

REMARKS: At reinforced buckets or buckets with heavy wear package attached, the pressure may be raised up
to 180 bar.

8. Stop the engine.

9. Switch pumps back to operation mode (Qmin OFF) via switch 11S150 at the X2-switch board.

10. Remove the pressure gauges.

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Hydraulics for the attachment cylinders Operating hydraulics

Adjusting of the SRV

1. Remove protective cap (Fig. 10-15, Pos. 1) of the SRVs.

2. Loosen lock nut (Fig. 10-15, Pos. 2).

3. Turn set screw (Fig. 10-15, Pos. 3) clockwise to increase the pressure or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

10 - 56 PC3000-6 SHOP-10 06279-xD-GB-1

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10.3.2 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED

10.3.2.1 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED – BOOM (FSA)

Fig. 10-16 Checks and adjustments of the lowering speed - boom (FSA)

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Operating hydraulics Hydraulics for the attachment cylinders

General:

On excavators equipped with face shovel attachment (FSA), there are two different operation modes for lowering
the boom:

– Floating position activated, the lowering speed is restricted by the stroke limiter (Fig. 10-16, Pos. 1) at the
single control block (standard adjustment: ’fully open’).
– Floating position deactivated, the lowering speed has to be adjusted at the flow restrictors (Fig. 10-16,
Pos. 5) (throttle valves 70.1, 70.2 and 70.13) at the distributor manifold (Fig. 10-16, Pos. 2).

Purpose of the throttle valves:

– To avoid an interruption of the oil flow.

– To provide an uniform and smooth cylinder movement.
– To limit the return oil flow through the control block to the maximum permissible volume / cylinder speed.

Checks and adjustments:

Standard test method is measuring the total cylinder running time (from start to final stop) by using a stop watch.

Basic adjustment of all restrictors as follows:

1. For easy turning of set-screw (Fig. 10-16, Pos. 3), lower the attachment to ground, stop engine and allow pres-
sure equalizing by moving the joysticks several times.

2. Loosen the lock nut (Fig. 10-16, Pos. 4) and turn the bolt (Fig. 10-16, Pos. 3) cw. for more restriction and ccw.
for less restriction. If more than one restrictor is used for one movement make sure all set-screws are equally
adjusted.

For the values to be set, refer to column "Nominal" in the PM-CLINIC data sheet for the respective attachment
(FSA / BHA).

REMARKS: During commissioning, a standard throttle valve adjustment has to be carried out.
For safety reasons, the throttle valves are basically adjusted before the machine is leaving the fac-
tory.

Due to the 2 different operation modes for lowering the boom, the lowering speed must be adjusted twice:

– Floating position activated, for adjustment see "Floating position activated" on page 10-60.
– Floating position deactivated, for adjustment see "Floating position deactivated" on page 10-62.
For more information, refer to PM-CLINIC.

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Hydraulics for the attachment cylinders Operating hydraulics

Floating position activated

Fig. 10-17 Checks and adjustments of the lowering speed (boom cylinder FSA, floating activated)

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Operating hydraulics Hydraulics for the attachment cylinders

Maximum permissible lowering speed

Refer to the PM-CLINIC sheet for your machine.

Adjustments / checks (floating position activated)

1. Use a stop watch to measure the time for the cylinder movement (from start to final stop).

REMARKS: Pay attention to measure the time of the cylinder movement only.

2. Raise the fully extended attachment with empty bucket to the maximum height (start position, Fig. 10-17,
Pos. A).

3. Run the engine at high idle.

4. Lower the attachment; do not press button 20S095 (floating position switch). Rapidly move the control lever
(Fig. 10-17, Pos. 3) to the front end position (start stop watch when the boom starts moving) and hold the con-
trol lever in this position until the final position (Fig. 10-17, Pos. B) is reached (stop the stop watch).

REMARKS: Lower the boom so that the bucket stops just above the ground.

5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced
by adjusting the stroke limiter of the single control block 132.3.
Adjust as follows:

– To decrease the lowering speed, loosen the lock nut (Fig. 10-17, Pos. 2) and turn the bolt (Fig. 10-17,
Pos. 1) clockwise.
– To increase the lowering speed, loosen the lock nut (Fig. 10-17, Pos. 2) and turn the bolt (Fig. 10-17,
Pos. 1) counter-clockwise.
6. Check the lowering speed again and repeat the adjustment, if necessary.

7. If the adjustment is finished, tighten lock nut (Fig. 10-17, Pos. 2).

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Floating position deactivated

Fig. 10-18 Checks and adjustments of the lowering speed (boom cylinder FSA, floating deactivated)

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Operating hydraulics Hydraulics for the attachment cylinders

Maximum permissible lowering speed

Refer to the PM-CLINIC sheet for your machine.

Adjustments / checks (floating position deactivated):

1. Use a stop watch to measure the time for the cylinder movement (from start to final stop).

REMARKS: Pay attention to measure the time of the cylinder movement only.

2. Raise the fully extended attachment with empty bucket to the maximum height (start position, Fig. 10-18,
Pos. A).

3. Run the engine at high idle.

4. Press push-button [20S095] (floating position switch) and keep it depressed while lowering the boom. Rapidly
move the control lever (Fig. 10-18, Pos. 4) to the front end position (start stop watch when the boom starts
moving) and hold the control lever in this position until the final position (Fig. 10-17, Pos. B) is reached (stop
the stop watch).

REMARKS: Lower the boom so that the bucket stops just above the ground.

5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced
by adjusting the throttle valves 63.8 and 63.9 at the distributor manifold (Fig. 10-18, Pos. 3).
Adjust as follows:

– To decrease the lowering speed, loosen the lock nut (Fig. 10-18, Pos. 2) and turn the bolt (Fig. 10-18,
Pos. 1) clockwise.
– To increase the lowering speed, loosen the lock nut (Fig. 10-18, Pos. 2) and turn the bolt (Fig. 10-18,
Pos. 1) counter-clockwise.
REMARKS: Since there are several valves throttling the return
oil flow, the valves must be set synchronously (see
Fig. 10-19).
The adjusting screws have to be turned in by the
same amount of revolutions.

Fig. 10-19

6. Check lowering speed again and repeat the adjustment, if necessary.

7. If the adjustment is finished, tighten lock nut (Fig. 10-18, Pos. 2).

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10.3.2.2 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED – BOOM (BHA)

Fig. 10-20 Checks and adjustments of the lowering speed (boom cylinder BHA)

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Operating hydraulics Hydraulics for the attachment cylinders

Maximum permissible lowering speed

Refer to the PM-CLINIC sheet for your machine.

Checks and adjustments

1. Use a stop watch to measure the time for the cylinder movement (from start to final stop).

REMARKS: Pay attention to measure the time of the cylinder movement only.

2. Raise the fully extended attachment with empty bucket to the maximum height (start position, Fig. 10-20,
Pos. A).

3. Run the engine at high idle.

4. Rapidly move the control lever (Fig. 10-20, Pos. 3) to the front end position (start stop watch when the boom
starts moving) and hold the control lever in this position until the final position (Fig. 10-20, Pos. B) is reached
(stop the stop watch).

REMARKS: Lower the boom so that the bucket stops just above the ground.

5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced
by adjusting the throttle valves 63.8 and 63.9 at the distributor manifold (Fig. 10-20, Pos. 3).
Adjust as follows:

– To decrease the lowering speed, loosen the lock nut (Fig. 10-20, Pos. 2) and turn the bolt (Fig. 10-20,
Pos. 1) clockwise.
– To increase the lowering speed, loosen the lock nut (Fig. 10-20, Pos. 2) and turn the bolt (Fig. 10-20,
Pos. 1) counter-clockwise.
REMARKS: Since there are several valves throttling the return
oil flow, the valves must be set synchronously (see
Fig. 10-21).
The adjusting screws have to be turned in by the
same amount of revolutions.

Fig. 10-21

6. Check lowering speed again and repeat the adjustment, if necessary.

7. If the adjustment is finished, tighten lock nut (Fig. 10-20, Pos. 2).

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10.3.2.3 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED – STICK (FSA)

Fig. 10-22 Checks and adjustments of the lowering speed - stick (FSA)

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Operating hydraulics Hydraulics for the attachment cylinders

General:

– On excavators equipped with face shovel attachment (FSA), there are two different operation modes for lower-
ing the stick:
– Floating position activated, the lowering speed is restricted by the stroke limiters (Fig. 10-22, Pos. 1) of the
single control blocks (standard adjustment: ’fully open’).
– Floating position deactivated, the lowering speed has to be adjusted at the flow restrictor (throttle valve)
at the distributor manifold (Fig. 10-22, Pos. 2).

Purpose of the throttle valves:

– To avoid an interruption of the oil flow.

– To provide an uniform and smooth cylinder movement.
– To limit the return oil flow through the control block to the maximum permissible volume / cylinder speed.

Checks and adjustments:

Standard test method is measuring the total cylinder running time (from start to final stop) by using a stop watch.

Basic adjustment of all restrictors as follows:

1. For easy turning of set-screw (Fig. 10-22, Pos. 3), lower the attachment to ground, stop engine and allow pres-
sure equalizing by moving the joysticks several times.

2. Loosen the lock nut (Fig. 10-22, Pos. 4) and turn the bolt (Fig. 10-22, Pos. 3) cw. for more restriction and ccw.
for less restriction. If more than one restrictor is used for one movement make sure all set-screws are equally
adjusted.

For the values to be set, refer to column "Nominal" in the PM-CLINIC data sheet for the respective attachment
(FSA / BHA).

REMARKS: During commissioning, a standard throttle valve adjustment has to be carried out.
For safety reasons, the throttle valves are basically adjusted before the machine is leaving the fac-
tory.

Due to the 2 different operation modes for lowering the stick, the lowering speed must be adjusted twice:

– Floating position activated

– Floating position deactivated
For more information, refer to PM-CLINIC.

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Floating position activated

Fig. 10-23 Checks and adjustments of the lowering speed (stick cylinder FSA, floating activated)

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Operating hydraulics Hydraulics for the attachment cylinders

Maximum permissible lowering speed

Refer to the PM-CLINIC sheet for your machine.

Adjustments / checks (floating position activated)

1. Use a stop watch to measure the time for the cylinder movement (from start to final stop).

REMARKS: Pay attention to measure the time of the cylinder movement only.

2. Raise the attachment with fully extended stick, and empty bucket to the start position (Fig. 10-23, Pos. A).

3. Run the engine at high idle.

4. Lower the attachment; do not press button 20S098 (floating position switch). Rapidly move the control lever
(Fig. 10-23, Pos. 3) to the back end position (start stop watch when the stick starts moving) and hold the con-
trol lever in this position until the final position (Fig. 10-23, Pos. B) is reached (stop the stop watch).

REMARKS: Lower the boom so that the bucket stops just above the ground.

5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced
by adjusting the stroke limiter of the single control blocks 132.1 and 132.2.
Adjust as follows:

– To decrease the lowering speed, loosen the lock nut (Fig. 10-23, Pos. 2) and turn the bolt (Fig. 10-23,
Pos. 1) clockwise.
– To increase the lowering speed, loosen the lock nut (Fig. 10-23, Pos. 2) and turn the bolt (Fig. 10-23,
Pos. 1) counter-clockwise.
6. Check the lowering speed again and repeat the adjustment, if necessary.

7. If the adjustment is finished, tighten lock nut (Fig. 10-23, Pos. 2).

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Floating position deactivated

Fig. 10-24 Checks and adjustments of the lowering speed (stick cylinder FSA, floating deactivated)

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Operating hydraulics Hydraulics for the attachment cylinders

Maximum permissible lowering speed

Refer to the PM-CLINIC sheet for your machine.

Adjustments / checks (floating position deactivated):

1. Use a stop watch to measure the time for the cylinder movement (from start to final stop).

REMARKS: Pay attention to measure the time of the cylinder movement only.

2. Raise the attachment with fully extended stick, and empty bucket to the start position (Fig. 10-24, Pos. A).

3. Run the engine at high idle.

4. Press push-button 20S098 (floating position switch) and keep it depressed while lowering the stick. Rapidly
move the control lever (Fig. 10-24, Pos. 4) to the back end position (start stop watch when the stick starts
moving) and hold the control lever in this position until the final position (Fig. 10-24, Pos. B) is reached (stop
the stop watch).

REMARKS: Lower the boom so that the bucket stops just above the ground.

5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced
by adjusting the throttle valves 63.5 and 63.6 at the distributor manifold (Fig. 10-24, Pos. 3).
Adjust as follows:

– To decrease the lowering speed, loosen the lock nut (Fig. 10-24, Pos. 2) and turn the bolt (Fig. 10-24,
Pos. 1) clockwise.
– To increase the lowering speed, loosen the lock nut (Fig. 10-24, Pos. 2) and turn the bolt (Fig. 10-24,
Pos. 1) counter-clockwise.
REMARKS: Since there are several valves throttling the return
oil flow, the valves must be set synchronously (see
Fig. 10-25).
The adjusting screws have to be turned in by the
same amount of revolutions.

Fig. 10-25

6. Check lowering speed again and repeat the adjustment, if necessary.

7. If the adjustment is finished, tighten lock nut (Fig. 10-24, Pos. 2).

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10.3.2.4 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED – STICK (BHA)

Fig. 10-26 Checks and adjustments of the lowering speed (stick cylinder BHA)

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Operating hydraulics Hydraulics for the attachment cylinders

Maximum permissible lowering speed

Refer to the PM-CLINIC sheet for your machine.

Checks and adjustments

1. Use a stop watch to measure the time for the cylinder movement (from start to final stop).

REMARKS: Pay attention to measure the time of the cylinder movement only.

2. Raise the fully extended attachment with empty bucket to the maximum height (start position, Fig. 10-26,
Pos. A).

3. Run the engine at high idle.

4. Rapidly move the control lever (Fig. 10-26, Pos. 4) to the back end position (start stop watch when the stick
starts moving) and hold the control lever in this position until the final position (Fig. 10-26, Pos. B) is reached
(stop the stop watch).

REMARKS: Lower the boom so that the bucket stops just above the ground.

5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced
by adjusting the throttle valves 63.3, 63.5, and 63.6 at the distributor manifold (Fig. 10-26, Pos. 42).
Adjust as follows:

– To decrease the lowering speed, loosen the lock nut (Fig. 10-26, Pos. 2) and turn the bolt (Fig. 10-26,
Pos. 1) clockwise.
– To increase the lowering speed, loosen the lock nut (Fig. 10-26, Pos. 2) and turn the bolt (Fig. 10-26,
Pos. 1) counter-clockwise.
REMARKS: Since there are several valves throttling the return
oil flow, the valves must be set synchronously (see
Fig. 10-27).
The adjusting screws have to be turned in by the
same amount of revolutions.

Fig. 10-27

6. Check lowering speed again and repeat the adjustment, if necessary.

7. If the adjustment is finished, tighten lock nut (Fig. 10-26, Pos. 2).

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10.3.2.5 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED – BUCKET (FSA)

Fig. 10-28 Checks and adjustments of the lowering speed (bucket cylinder FSA)

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Operating hydraulics Hydraulics for the attachment cylinders

Maximum permissible lowering speed:

Refer to the PM-CLINIC sheet for your machine.

Checks and adjustments

1. Use a stop watch to measure the time for the cylinder movement.

2. Raise the attachment into start position (Fig. 10-28, Pos. A), bucket against mechanical stop (boom cylinders
2/3 extended, stick cylinders half extended, bucket cylinders completely retracted).

3. Run the engine at high idle.

4. Rapidly move the control lever (Fig. 10-28, Pos. 4) to the R.H. end position (start the stop watch) and hold the
control lever in this position until the final position (Fig. 10-28, Pos. B) is reached (stop the stop watch).

5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced
by adjusting the throttle valves 63.1 and 63.2 at the distributor manifold (Fig. 10-28, Pos. 42).
Adjust as follows:

– To decrease the lowering speed, loosen the lock nut (Fig. 10-28, Pos. 2) and turn the bolt (Fig. 10-28,
Pos. 1) clockwise.
– To increase the lowering speed, loosen the lock nut (Fig. 10-28, Pos. 2) and turn the bolt Fig. 10-28, Pos. 1)
counter-clockwise.
REMARKS: Since there are several valves throttling the return
oil flow, the valves must be set synchronously (see
Fig. 10-29).
The adjusting screws have to be turned in by the
same amount of revolutions.

Fig. 10-29

6. Check lowering speed again and repeat the adjustment, if necessary.

7. If the adjustment is finished tighten lock nut (Fig. 10-28, Pos. 2).

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10.3.2.6 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED – BUCKET (BHA)

Fig. 10-30 Checks and adjustments of the lowering speed (bucket cylinder BHA)

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Operating hydraulics Hydraulics for the attachment cylinders

Maximum permissible lowering speed:

Refer to the PM-CLINIC sheet for your machine.

Checks and adjustments

1. Use a stop watch to measure the time for the cylinder movement.

2. Raise the fully extended attachment with empty bucket to the maximum height position (Fig. 10-28, Pos. A).

3. Run the engine at high idle.

4. Rapidly move the control lever (Fig. 10-28, Pos. 4) to the R.H. end position (start the stop watch) and hold the
control lever in this position until the final position (Fig. 10-30, Pos. B) is reached (stop the stop watch).

5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced
by adjusting the throttle valve 63.7 at the distributor manifold (Fig. 10-30, Pos. 42).
Adjust as follows:

– To decrease the lowering speed, loosen the lock nut (Fig. 10-30, Pos. 2) and turn the bolt (Fig. 10-30,
Pos. 1) clockwise.
– To increase the lowering speed, loosen the lock nut (Fig. 10-30, Pos. 2) and turn the bolt Fig. 10-30, Pos. 1)
counter-clockwise.
REMARKS: Since there are several valves throttling the return
oil flow, the valves must be set synchronously (see
Fig. 10-31).
The adjusting screws have to be turned in by the
same amount of revolutions.

Fig. 10-31

6. Check lowering speed again and repeat the adjustment, if necessary.

7. If the adjustment is finished tighten lock nut (Fig. 10-30, Pos. 2).

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10.3.2.7 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED – CLAM (FSA)

Vertical (back wall)

Horizontal
(back wall)

Fig. 10-32 Checks and adjustments of the lowering speed (clam cylinder FSA)

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Operating hydraulics Hydraulics for the attachment cylinders

Maximum permissible lowering speed:

Refer to the PM-CLINIC sheet for your machine.

Checks and adjustments

The following checks and adjustments have to be carried out twice (for horizontal and vertical back wall).

1. Use a stop watch to measure the time for the cylinder movement.

2. Raise the attachment as shown in Fig. 10-32 to the respective start position (Fig. 10-32, Pos. A). Open the
clam of the empty bucket to the maximum height position.

3. Run the engine at high idle.

4. Rapidly push the control pedal (Fig. 10-32, Pos. 4) to the end position (start the stop watch) and hold the con-
trol pedal in this position until the final position (Fig. 10-32, Pos. B) is reached (stop the stop watch).

5. If the lowering speed is too high (measured time is less than the permissible time), the speed must be reduced
by adjusting the throttle valve 70.6 at the distributor manifold (Fig. 10-32, Pos. 42).
Adjust as follows:

– To decrease the lowering speed, loosen the lock nut (Fig. 10-32, Pos. 2) and turn the bolt (Fig. 10-32,
Pos. 1) clockwise.
– To increase the lowering speed, loosen the lock nut (Fig. 10-32, Pos. 2) and turn the bolt (Fig. 10-32,
Pos. 1) counter-clockwise.
6. Check lowering speed again and repeat the adjustment, if necessary.

7. If the adjustment is finished, tighten lock nut (Fig. 10-32, Pos. 2).

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Hydraulics for the slew circuit Operating hydraulics

10.4 HYDRAULICS FOR THE SLEW CIRCUIT

10.4.1 SLEW CIRCUIT

Fig. 10-33 Hydraulic slew circuit

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Operating hydraulics Hydraulics for the slew circuit

Legend for Fig. 10-33:

(3) Main pump #3 (71) Pilot oil unit: L.H. control lever

(11) Main control block III (88) Pilot oil unit: Slew brake control pedal

(60) Slew motor (102) Slew parking brake

(61) Dynamic slew brake valve block (256) Control block - slew brake
(slew service brake)

[57Q505] Solenoid valve, slew parking brake control pressure

[57Q620] Solenoid valve, emergency service brake control

Brief description (service circuits)

The slew motor (Fig. 10-33, Pos. 60) is driven by main pump #3 (Fig. 10-33, Pos. 3).
The oil flows from the pump through high pressure filters to the main control block III (Fig. 10-33, Pos. 11).
With the spools in neutral position, oil flows via the return oil lines back to the tank.

On the way back to the tank the oil must flow through the back pressure valve and the return oil filters (for the back
pressure valve function, refer to section Fig. 5-6 on page 5-10). When operating the control lever for "slewing"
(Fig. 10-33, Pos. 71), the pump lines are connected, via main control block III, with the corresponding service line
(A or B) to the slew motor. The oil flows from the control block through the dynamic slew brake valve block
(Fig. 10-33, Pos. 61) and the slew motor. The slew motor leak oil (case drain) flows back to the tank.
When operating the slew brake control pedal (Fig. 10-33, Pos. 88), the dynamic slew brake valve block creates a
back pressure to the motor return line which create a brake torque; the dynamic slew brake is acting as "service
brake".

REMARKS: For the description of the dynamic slew brake valve block refer to section 10.4.7 on page 10-92).

The slew gear includes a spring loaded multi-disk brake (Fig. 10-33, Pos. 102) for locking the superstructure
(slew parking brake).
When brake switch [20S029] in the operator’s cab is actuated solenoid valve [57Q505] is enegized and the slew
parking brake is released.

Before initial operation or after repairs on the hydraulic circuit, the slew parking brake has to be vented at the oil
pressure port, refer to section "Slew parking brake (L&S)" on page 10-88 or section "Slew parking brake (SIEBEN-
HAAR)" on page 10-88.

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10.4.2 SLEW MOTOR

Fig. 10-34 Axial piston motor A2FLM (with SL-bearing)

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Legend for Fig. 10-34:

(1) Drive shaft (9) End plate

(2) Housing (10) Centering spring

(3) Case drain port (11) Taper roller bearing

(4) Retaining plate (12) Spring

(5) Piston (13) Slipper pads

(5a) Pivot (center) pin (14) Thrust washer

(6a) Upper dead point (15) Roller bearing

(6b) Lower dead point (16) Circlip

(7) Cylinder (17) Sealing flange

(8) Control lens (18) Radial seal ring

Axial piston motor A2FM

The axial piston units of product group A2FM with fixed displacement can operate as a hydraulic motor only.
The drive speed is proportional to the consumption capacity. The output torque increases with the pressure drop
between high and low pressure side. The motor converts hydrostatic energy into mechanical energy.

Description of the SL-bearing (SL = Slipper Bearing)

The main part of the axial forces is supported by the slipper pads (Fig. 10-34, Pos. 13) which are installed on the
driving circular side of the drive shaft. Each piston is allocated to one slipper pad. These slipper pads are located
in the cylinder chamber and get pressurized via piston borings (Fig. 10-34, Pos. 5).

The slipper pads support themselves on the thrust washer (Fig. 10-34, Pos. 14) and discharge axially the tapered
roller bearing (Fig. 10-34, Pos. 11). Without pressure, the slipper pads are kept on the thrust washer by means of
spring (Fig. 10-34, Pos. 12).

Function

The pressure oil inlet (Fig. 10-34, Pos. A or B) and consequent oil outlet (Fig. 10-34, Pos. B or A) determine the
output drive direction of the drive shaft (Fig. 10-34, Pos. 1).

Direction of rotation:

– "Clockwise" = Direction of flow A to B

– "Counterclockwise" = Direction of flow B to A
with view onto drive shaft!

Via the control lens (Fig. 10-34, Pos. 8), the oil is directed to the cylinder bores.

The piston (Fig. 10-34, Pos. 5) is moved from the lower (Fig. 10-34, Pos. 6b) to the upper dead point (Fig. 10-34,
Pos. 6a) by means of the force acting on it and causes the drive shaft to rotate. On further rotation of the drive
shaft (additional pistons are pressurized), this piston is moved towards the lower dead point again, and oil of the
cylinder chamber is forced out through the kidney formed openings of the control lens. This oil is fed back to the
tank via the return line.
If the supply and return line is changed, it changes the output drive direction of the drive shaft.

By means of the angled arrangement of the cylinder (Fig. 10-34, Pos. 7) (bent axis design), a certain piston stroke
is produced which results in a fixed displacement per revolution of the drive shaft. According to the size of the
applied flow, this produces a specific output speed. The output torque at the drive shaft is dependent on the size of
the motor and the required operating pressure.

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10.4.3 SLEW GEARBOX (L&S)

Fig. 10-35 Slew gearbox (L&S)

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Operating hydraulics Hydraulics for the slew circuit

Legend for Fig. 10-35:

(1) Drive housing (13) Spherical roller bearing

(2) Drive shaft (14) Oil drain plug, gearbox

(3) Sun gear shaft (15) Cylindrical roller bearing

(4) Multi-disk brake (16) Oil level gauge (dipstick), gearbox

(5) Breather filter, drive shaft housing (17) First planetary stage

(6) Oil level gauge (dipstick), drive shaft hous- (18) Drive shaft to second stage
ing

(7) Disk brake housing (19) Second planetary stage

(8) Cylindrical roller bearing (20) Radial seal ring

(9) Internal ring gear (21) Drive pinion

(10) Cylindrical roller bearing (22) Grease line port

(11) Bearing ring (22) Grease line port

(12) Cartridge (23) Machined diameter

Description

The slew gear is of compact design with a two stage planetary gear including a multi-disk brake.

The gear is bolted to the superstructure and fits firmly due to the machined diameter (Fig. 10-35, Pos. 23) and the
bolt torque. The torque loaded on the hydraulic motor is transmitted by drive shafts (Fig. 10-35, Pos. 2) and sun
gear shaft (Fig. 10-35, Pos. 3) to the first planetary stage (Fig. 10-35, Pos. 17).

The sun shaft of the first planetary stage (Fig. 10-35, Pos. 17) transmits the torque into the second planetary stage
(Fig. 10-35, Pos. 19). By the planetary gears, the output drive shaft is rotated and transmits the torque to the pinion
(Fig. 10-35, Pos. 21).

The drive housing and the gearbox are filled with gear oil. Ventilation is done by breather filters.
To lubricate the lower pinion bearing (Fig. 10-35, Pos. 15), the grease line port (Fig. 10-35, Pos. 22) is connected
to the central lubrication system.

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10.4.4 SLEW GEARBOX (SIEBENHAAR)

Fig. 10-36 Slew gearbox (SIEBENHAAR)

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Operating hydraulics Hydraulics for the slew circuit

Legend for Fig. 10-36:

(1) Drive housing (15) Grease line port

(2) Drive shaft (16) Cylindrical roller bearing

(3) Sun gear shaft (17) Drive pinion

(4) Multi-disk brake (18) Shaft sealing rings

(5) Equalizing reservoir (19) Fixed bearing bushing

(6) Oil level gauge (dipstick), gearbox (20) Second planetary stage

(7) Oil level gauge (dipstick), parking brake (21) Cylindrical roller bearing

(8) Adapter (gearbox / brake housing) (22) Cylindrical roller bearing

(9) First planetary stage (23) Oil drain plug, parking brake

(10) Sun wheel (drive shaft to second stage) (24) Pressure oil port, parking brake

(11) Annulus gear (25) Oil drain plug, motor

(12) Spherical roller bearing (26) Oil filler pipe, gearbox

(13) Oil drain plug, gearbox (27) Oil level gauge (dipstick), motor

(14) Bearing center

Description

The slew gear is of compact design with a two stage planetary gear including a multi-disk brake.
The gear is bolted to the superstructure and fits firmly due to the machined diameter (Fig. 10-36, Pos. A) and the
bolt torque.

The torque loaded on the hydraulic motor is transmitted by drive shaft (Fig. 10-36, Pos. 2) and sun gear shaft
(Fig. 10-36, Pos. 3) to the first planetary stage (Fig. 10-36, Pos. 9).

Through the pivot carrier of the planetary wheels, the torque is transmitted to sun wheel (Fig. 10-36, Pos. 10) of
the second planetary stage (Fig. 10-36, Pos. 20).
By the planetary gears of the second stage, the output drive shaft is rotated and transmits the torque to the pinion
(Fig. 10-36, Pos. 17).

Drive housing, gearbox and brake housing are filled with oil. Ventilation is done by breather filters.

REMARKS: In opposition to the parking brake installed to the L&S slew gear, the SIEBENHAAR slew parking
brake is not splash lubricated through gearbox oil.

To lubricate the lower pinion bearing (Fig. 10-36, Pos. 16), the grease line port (Fig. 10-36, Pos. 15) is connected
to the central lubrication system.

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10.4.5 SLEW PARKING BRAKE (L&S)

Fig. 10-37 Slew parking brake (L&S)

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Legend for Fig. 10-37:

(1) Disk housing (8) Quad-ring with back-up rings

(2) Thrust washer (9) Springs

(3) Inner disks (lamellas) (10) Thrust washer

(4) Outer disks (lamellas) (11) Circlip

(5) Sinus (spacing) ring (12) Drive shaft

(6) Piston (13) Oil pressure port

(7) Quad-rings with back-up rings

Description

The spring loaded multi-disk brake is a safety brake, applied by spring force and released by oil pressure.

The slew parking brake is a "wet brake", because the brake housing is splash lubricated by the gearbox oil.

Function

– Brake applied:
The outer disks (Fig. 10-37, Pos. 4) engaged to the housing by serration and the inner disks (Fig. 10-37,
Pos. 3) in serrated connection with drive shaft (Fig. 10-37, Pos. 12) are pressed together by the springs
(Fig. 10-37, Pos. 9). This results in a fixed connection between housing and drive shaft.
– Brake released:
Oil pressure via port (Fig. 10-37, Pos. 13) reaches the bottom of the piston (Fig. 10-37, Pos. 6) and forces the
piston upwards against the thrust washer (Fig. 10-37, Pos. 10). This function eliminates the spring force onto
the disks so that the sinus (spacing) rings can keep the outer disks Fig. 10-37, Pos. 4) apart, thus the brake is
released.
The releasing pressure is 19–20 bar, the maximum permissible pressure 60 bar.

NOTICE
BRAKE NOT RELEASED COMPLETELY!
If not bled properly the slew parking brake can not be released completely due to air in the hydraulic sys-
tem. This may cause severe damage to the brake lamellas.

Before initial operation or after repairs on the hydraulic circuit, the slew parking brake has to be vented at
the oil pressure port (Fig. 10-37, Pos. 13).

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10.4.6 SLEW PARKING BRAKE (SIEBENHAAR)

Fig. 10-38 Slew parking brake (SIEBENHAAR)

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Legend for Fig. 10-38:

(1) Outer disk (lamella) (8) Inner piston seal

(2) Inner disk (lamella) (9) Outer piston seal

(3) Oil drain plug (10) Disk housing

(4) Pressure oil port (11) Through-hole for attaching gearbox

(5) Piston (12) Rotary shaft seal

(6) Springs (13) Drive shaft

(7) Ball bearing seal

Description

The spring loaded multi-disk brake is a safety brake, applied by spring force and released by oil pressure.

The slew parking brake is a "wet brake", because the brake disks are lubricated by the oil filling in the brake hous-
ing.

Function

– Brake applied:
The outer disks (Fig. 10-38, Pos. 1) engaged to the housing by serration and the inner disks (Fig. 10-38,
Pos. 2) in serrated connection with drive shaft (Fig. 10-38, Pos. 13) are pressed together by the springs
(Fig. 10-38, Pos. 6). This results in a fixed connection between housing (Fig. 10-38, Pos. 11) and drive shaft.
– Brake released:
Pressure oil runs through port (Fig. 10-38, Pos. 4) to the chamber between the piston (Fig. 10-38, Pos. 5) and
the brake housing ring. The oil moves the piston upwards away from the brake disks (Fig. 10-38, Pos. 1 and 2)
when the resulting force exceeds the force of the springs (Fig. 10-38, Pos. 6).
When the piston is lifted, the spring force onto the disks is eliminated. The required releasing pressure is
19-20 bar, the maximum permissible pressure 60 bar.

NOTICE
BRAKE NOT RELEASED COMPLETELY!
If not bled properly the slew parking brake can not be released completely due to air in the hydraulic sys-
tem. This may cause severe damage to the brake lamellas.

Before initial operation or after repairs on the hydraulic circuit, the slew parking brake has to be bled at the
oil pressure port (Fig. 10-38, Pos. 4).

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10.4.7 SLEW BRAKE VALVE

Fig. 10-39 Slew brake valve

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Legend for Fig. 10-39:

(1) Anti-cavitation valve circuit A (8) Spring

(2) Anti-cavitation valve circuit B (9) Valve poppet

(3) Check valve circuit B (10) Jet bore

(4) Check valve circuit A (11) Spring of main piston

(5) Pressure increasing valve (item 6-13) (12) Jet bore of main piston plug

(6) Pilot pressure piston (13) Main piston

(7) Intermediate piston

Ports

(Y) Leak oil (A’) Service line to the motor

(T) Return oil (B) Service line from control block

(A) Service line from control block (B’) Service line to the motor

Pressure test ports

(MA) Circuit A (MB) Circuit B

Function

When ever a slew motion is carried out or the foot brake is used, pilot pressure arrives at the pressure increasing
valve (Fig. 10-39, Pos. 5) at port "X". The pilot pressure pre-loads these low stages. The oil for the hydraulic motor
from the control block arrives at the service line port A or B, depending if a R.H. or a L.H. slew motion is carried out
with max. MRV pressure.

The ports A and B are internally connected to the ports A’ and B’, and these ports supply the hydraulic motor. The
operating pressure, either at port A or B, closes the anti-cavitation valves (Fig. 10-39, Pos. 1 or 2) and opens the
anti cavitation valves (Fig. 10-39, Pos. 3 or 4). That means by the check valves (Fig. 10-39, Pos. 3 or 4), the ser-
vice lines are connected to the pressure increasing valve.

Whenever the pressure is higher than the setting of the pressure increasing valve, this valve opens and dumps the
oil into the return line (Fig. 10-39, Pos. T) to tank. The pressure can be checked at the test ports MA or MB.
If after a slew motion the joystick is put into neutral position without using the foot brake, the superstructure is
turned by inertial force and the hydraulic motor acts as a pump because it is driven by the slew gear.

In this period the pressure in the service line is lower than the pressure in the return line, because there is a back
pressure valve at the tank line, and oil is forced through the anti-cavitation valves into the service line.

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Function of the double stage valve

When ever a slew motion is carried out or the foot brake is used, pilot pressure arrives the pressure increasing
valve (Fig. 10-39, Pos. 5) at port "X". The pilot pressure pre-loads these valves.

By applying pilot pressure via the external port X to piston (Fig. 10-39, Pos. 6), the pre-tensioning of the pressure
spring (Fig. 10-39, Pos. 8) is increased by the amount of the piston stroke "S", which results in the actual valve set-
ting.

The system pressure is in front of the main piston (Fig. 10-39, Pos. 13) and via the jet bore (Fig. 10-39, Pos. 12)
also in the chamber of the spring (Fig. 10-39, Pos. 11) and via the jet bore (Fig. 10-39, Pos. 10) at the pressure
relief valve poppet (Fig. 10-39, Pos. 9).

Due to the force balance, the piston (Fig. 10-39, Pos. 13) is kept in its position supported by the spring (Fig. 10-39,
Pos. 11).

Does the system pressure exceed the setting of the valve (Fig. 10-39, Pos. 9), this valve opens a channel to the
dump line port (Fig. 10-39, Pos. Y). Due to the drop of force, the piston (Fig. 10-39, Pos. 13) is moved to the right.

The pressure line gets connected with the return line (Fig. 10-39, Pos. T). The shuttle valves (276.1 and 276.2)
stabilize the pilot pressure for the double stage valve (lower stage) to avoid pressure sequences when starting
slewing.

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10.4.8 CHECKS AND ADJUSTMENTS FOR THE SLEW CIRCUIT

10.4.8.1 CHECKS & ADJUSTMENTS, DOUBLE STAGE VALVE

Fig. 10-40 Checks and adjustments

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REMARKS: It is important that the complete MRV-valve and the double stage valve (DSV) is firmly tightened
(with 300 Nm). Otherwise internal leaks could occur resulting in loud flow noises and wrong adjust-
ments.

Whenever pressure checks are carried out, they must be carried out for both slew directions to make
sure the control lines and the check valves in the brake valve block are in good condition.

High pressure stage check / adjustment

1. Connect a pressure gauge (0 -400 bar) to check point M11.3 at main control block III.

2. Switch key switch 20S001 into ON-position.

3. Move the controls several time until the pilot pressure is released.
The pressure gauge must show 0 bar.

4. Disconnect the pilot pressure line from the double stage valve and close the line with a suitable plug
(Fig. 10-40, Pos. P).

5. Loosen lock nut (Fig. 10-40, Pos. 3) of the double stage valves (DSV) and screw in set-screw (Fig. 10-40,
Pos. 4) carefully until piston (Fig. 10-40, Pos. 5) comes to stop.

6. Start the engine and let it run in high idle.

7. Check that the safety lever 20S105 is in DOWN position and the access ladder / service arm is upper end
position.

8. Lower attachment to ground and apply the slew parking brake with switch 20S029.

9. Slowly increase the pump supply line pressure by turning in set screws (Fig. 10-40, Pos. c) of the MRV in con-
trol block III while observing the pressure gauge. Stop as soon as the pressure does not rise any further, see
"Adjusting of the MRV" on page 10-98.
The gauges should show: 350±5 bar.

10. Actuate either L.H. or R.H. rotation until the hydraulic system stalls.
Read the pressure, required = 330±5 bar.

11. Carry out the steps 12 to 14 only if the gauge shows a lower or higher value so the high pressure stage must
be adjusted.

NOTICE
STRONG PULSATION OF THE RETURN LINE HOSES!
Strong pulsation of the return line hoses indicates deviation in opening pressure of DSVs and must be
avoided.

Repeat the adjusting procedure until the oil returns well-balanced via all involved secondary relief valves.

12. Loosen lock nut (Fig. 10-40, Pos. 1) of the second stage (330 bar) of the DSV.

13. Reduce the pressure with set-screw (Fig. 10-40, Pos. 2) to a value of ~320 bar, and then raise the pressure up
to the required value of 330±5 bar.

14. Secure adjusted set-screw (Fig. 10-40, Pos. 2) by tightening lock nut (Fig. 10-40, Pos. 1).

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Low pressure stage check / adjustment

15. Actuate either L.H. or R.H. rotation until the hydraulic system stalls.

16. Loosen lock nut (Fig. 10-40, Pos. 3) of the DSV.

17. Reduce the pressure with set-screw (Fig. 10-40, Pos. 4) to a value of ~110 bar, and then raise the pressure up
to the required value of 150±5 bar.

18. Secure adjusted set-screw (Fig. 10-40, Pos. 4) by tightening lock nut (Fig. 10-40, Pos. 3).

19. Stop engine and release the pilot pressure by moving the controls several times.

20. Remove the plug from the plugged pilot hose and re-plug and connect the pilot pressure line.

21. Re-set MRVs to 315+5 bar and remove the gauges after the check / adjustment is finished, see "Adjusting of
the MRV" below.

Adjusting of the MRV

1. Remove protective cap (Fig. 10-40, Pos. a).

2. Loosen lock nut (Fig. 10-40, Pos. b).

3. Turn set screw (Fig. 10-40, Pos. c) clockwise to increase the pressure, or counterclockwise to decrease the
pressure.

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10.4.8.2 CHECKS & ADJUSTMENTS, SLEW BRAKE PILOT PRESSURE

REMARKS: Refer to Fig. 10-40.

1. Connect a pressure gauge (0 - 60 bar) to test port M28.3 at the slew brake valve block (61) on top of the slew
motor.

2. Move the attachment to ground to prevent slew movement.

3. Check that the safety lever 20S105 is in DOWN position and the access ladder / service arm is upper end
position.

4. Start the engine and let it run at high idle.

5. Press down the slew brake pedal (88) fully and read the pressure: nominal value 19±1 bar.

6. If necessary adjust the pedal way / stop.

7. Release the slew brake pedal.

8. Disconnect solenoid valve [57Q505].

9. Carefully activate slew-left & slew-right fully against the slew brake.
The superstructure must stand still, no movements.

10. Reconnect solenoid valve [57Q505].

11. Shut off the engine.

12. Disconnect the pressure gauge.

10.4.8.3 CROSSCHECK OF THE DSV SETTING

1. Connect pressure gauges (0 - 400 bar) to check point M28.1 and M28.2 at the slew brake valve block (61) on
top of the slew motor.

2. Check that the safety lever 20S105 is in DOWN position and the access ladder / service arm is upper end
position.

3. Start engine and let it run in high idle.

4. Release the slew parking brake using brake switch [20S029] in the operator’s cab and actuate either L.H. or
R.H. rotation and slew 1 turn as an approach slew movement.

5. Rapidly return the control lever into neutral position without using the slew service brake pedal.

6. Check the pressure gauges during the slowing down. The pressure at one pressure gauge should increase to
the minimum service brake pressure of 150±5 bar for a short time.

7. Activate the slew function in one direction.

8. Release the slew parking brake using brake switch [20S029] in the operator’s cab and actuate either L.H. or
R.H. rotation and slew 1 turn as an approach slew movement.

9. Rapidly return the control lever into neutral position with using the slew service brake pedal.

10. Check the pressure gauges during the slowing down. The pressure at one pressure gauge should increase to
the maximum service brake pressure of 330±5 bar for a short time.

REMARKS: Also refer to the PM-Clinic (slew brake performance test (Brake Angle)).

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10.4.8.4 ADJUSTMENT OF THE SLEW MOTION DETECTION

The timing relay 11K173 blocks the switching to low idle while slewing to prevent cavitation inside the slewing sys-
tem.

NOTICE
FAULTY SETTING OF TIMING RELAY!
A faulty setting of timing relay 11K173 may cause damage to the slew system due to cavitation.

Factory pre-adjustment must not be changed until the timing relay is being replaced.

(1) Setting of the 2nd c/o contact

(2) Adjustment of the time range by selecting the max. value

(3) Direct reading scale to set the time value

(4) Function selection

Adjustment procedure for timing relay 11K173

1. Set Inst. Del. scale (Fig. 10-41, Pos. 1) to position D.

2. Set the T-Range scale (Fig. 10-41, Pos. 2) to 10 s (white

scale).

3. Set the Time scale (Fig. 10-41, Pos. 3) to 3 s.

4. Set the Function scale (Fig. 10-41, Pos. 4) to position Fig. 10-41
(OFF-delay with Time adjusted time delay).

NOTE! The setting of the Function scale is important for

proper function.

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10.4.9 FUNCTION CHECK FOR THE HYDRAULIC SLEW PARKING

BRAKE

Fig. 10-42 Function check for hydraulic slew parking brake

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Legend for Fig. 10-42:

(M10) Test port

[20S105] Switch – lock lever

[55B023] Sensor – service arm in upper end position

[57K620] Solenoid valve – hydraulic slew brake ON - OFF

[70B091] Sensor – access ladder in upper end position

[70B122] Sensor – access ladder in lower end position

Safety circuit

The hydraulic slew brake will be applied automatically when the access ladder and/or the service arm of the cen-
tral refilling system is not in its upper end position and/or if the safety lever [20S105] is not in DOWN position.

Brake apply pressure

1. Connect a gauge to test port M10 (Fig. 10-42).

2. Start the engine and let it run at high idle.

3. Lift the access ladder and service arm to the upper end position.

4. Release the slew parking brake. Therefore, set the slew brake with switch [20S029] to "0" (OFF).

5. Check the pressure at test port M10 under the following conditions:

– Safety lock lever [20S105] DOWN and access ladder / service arm in UP position:
35±3 bar => brake released.
No message should appear on the KOMTRAX monitor.
– Safety lock lever [20S105] UP and access ladder / service arm in UP position:
0 bar => brake applied.
Message G00091 "Pilot control cut out" should appear on the KOMTRAX monitor.
– Safety lock lever [20S105] DOWN and access ladder / service arm in DOWN position:
0 bar => brake applied.
Message G00091 "Pilot control cut out" should appear on the KOMTRAX monitor.
6. Apply the slew parking brake. Therefore, set the slew brake with switch [20S029] to "1" (ON).

7. Shut off the engine.

8. Disconnect the pressure gauge.

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10.5 HYDRAULICS FOR THE TRAVEL CIRCUIT

10.5.1 TRAVEL CIRCUIT

Fig. 10-43 Travel circuit

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Legend for Fig. 10-43:

(1)+(2) Main pumps (257) Control block - travel parking brake

(9)+(10) Main control blocks I + II (59.1)+(59.2) Travel motors

(14.1)+(14.2) Travel brake valves (104.1)+(104.2) Travel parking (house) brakes

(58) Rotary joint [57Q516[ Solenoid valve - travel parking brake

(62)+(74) Pilot oil unit: Travel control pedal

Function

The travel motors (Fig. 10-43, Pos. 59.1 and 59.2) are driven by the pumps (Fig. 10-43, Pos. 1 and 2). The oil
flows from the pumps through the high pressure filters to the control blocks (Fig. 10-43, Pos. 9 and 10). In neutral
position of the spools the oil flows via the return oil lines into the collector tube, and further through the filter back
to the tank.

On its way to the tank the oil must flow through the back pressure valve and the return oil filter (for back pressure
valve function refer to section 6.2 on page 6-4).
When operating a foot pedal for travelling (Fig. 10-43, Pos. 62 or 74) the respective pump line of the main control
block is connected to the travel motor service line (A or B), via the rotary joint (Fig. 10-43, Pos. 58) and travel
brake valves (Fig. 10-43, Pos. 14.1 and 14.2).

The travel brake valve acts as a flow control valve in order to avoid the travel motors picking up speed when trav-
elling downhill. Each travel gear includes a spring loaded multi-disk brake (Fig. 10-43, Pos. 104.1 and 104.2).
They are used as parking brakes, automatically applied by the function of solenoid valve [57Q516] whenever the
engine is switched OFF, or the ladder or the refilling arm is in DOWN-position.
The leak oil (case drain) of the travel motors flows back to the tank.

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10.5.2 TRAVEL MOTOR

Fig. 10-44 Travel motor

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Legend for Fig. 10-44:

(1) Drive shaft (8) Control lens

(2) Housing (9) End plate

(3) Case drain port (10) Taper roller bearing

(4) Retaining plate (11) Roller bearing

(5) Piston (12) Thrust washer

(5a) Pivot (center) pin (13) Circlip

(6a) Upper dead point (14) Circlip

(6b) Lower dead point (15) Sealing flange

(7) Cylinder (16) Radial seal ring

Axial Piston Motor A2F

The axial piston units of product group A2F with fixed displacement can operate as a hydraulic motor only.
The drive speed is proportional to the consumption capacity.

The output torque increases with the pressure drop between high and low pressure side.
The motor converts hydrostatic energy into mechanical energy.

Function

The pressure oil inlet (Fig. 10-44, Pos. A or B) and consequent oil outlet (Fig. 10-44, Pos. B or A) determine the
output drive direction of the drive shaft (Fig. 10-44, Pos. 1).

Direction of rotation (with view onto drive shaft):

"Clockwise" = Direction of flow: A to B
"Counterclockwise" = Direction of flow: B to A

Via the control lens (Fig. 10-44, Pos. 8), the oil is directed to the cylinder bores. The piston (Fig. 10-44, Pos. 5) is
moved from the lower (Fig. 10-44, Pos. 6b) to the upper point (Fig. 10-44, Pos. 6a) by means of the force acting on
it and causes the drive shaft to rotate.

On further rotation of the drive shaft (additional pistons are pressurized), this piston is moved towards the lower
point again and oil of the cylinder chamber is forced out through the kidney formed openings of the control lens.
This oil is fed back to the tank via the return line.

If the supply and return line are interchanged, the output drive direction of the drive shaft is changed.
By means of the angled arrangement of the cylinder (Fig. 10-44, Pos. 7) (bent axis design), a certain piston stroke
is produced which results in a fixed displacement per revolution of the drive shaft.

According to the size of the applied flow, this produces a specific output speed. The output torque at the drive shaft
is dependent on the size of the motor and the required operating pressure.

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10.5.3 ROTARY JOINT

Fig. 10-45 Rotary joint

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Legend for Fig. 10-45:

(1) Rotary joint housing (7) O-ring with sealing lip

(2) Rotor (8) Rotor guide ring

(3) Cover mounting screw (9) O-ring

(4) Cover (10) O-ring

(5) Race (11) Sealing element

(6) Plug screw (12) Rotary joint assembly

Ports

(A–D) Main lines to motors (L) Leak oil

(K1/ Track tensioning (St) Control oil – travel brake

K2)

Task

The rotary joint (Fig. 10-45, Pos. 12) permits a hydraulic connection between the superstructure and the undercar-
riage, that means between the rotating and the stationary part.

Function

During operation superstructure and undercarriage constantly rotate towards each other.
Nevertheless, the travel oil motors must be supplied with hydraulic oil in every position in which the superstructure
is moved in regard to the undercarriage.

By the control blocks, the oil is directed to the ports (A-D) of the rotary joint housing (Fig. 10-45, Pos. 1). The oil
flows to the outlet ports (Fig. 10-45, Pos. A-D), of the rotor (Fig. 10-45, Pos. 2) via ring grooves as well as longitu-
dinal and cross holes.

The rotor (Fig. 10-45, Pos. 2) is bolted to the undercarriage. The sealing of the ring grooves among one another is
done by sealing elements (Fig. 10-45, Pos. 10/11).

The hydraulic connection for return oil, leak oil, travel brake and the track tensioning cylinders is done via the ports
(K1/K2), (L), and (St).

The entering of dirt gets blocked by the lip-seal (Fig. 10-45, Pos. 7).

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10.5.4 TRAVEL GEARBOX

Fig. 10-46 Travel gearbox

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Legend for Fig. 10-46:

(1) Side frame mounting flange (10) Spur gear

(2) Sprocket hub (11) Sun gear of first planetary stage

(3) Planetary gear box housing, ring gear, (12) Drive shaft between first and second
circulative planetary gear

(4) First planetary stage, (13) Travel arking brake, multi disc spring loaded
stationary gear box area

(5) Second planetary stage, circulative gear (14) Live time seal
box area

(6) Third planetary stage, (15) Tapered roller bearing, main bearing
circulative gear box area

(7) Cover plate, circulative gear box t1 Max input torque t1 = 2465 Nm

(8) Input drive shaft t2 Max output torque t2 = 600,300 Nm,

(9) Stationary gear box, includes spur gear and FF Force flow from t1 through the gears to t2
first planetary gear

The travel gear consists of one spur gear set and three planetary stages.

The travel gearbox is fitted to the side frame with bolts.

Function

The hydraulic motor (not drawn) propels the input drive shaft (Fig. 10-46, Pos. 8) which drives the first reduction
spur gear (Fig. 10-46, Pos. 10).
The travel parking brake (Fig. 10-46, Pos. 13) is mounted between the hydraulic motor flange and the spur gear.

The output gear of the spur gear drives the planetary gear carrier of the first planetary stage (Fig. 10-46, Pos. 4).
The spur gear and the first planetary gear is arranged in the stationary gear box (Fig. 10-46, Pos. 9).

The sun gear (Fig. 10-46, Pos. 11) of the first planetary stage drives the sun gear of the second planetary stage
(Fig. 10-46, Pos. 5) via the drive shaft (Fig. 10-46, Pos. 12).

The planetary gear carrier of the second planetary stage drives the sun gear of the third planetary stage
(Fig. 10-46, Pos. 6). This third planetary stage drives the inner gear of the circulative planetary gear box
(Fig. 10-46, Pos. 3) which drives the direct bolted sprocket hub (Fig. 10-46, Pos. 2).

The sprocket hub is supported by the tapered roller bearing (Fig. 10-46, Pos. 15).

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10.5.5 TRAVEL PARKING BRAKE

10.5.5.1 TRAVEL PARKING BRAKE

Fig. 10-47 Travel parking brake (gear house brake) ZOLLERN (exemplarily)

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Legend for Fig. 10-47:

(1) Brake housing with motor flange (8) Piston seal ring

(2) Control pressure port to release the brake (9) Drive shaft seal

(3) Clip ring (10) Intermediate ring

(4) Inner disc carrier / drive sleeve (11) Springs,

36 main springs and 18 adjustment springs

(5) Disc package, inner and outer disc (12) Disc support ring

(6) Clip ring (13) Spring carrier and piston

(7) Input drive shaft (14) Oil drain plug, disc lubrication oil

The spring loaded multi-disk brake is a safety brake; applied by spring force and released by oil pressure.

Function

Brake applied:
By means of toothings, the outer disks of the brake disc package (Fig. 10-47, Pos. 5) are engaged to the housing
(Fig. 10-47, Pos. 1), the inner disks to the disk carrier / drive sleeve (Fig. 10-47, Pos. 4).
Inner and outer disks are pressed together by the piston (Fig. 10-47, Pos. 13) with the force of the springs
(Fig. 10-47, Pos. 11).
This results in a fixed connection between housing and inner disk carrier / drive sleeve.

Brake released:
Pressure oil runs through port (Fig. 10-47, Pos. 2) to the chamber between intermediate ring (Fig. 10-47, Pos. 10)
and piston (Fig. 10-47, Pos. 13).
When the resulting force of the oil pressure exceeds the force of the compression springs, the piston is moved
away from the brake disc package (Fig. 10-47, Pos. 5) against the force of the springs (Fig. 10-47, Pos. 11) to the
motor flange.
Now the disks are not longer pressed against each other, the brake is released.

The minimum releasing pressure is 19-20 bar, the maximum permissible pressure 60 bar.

NOTICE
BRAKE NOT RELEASED COMPLETELY!
If not bled properly the brake can not be released completely due to air in the hydraulic system. This may
cause serious damage to the brake lamellas when traveling.

Before initial operation or after repairs on the hydraulic circuit, the travel parking brakes have to be bled.
For bleeding, a hose can be connected to the vent plug.

NOTE! The parking brake at the travel gearbox is a "wet brake". Oil is required in the brake housing / on the
brake disks.

SHOP-10 06279-xD-GB-1 PC3000-6 10 - 113

Travel brake valve Operating hydraulics

10.6 TRAVEL BRAKE VALVE

Fig. 10-48 Travel brake valve

10 - 114 PC3000-6 SHOP-10 06279-xD-GB-1

Operating hydraulics Travel brake valve

Legend for Fig. 10-48:

(1) Valve spool

(2) Spring

(3) Check valve

Task

Travel brake valves control the oil flow from the hydraulic motor to the tank depending on the operating pressure.
This braking action prevents the motors from overspeeding.

Function

Spring force keeps the spool in the lowest flow position. With increasing operating pressure the opening for the
return oil flow becomes larger.

On its way to the hydraulic motor the oil flows from A to A1 or B to B1, depending on the selected travel motion.

Example

The operating pressure at port A moves spool (Fig. 10-48, Pos. 1) against the force of the spring (Fig. 10-48,
Pos. 2) and opens the way for the return oil (Fig. 10-48, Pos. B1 to B).

The check valve (Fig. 10-48, Pos. 3) prevents a direct oil flow from B1 to B.

If the operating pressure decreases to such an extend that the spring force overcomes the pressure, the flow to
the tank becomes restricted, resulting in braking of the machine.

SHOP-10 06279-xD-GB-1 PC3000-6 10 - 115

Travel brake valve Operating hydraulics

10.6.1 CHECKS AND ADJUSTMENTS

10.6.1.1 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT

Fig. 10-49 Checks and adjustments

10 - 116 PC3000-6 SHOP-10 06279-xD-GB-1

Operating hydraulics Travel brake valve

L.H. track R.H. track

M11.1 = Operating pressure for the L.H. motor M12.1 = Operating pressure for the R.H. motor

M31.1 = SRV pressure L.H. travel forward M31.3 = SRV pressure R.H. travel forward

M31.2 = SRV pressure L.H. travel backward M31.4 = SRV pressure R.H. travel backward

Table 10-16 Test ports for checks

Checks

1. Connect pressure gauges (0 - 400 bar) to the test ports listed in Table 10-16.

2. Unplug the solenoid valve [57Q516] located at the control and filter plate to keep the parking brake applied.

REMARKS: Brake OFF means that there is no pressurized oil to release/lift the brakes against spring force, so
the travel parking brake is applied.

3. Start the engine and let it run at high idle (operating temperature T3 is reached).

4. Switch pumps to Qmin via switch 11S150 at the X2-switch board.

5. Slowly increase the pump supply line pressure by turning in set screws (Fig. 10-49, Pos. 3) of the MRV while
observing the pressure gauges. Stop as soon as the pressure does not rise any further, see "Adjusting of the
MRV" on page 10-118. The gauge should show: 310±5.0 bar.
If the gauge shows a smaller or greater value, the SRV must be adjusted.

REMARKS: To ensure that only the SRVs open during checks and adjustments, it is necessary to further
increase the setting of the MRVs to approx. 330 bar.
A faulty anti-cavitation valve (68.3 + 68.4, 68.7 + 68.8) or a leaking seal of the rotary joint (Fig. 10-49,
Pos. 19) can influence the SRV pressure reading / setting. Repair or replace faulty parts, if neces-
sary.

6. Turn set screw (Fig. 10-49, Pos. 3) of the MRV ½ turn further in. The pressure will remain at the value shown
in step 5.

7. Stall the respective circuit with function against final stop.

Carefully engage the desired travel motion and keep the pedal in final position to built up max. pressure.

Adjusting

8. Carefully engage the desired travel motion and keep the pedal in final position to built up max. pressure.

9. Reduce the pressure at the required SRV to a value below the required value, then increase the pressure to
the required value of 310±5.0 bar while observing all gauges, see "Adjusting of the SRV" on page 10-118.
Adjust in steps of ¼ turn.

10. After the check / adjustment is finished reset the MRV at control block(s) to 315+5 bar, see "Adjusting of the
MRV" on page 10-118.

11. Switch pumps back to operation mode (Qmin OFF) via switch 11S150 at the X2-switch board.

12. Stop the engine.

13. Re-plug solenoid valve [57Q516].

14. Remove the pressure gauges.

REMARKS: It is important that the valve bodies of the MRVs and the SRVs are firmly tightened (with 300 Nm).
Otherwise internal leaks could occur, resulting in loud flow noises and wrong adjustments.

SHOP-10 06279-xD-GB-1 PC3000-6 10 - 117

Travel brake valve Operating hydraulics

Adjusting of the SRV

1. Remove protective cap (Fig. 10-49, Pos. 4) of the SRVs.

2. Loosen lock nut (Fig. 10-49, Pos. 5).

3. Turn set screw (Fig. 10-49, Pos. 6) clockwise to increase the pressure or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

Adjusting of the MRV

1. Remove protective cap (Fig. 10-49, Pos. 1).

2. Loosen lock nut (Fig. 10-49, Pos. 2).

3. Turn set screw (Fig. 10-49, Pos. 3) clockwise to increase the pressure, or counterclockwise to decrease the
pressure.

4. Tighten lock nut and reinstall protective cap.

10 - 118 PC3000-6 SHOP-10 06279-xD-GB-1

Operating hydraulics Travel brake valve

Please continue reading on the next page.

SHOP-10 06279-xD-GB-1 PC3000-6 10 - 119

Travel brake valve Operating hydraulics

10.6.1.2 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE

Fig. 10-50 Function check for the travel parking brake

10 - 120 PC3000-6 SHOP-10 06279-xD-GB-1

Operating hydraulics Travel brake valve

Travel parking brake release pressure

1. Connect a pressure gauge (0 - 60 bar) to test port M1.2.

2. Start engine, let it run at high idle.

3. Read the X2 pressure. Required = 35±3 bar.

If not, the pilot pressure adjustment must be corrected (refer to section 7.4.2 on page 7-12).

4. Unplug the solenoid valve [57Q516] located at the valve and cartridge block to keep the parking brake applied.

5. Operate the travel pedals; the machine should not travel.

NOTE! If the machine moves, the travel parking brake is defective and must be repaired.

6. Re-plug solenoid valve [57Q516].

REMARKS: In case of malfunction check the electrical control system and the function of the solenoid valve
[57Q516].

7. Stop the engine.

8. Disconnect the pressure gauge.

SHOP-10 06279-xD-GB-1 PC3000-6 10 - 121

Travel brake valve Operating hydraulics

Please continue reading on the next page.

10 - 122 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic track tensioning system

11 HYDRAULIC TRACK
TENSIONING SYSTEM

SHOP-10 06279-xD-GB-1 PC3000-6 11 - 1

General Hydraulic track tensioning system

11.1 GENERAL

Fig. 11-1 Overall view of the hydraulic track tensioning system

11 - 2 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic track tensioning system General

Legend for Fig. 11-1:

(58) Rotary joint

(89.1) Shut-off cock at the track tensioning valve block (90)

(89.2) Service / transport shut-off cock for L.H. side *("O" = open / "C" = closed)

(89.3) Service / transport shut-off cock for R.H. side *("O" = open / "C" = closed)

(93.1 + 93.2) Bladder accumulator, 5 liters (pre-charge gas pressure: 150 bar)

(100.1 + 100.2) Track tensioning cylinders

(89.1 + 89.2) Membrane accumulator, 0.7 liter (pre-charge gas pressure: 31 bar)

(90) Track tensioning valve block

(L11) Supply line (travel parking brake circuit)

M29.1 + M29.4 Bleeder and hydraulic pressure test ports at the tensioning cylinders, L.H. side

M29.2 + M29.3 Bleeder and hydraulic pressure test ports at the tensioning cylinders, R.H. side

M15.5 Bleeder and hydraulic pressure test port at the bladder accumulator (93.1), L.H.-side.

M15.6 Bleeder and hydraulic pressure test port at the bladder accumulator (93.2), R.H.-side.

General information

The hydraulic track tensioning system automatically ensures the correct tension of the tracks.

The track tensioning pressure (35 bar) provides the force to move the guide wheels to the front until the correct
track tension is obtained.

The track safety function is controlled by valve block (Fig. 11-1, Pos. 90) with a double stage valve (35±2 /
310±5 bar).

Pressure peaks due to external forces acting on the idlers will be absorbed by means of the pressure accumula-
tors of the first (Fig. 11-1, Pos. 100.1 & 100.2) and second stage (Fig. 11-1, Pos. 93.1 & 93.2).
Heavy shocks and high pressure peaks will be eliminated by the double stage valve of the 310 bar section in the
valve block (Fig. 11-1, Pos. 90).

NOTICE
CLOSED SERVICE SHUT-OFF COCKS!
Traveling with closed service shut-off cocks will result in severe damage to the track tension cylinders
due to the missing pressure peak absorbtion from the pressure accumulators.

Only for service or repair reasons, the service shut-off cocks (Fig. 11-1, Pos. 89.2 & 89.3) may be shut.
Never move the shovel with closed service shut-off cocks.

NOTE! After the assembly and during commissioning, before the shovel moves for the first time, each track
tensioning cylinder has to be bled via the test ports M29.1...M29.4 until air-free oil is draining off.

Under normal operating conditions, the shut-off cocks (Fig. 11-1, Pos. 62.2 & 62.3) inside the side frames must
always be open. Only for service or repair reasons, the cocks may be shut.

The accumulators are to be maintained frequently (every 3000 hours) because of the gas pressure charge. See
KMG tool catalogue for the charging tool box.
After 30,000 hours, the accumulators are to be replaced by new ones.

SHOP-10 06279-xD-GB-1 PC3000-6 11 - 3

Functional description Hydraulic track tensioning system

11.2 FUNCTIONAL DESCRIPTION

Fig. 11-2 Circuit diagram of the hydraulic track tensioning system

11 - 4 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic track tensioning system Functional description

If solenoid valve 57Q516 is actuated, the oil flows via the rotary joint (58), the orifice, the two check valves (92.1 +
92.2) and the service shut-off cocks (89.2 + 89.3) into the tensioning cylinders (94.1...94.4).
The resulting force moves the guide wheels toward the front until the correct track tension is obtained.

Simultaneously the system is connected to the double-stage valve (87) via check valves (92.1 + 92.2).

External forces acting at the guide wheels will be absorbed through the pressure accumulators (100.1 + 100.2, first
stage) and (93.1 + 93.2, second stage).

Purpose of the double-stage valve

The two system pressures

– 35±2 bar: To maintain the track tension

– 310±5 bar: Secondary relief valve pressure to prevent an overload
are controlled by the double-stage valve (87).

Cushioning function

When the tensioning cylinders (94.1...94.4) are moved in by external forces, the check valves (92.1 + 92.2) will be
closed. A certain amount of the displaced oil from the tensioning cylinders is taken up by the pressure accumula-
tors.

– First stage:
At a pressure higher than 31 bar, oil is taken up by the membrane accumulators (100.1 + 100.2) mounted at
the side frames.
– Second stage:
At a pressure higher than 150 bar, oil is taken up by the bladder accumulators (93.1 + 93.2) in the middle of
the car body.
The system pressure can rise up to 310±5 bar according to the setting of the double stage valve (140) inside the
valve block (90).

When the external forces drop below the forces created by the track tensioning cylinders, the oil taken up by the
accumulators is pushed back into the track tensioning cylinders (94.1...94.4).

If the whole amount of oil could not be taken up the accumulators, oil is added from the pilot pressure circuit
(35 bar) when the tensioning cylinders move back to their initial position.

SHOP-10 06279-xD-GB-1 PC3000-6 11 - 5

Double stage valve Hydraulic track tensioning system

11.3 DOUBLE STAGE VALVE

Fig. 11-3 Pressure double stage valve

(1) Pilot valve with valve seat (7) Set screw – low pressure (35 bar)

(2) Valve poppet (8) Set screw – high pressure (315 bar)

(3) Compression spring (9) Piston

(4) Main valve with sleeve (10) Pin

(5) Main piston (11,12) Jet bore

(6) Closing spring (13,14) Lock nut

11 - 6 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic track tensioning system Double stage valve

Description

The double-stage valve is a remote controlled pressure relief valve.

Function

The valve poppet (Fig. Fig. 11-3, Pos. 2) is connected to port "P" via jet bores (Fig. Fig. 11-3, Pos. 11 and 12).

If static pressure increases above the set pressure value, the valve poppet (Fig. Fig. 11-3, Pos. 2) opens and
allows the oil to flow freely to the tank (Fig. Fig. 11-3, Pos. T1).
This oil generates a pressure drop in the spring chamber of the main spool, the closing force of the spring
(Fig. Fig. 11-3, Pos. 6) is cancelled, and the main piston (Fig. Fig. 11-3, Pos. 5) opens to allow the oil flow to the
tank (Fig. Fig. 11-3, Pos. T2).

SHOP-10 06279-xD-GB-1 PC3000-6 11 - 7

Tensioning cylinder Hydraulic track tensioning system

11.4 TENSIONING CYLINDER

Fig. 11-4 Tensioning cylinder

11 - 8 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic track tensioning system Tensioning cylinder

Legend for Fig. Fig. 11-4:

(1) Cylinder tube (7) Scraper

(2) Piston (8) Retracting device

(3) Piston guide ring (9) Seal ring (dark)

(4) Piston guide strap (M) Bleeder port

(5) Seal ring (light) (P) Oil supply

(6) O-ring

SHOP-10 06279-xD-GB-1 PC3000-6 11 - 9

Adjustments / checks Hydraulic track tensioning system

11.5 ADJUSTMENTS / CHECKS

Fig. 11-5 Adjustments / checks on hydraulic track tensioning system

11 - 10 PC3000-6 SHOP-10 06279-xD-GB-1

Hydraulic track tensioning system Adjustments / checks

Legend for Fig. Fig. 11-5:

[57Q516] Solenoid valve – travel parking brake

(257.1) Safety relief valve (SRV) – safety valve for travel parking brake / track tensioning system (50 bar)

M9 Test port – travel parking brake operating pressure (35 bar)

Basic check

1. Connect a pressure gauge (0...60 bar) to test ports M9and M15.5.

2. Start the engine and let it run at high idle.

3. Ensure that the access ladder and the refilling arm are in the upper end position (as the pre-condition for
releasing the travel parking brake).

4. Read the track tensioning operating pressure at test port M9 (nominal value: 35±2 bar).

REMARKS: Ensure that the track tensioning operating pressure at pressure test port M9 is the same as at test
port M15.5 (Fig. 11-5).
If not, check the double stage valve (refer to section 11.3 on page 11-6) and adjust the low pressure
stage set screw (Fig. 11-3, Pos. 7) to 35±2 bar, or check the rotary joint for leaks.

5. Stop the engine.

6. The pressure should now drop to 0 bar because the solenoid valve [57Q516] is de-energized, allowing the oil
to flow back to the tank.

7. Disconnect the pressure gauge.

REMARKS: The high pressure stage of the double stage valve is bench adjusted (310±5 bar).

SHOP-10 06279-xD-GB-1 PC3000-6 11 - 11

Adjustments / checks Hydraulic track tensioning system

Please continue reading on the next page.

11 - 12 PC3000-6 SHOP-10 06279-xD-GB-1

Access ladder, hydraulically operated

12 ACCESS LADDER,
HYDRAULICALLY
OPERATED

SHOP-10 06279-xD-GB-1 PC3000-6 12 - 1

General Access ladder, hydraulically operated

12.1 GENERAL

Fig. 12-1 Hydraulically operated access ladder

12 - 2 PC3000-6 SHOP-10 06279-xD-GB-1

Access ladder, hydraulically operated General

Legend for Fig. 12-1:

(1) Access ladder

(S1) Reduced speed at ladder up only

(S2) Standard speed at ladder up/down

(S3) Reduced speed at ladder down only

[70B091] Ladder limit switch - DOWN-position

[70B122] Ladder limit switch - UP-position

[20S084] Ladder switch (up/down), operator’s cab

[70S018] Light switch, ladder

[70S073] Ladder switch, up/down

[70S073b] Ladder switch, up/down - 2nd hand

[70S084a] Ladder pull switch

General

The access ladder is hydraulically operated by a hydraulic cylinder with the pilot pressure X4 of 60±1 bar.
The movement of the ladder is controlled by the function of switches [70S073] and [70S073b] in double-hand
operation or with the function switch [20S084] at the operator’s cab.

There is an additional pull switch [70S084a] below the ladder support. With this switch activated the ladder can be
moved down from the ground using the pull chain.

REMARKS: The pull switch [70S084a] also acts as safety switch for emergency lowering of the access ladder.
When the chain is being pulled down with the engine running, the pilot control system is made inop-
erative preventing further movement of the shovel.

Lifting the ladder is only possible with the engine running. The lowering movement is possible by hydraulic force
with the engine running or by the force of gravity with the engine at standstill.

If the ladder is not in the upper end position (sensor [70B122] not activated), the pilot control is switched off via
relay [11K111]. Solenoid valve [57K620] activates the hydraulic slew parking brake and a message appears on the
display in the operators cab.

NOTE! In case of replacing the pull chains take care of their length. Make sure that the pull chains can not
come in contact with any parts of the undercarriage e.g. track.

SHOP-10 06279-xD-GB-1 PC3000-6 12 - 3

Function of the hydraulically operated access ladder Access ladder, hydraulically operated

12.2 FUNCTION OF THE HYDRAULICALLY OPERATED

ACCESS LADDER

Fig. 12-2 Hydraulic diagram for the hydraulically operated access ladder

12 - 4 PC3000-6 SHOP-10 06279-xD-GB-1

Access ladder, hydraulically operated Function of the hydraulically operated access ladder

Legend for Fig. 12-2:

[57Q623a] Solenoid valve – access ladder UP

[57Q623b] Solenoid valve – access ladder DOWN

[57Q625] Solenoid valve (speed control) (OFF => reduced speed)

(26.1) Pilot pressure filter (258.3) Pressure relief valve (safety valve 70 bar)

(105) Hydraulic cylinder (258.4) Shuttle valve

(249) Solenoid valve 57Q623a/b (258.5 ) Check valve

(252.1) X2 pressure reducing valve (35±3 bar) (258.6) Check valve

(252.2) X4 pressure relief valve (60±1 bar) (258.7) Orifice

(258.1) Solenoid valve 57Q625

Engine running

REMARKS: Refer to Fig. 12-1 and Fig. 12-2.

The pilot oil pump delivers the oil through the filter (26.1) to port A of pressure relief valve (252.2).

The pressure relief valve maintains the adjusted pressure of 60±1 bar, called X4-pressure.

The X4-pressure is present at port P of solenoid valve 57Q623a/b.

If solenoid valve 57Q623a/b is energized, the oil flows to the cylinder and the ladder will move up or down.
Return oil from cylinder (105) flows back via solenoid valve 57Q623a/b to solenoid valve 57Q625.

REMARKS: The signal horn at the cab base is activated at every ladder movement.

Every ladder movement starts at maximum speed and ends with reduced speed (cushioning function) until final
position is reached.

Ladder DOWN:
With the main key switch 20S001 ON, when Ladder DOWN is activated using switches 70S073 and 70S073b in
double-hand operation or using switch 20S084 at the operator’s cab, solenoid valve 57Q623b is energized.
The ladder movement starts at maximum speed. Solenoid valve 57Q625 is activated and the return oil flow is not
restricted.
As soon as sensor 70B091 is activated while ladder is moving down the solenoid valve 57Q625 is de-activated
and the return oil flow is restricted by orifice (258.7), resulting in reduced cylinder speed (Fig. 12-1, Pos. S3).

REMARKS: If all switches 70S084, 70S073 and 70S073b are in neutral position with the ladder in “DOWN-posi-
tion” sensor 70B091 de-energizes all solenoids (57Q625, 57Q623a+b). So the ladder is “blocked” in
“DOWN-position”.

Ladder UP:
With the main key switch 20S001 ON, when Ladder UP is activated using switches 70S073 and 70S073b in dou-
ble-hand operation or using switch 20S084 at the operator’s cab, solenoid valve 57Q623a is energized.
The ladder movement starts at maximum speed. Solenoid valve 57Q625 is activated and the return oil flow is not
restricted.
As soon as sensor 70B122 is activated while ladder is moving up the solenoid valve 57Q625 is de-activated and
the return oil flow is restricted by orifice (258.7), resulting in reduced cylinder speed (Fig. 12-1, Pos. S1).

REMARKS: If all switches 70S084, 70S073 and 70S073b are in neutral position with the ladder in “UP-position”
sensor 70B122 de-energizes solenoid valve 57Q625 and energizes solenoid valve 57Q623a. So the
ladder is “blocked” in "UP-position". The cylinder is always charged with pressure in this position.

SHOP-10 06279-xD-GB-1 PC3000-6 12 - 5

Function of the hydraulically operated access ladder Access ladder, hydraulically operated

Fig. 12-3 Hydraulic diagram for the hydraulically operated access ladder

12 - 6 PC3000-6 SHOP-10 06279-xD-GB-1

Access ladder, hydraulically operated Function of the hydraulically operated access ladder

Engine is not running and the ladder is in the “final upper position”

REMARKS: Refer to Fig. 12-1 and Fig. 12-2.

With the main key switch 20S001 ON, when Ladder DOWN is activated using switches 70S073 and 70S073b in
double-hand operation or using switch 20S084 at the operator’s cab, solenoid valve 57Q623b is energized. Sole-
noid valve 57Q623b connects the piston side of the hydraulic cylinder to the return line, and solenoid valve
57Q625 is activated, so that the oil can return to the tank without resistance.
Now the ladder can move down only by its own mass (due to the force of gravity).
As soon as sensor 70B091 is activated the solenoid valve 57Q625 is de-activated and the return oil flow is
restricted by orifice (258.7), resulting in reduced cylinder speed (Fig. 12-1, Pos. S3).

The rod site of the cylinder receives oil via anti-cavitation valve (258.5).

There is an additional pull switch 70S084a below the ladder support. With this switch activated the ladder can be
moved down, from the ground.

REMARKS: The pull switch 70S084a also acts as safety switch for emergency lowering of the access ladder from
the ground.
When the chain is being pulled down with the engine running, the pilot control system is made inop-
erative preventing further movement of the shovel.

NOTICE
BLOCKED MOVING RANGE!
The hydraulic access ladder may get damaged if it comes in contact with any obstacles in the moving
range.

Make sure that there are no obstacles in the moving range of the ladder.
Stop raising the ladder by releasing the control switch [70S0S84] if there are any obstacles in the moving
range.

WARNING
RISK OF DOWNFALL!
Serious injury or death could occur when persons are lifted with the hydraulic access ladder.

Do not lift persons or objects (tools) with the hydraulic access ladder.

SHOP-10 06279-xD-GB-1 PC3000-6 12 - 7

Adjustments / checks Access ladder, hydraulically operated

12.3 ADJUSTMENTS / CHECKS

Fig. 12-4 Adjustments / checks

12 - 8 PC3000-6 SHOP-10 06279-xD-GB-1

Access ladder, hydraulically operated Adjustments / checks

1. Connect pressure gauges to test ports M1.1 and M37.1.

2. Start the engine and let it run at high idle.

3. Lift the access ladder to the upper end position using switch 70S073 and 70S073b in double-hand operation
or using switch 20S084 at the operator’s cab.

4. Check the pressure at the test ports M1.1 and M37.1.

Both pressures must be X4-pressure: 60±1 bar

5. If adjustment is required loosen the lock nut (Fig. 12-4, Pos. 1) and adjust the X4-pressure to 60±1 bar at the
set screw (Fig. 12-4, Pos. 2). At last, tighten the lock nut (Fig. 12-4, Pos. 1).

6. Stop the engine.

7. Remove the pressure gauges.

SHOP-10 06279-xD-GB-1 PC3000-6 12 - 9

Adjustments / checks Access ladder, hydraulically operated

Please continue reading on the next page.

12 - 10 PC3000-6 SHOP-10 06279-xD-GB-1

Central refilling system (refilling arm)

13 CENTRAL REFILLING
SYSTEM (REFILLING ARM)

SHOP-10 06279-xD-GB-1 PC3000-6 13 - 1

Refilling arm location Central refilling system (refilling arm)

13.1 REFILLING ARM LOCATION

Fig. 13-1 Overall view on the central refilling system

13 - 2 PC3000-6 SHOP-10 06279-xD-GB-1

Central refilling system (refilling arm) Refilling arm location

Legend for Fig. 13-1:

(1) Pull chain for refilling arm

(2) Hydraulic refilling arm "down" - refilling position

(3) Hydraulic cylinder

[55B023] Refilling arm limit switch - UP-position

[55S087] Refilling arm pull switch (for actuating chain (1))

General

The excavator is equipped with a central refilling system for easy service and maintenance.

One part of this system is the movable refilling arm (Fig. 13-1, Pos. 2). This arm is hydraulically driven by cylinder
(Fig. 13-1, Pos. 3) and mounted below the power frame.

The refilling arm can be moved up and down by actuation switch [55S087] when the engine is running and when
the refilling arm enabling switch 20S094 on the dashboard is turned ON (position “1”).
When the engine is not running the refilling arm can only be moved dow when actuating switch [55S087].

REMARKS: As long as the pull chain (Fig. 13-1, Pos. 1) is being pulled and actuation switch [55S087] is acti-
vated, the refilling arm continues to move up or down until the upper or lower end-position is
reached.
If the actuation switch is released, the refilling arm stops.

CAUTION
RISK OF BEING HIT BY THE REFILLING ARM!
Injury could occur when persons are hit by the moving arm.

Before initiating a refilling arm movement, make sure that nobody is within the moving range of the refill-
ing arm.

NOTICE
For correct operation of the refilling arm, refer to the OPERATION MANUAL.

If the refilling arm moves out of its upper position, the pilot control will stop all working functions and
activate the slew brake. A message is displayed on the monitor in the operators cab.

SHOP-10 06279-xD-GB-1 PC3000-6 13 - 3

Function Central refilling system (refilling arm)

13.2 FUNCTION

Fig. 13-2 Hydraulic circuit diagram of the central refilling system

13 - 4 PC3000-6 SHOP-10 06279-xD-GB-1

Central refilling system (refilling arm) Function

Legend for Fig. 13-2:

[57KQ24a] Solenoid valve – refilling arm UP

[57Q624b] Solenoid valve – refilling arm DOWN

[57Q624c] Solenoid valve – refilling arm LOCK

(5) Control oil pump (252.2) X4 pressure relief valve (60±1 bar)

(26.1) Pilot pressure filter (259.3 ) Check valve

(105) Hydraulic cylinder (259.4) Check valve

(252.1) X2 pressure reducing valve (35±3 bar) (258.4) Orifice

Description

REMARKS: Pre-condition: the engine is running.

The control oil pump (Fig. 13-2, Pos. 5) delivers oil through filter (Fig. 13-2, Pos. 26.1) to port A of pressure limiting
valve (Fig. 13-2, Pos. 252.2). The pressure limiting valve maintains the adjusted pressure of 60±1 bar, called X4
pressure.

By means of the pressure reducing valve (Fig. 13-2, Pos. 252.1), the X4 pressure is reduced to 35±3 bar (called
X2 pressure). X2 pressure is present at port P of solenoid valve [57Q624a/b].

If solenoid valves [57Q624a] and [57Q624c] are energized, pressurized oil flows to the piston side of the refilling
arm cylinder, and the refilling arm moves up.
If solenoid valves [57Q624b] and [57Q624c] are energized, pressurised oil flows to the rod side of the refilling arm
cylinder, and the refilling arm moves down.

Under working conditions, solenoid valve [57Q624c] is permanently energized to hold the refilling arm in the upper
position under pressure. When the solenoid valve is de-energized by key switch 20S001 in OFF position, the refill-
ing arm position is held by the non-return valve in solenoid valve [57Q624c].

The refilling arm can only be moved up or down with activated key switch 20S001 and activated refilling arm
enabling switch 20S094 in the operator’s cab.

The proximity switch 55B023 signalizes that the refilling arm is in the upper position.

If the refilling arm enabling switch 20S094 is OFF, the pilot pressure is cut off.
Pilot pressure is also cut off when the service arm is out of range of the proximity switch 55B023 in order to pre-
vent damage to the lowered service arm.

SHOP-10 06279-xD-GB-1 PC3000-6 13 - 5

Function Central refilling system (refilling arm)

Please continue reading on the next page.

13 - 6 PC3000-6 SHOP-10 06279-xD-GB-1

Hints for reading the hydraulic diagram

14 HINTS FOR READING

THE HYDRAULIC DIAGRAM

SHOP-10 06279-xD-GB-1 PC3000-6 14 - 1

General Hints for reading the hydraulic diagram

14.1 GENERAL

Fig. 14-1 Example of a hydraulic circuit diagram

14 - 2 PC3000-6 SHOP-10 06279-xD-GB-1

Hints for reading the hydraulic diagram General

REMARKS: The illustration is only used exemplarily.

Use the circuit diagram corresponding to your machine for details.

Legend for Fig. 14-1:

Number/Code
Item Description Explanation
[Example]

Diagram no. and type of the 948 552 40 b Diagram no. is only valid for the specified
A
specified machine PC4000-D machine.

B Defined serial no. 08199 —

Sheet no. / total number of

C
sheets
01 / 02 1st of two sheets

"Hydraulikplan KS" (KS: Klappschaufel)

= Hydraulic Diagram FSA
(FSA: Front Shovel Attachment) /
D Diagram title Hydraulikplan KS
"Hydraulikplan TL" (TL: Tieflöffel)
= Hydraulic Diagram BHA"
(BHA: Backhoe Attachment)
Coordinates to specify the Page 1, coordinate C vertically and coordinate
E 1 C 10
location of a component 10 horizontally

F Component no. 9 No. for main control block III

Line no. 20; coming from / going to sheet 2

G Line no. with cross reference L20/ 2D4
coordinates D4
The rectangles represent the main control block
spools (numbered from bottom up); when
Assignment of main control
divided in two parts, spool "a…" (left) and spool
H block spools to machine —
"b…" (right) are used for different components.
functions, function priorities
Rectangles appearing on the lower right stand
for additional components for special functions.
Position of main pumps (with no.) on the PTO
Block diagram for assignment
J — and the associated main control block (with
of pumps to main control blocks
control spool designations)
See Fig. 14-2 on next page: The machine control determines the switching
Switching points for functions points according to the applied oil type/viscos-
K —
acc. to PTO and hydraulic oil ity; therefore, the correct type has to be entered
temperatures and type of oil via KOMTRAX Plus.

Further remarks:

– All components are shown in neutral and pressureless position.

– A wide continuous black line shows a main component or assembly (e.g.: valve and filter panel, main pump,
hydraulic tank, …).
– A continuous black line shows a main hydraulic line. This line is temporarily or permanently loaded with high or
pilot pressure.
– A broken line represents a return, drain or control oil line.
– A black dot shows a connection point. The position of this connection is not explicitly defined.
– A white dot shows a connection or port of a component with a well-defined position at the component
(e.g.: via port marking/number).

SHOP-10 06279-xD-GB-1 PC3000-6 14 - 3

Hydraulic symbols Hints for reading the hydraulic diagram

14.2 HYDRAULIC SYMBOLS

Fig. 14-2 Example of a hydraulic circuit diagram

14 - 4 PC3000-6 SHOP-10 06279-xD-GB-1

Hints for reading the hydraulic diagram Hydraulic symbols

REMARKS: The illustration is only used exemplarily. Use the original circuit diagram for better readability.

There are symbols described on the following pages not marked in Fig. 14-2.

The list of hydraulic symbols is not intended to be exhaustive.

For more information, refer to standard ISO 1219.

14.2.1 LINES, UNIONS

Lines, unions

Item Symbol Description Used as / at / on

1.
Suction line or pressurized line
Oil supply line, of main hydraulic circuit, pilot
hose or pipe pressure circuit or auxiliary
circuits

2.
Return lines connected to the
Return oil line,
return oil filter chamber of the
hose or pipe
main oil tank

3.
Return line connected to the
Case drain line (leak oil),
case drain oil filter chamber
hose or pipe
of the main oil tank

4.

Control oil line, Pilot control, pump regulation

hose or pipe line, parking brake control line

5.

Pipes or hoses not connected

Crossed line
with each other

6.

Connection of hydraulic lines

Connection point
without a well-defined position

7.
Connection to components like
valve blocks, tanks, pumps.
Component connection point
Connection with a well-defined
position at a component.

SHOP-10 06279-xD-GB-1 PC3000-6 14 - 5

Hydraulic symbols Hints for reading the hydraulic diagram

Lines, unions

Item Symbol Description Used as / at / on

8.

Plugged connection point, Shut (currently not used)

plugged with any kind of plug connection point

9.

Plugged connection point, Shut (currently not used)

plugged with any kind of plug connection point

10.
Compensator,
compensates line differences in Oil reservoir outlet to the
length due to vibration and suction tank
change in temperature

11.
Tank drain couplings and lines to
Quick coupling,
be removed frequently, e.g. at
special union with integrated
lubrication systems with remov-
check valve
able barrels.

12.
Orifice restriction,
not adjustable, with stated orifice E.g.: oil cooler inlet
diameter [mm]

13.

Pressure test port, HP filter, fan valve block....

with a special quick coupling at all important circuits

14.
Connection of lines with the
Distributor block same destination, e.g. return
lines to tank

14 - 6 PC3000-6 SHOP-10 06279-xD-GB-1

Hints for reading the hydraulic diagram Hydraulic symbols

14.2.2 COMPONENTS, VALVES

Components, valves

Item Symbol Description Used as / at / on

15.
Accumulator,
Input line to the remote control
filled with nitrogen with the
valves, return oil collecting tube,
specified pressure for the
track tensioning system
accumulator

16.
Installed in suction lines to the
Screen filter
pumps, oil tank outlet and
(min. screening size: 1.0 mm)
return oil collecting tube.

17.

Hydraulic oil cooler,

Oil cooler
PTO oil cooler

18.

On top of PTO or hydraulic oil

Breather filter
tank

19.

Spray nozzles,
Gearbox (PTO) cooling
inside a case for cooling
and lubrication system
and lubrication

Table 14-1 Symbols for lines and unions

14.2.3 SENSORS

Sensors

Item Symbol Description Used as / at / on

20.
Pressure switch / sensor
Input = pressure E.g.: return/leak oil tank (digital),
Output = electrical signal high pressure filter (analogue)
(analogue or digital)

21.
Pressure switch
E.g.: Filter monitoring
Input = pressure
PTO lubrication
Output = digital

SHOP-10 06279-xD-GB-1 PC3000-6 14 - 7

Hydraulic symbols Hints for reading the hydraulic diagram

Sensors

Item Symbol Description Used as / at / on

22.
Temperature sensor
Input = temperature
E.g.: hydraulic tank
Output = electrical signal,
proportional to the temperature

23.
Level sensor
Input = fluid level
Hydraulic tank
Output = electrical signal,
analogue or digital

Table 14-2 Symbols for sensors

14.2.4 VALVES, VALVE COMPONENTS

Valves, valve components

Item Symbol Description Used as / at / on

24.

Valve in track tensioning system

Manually operated lever
to hold the cylinders’ position

25.

Electric / magnetic operated unit

Solenoid valves
Solenoid

26.

Pressure relief valves,

Pilot pressure controlled unit
disc brakes

27.

Spring (fixed force) Solenoid valves

28.

Spring (adjustable spring force) Pressure relief valves

14 - 8 PC3000-6 SHOP-10 06279-xD-GB-1

Hints for reading the hydraulic diagram Hydraulic symbols

Valves, valve components

Item Symbol Description Used as / at / on

29.
Check valve
E.g.: main pump outlet, slew
In drawn position: free flow from
brake valve block, anti cavitation
right to left, blocked flow from
valves at main control blocks
left to right

30.
Check valve, spring loaded
Opens in flow direction only
against spring force (if pressure
exceeds spring force)

31.
Double check valve
In shown position: valve only
Slew brake control
allows flow from left to bottom or
from right to bottom

32.
Shut-off valve with monitoring
switch. Main shut-off valve between
The adjustable switch monitors oil tank and suction tank
the valve position

33.
2/2 control valve, manually
operated (with lever); check Track tensioning system
valve

34.

3/2 control valve, manually Change-over valve of

operated; change-over valve pump regulation

35. 4/2 directional control valve,

electrically controlled Slew parking brake,
(4/2 solenoid valve) travel parking brake,
Neutral position: ladder control
P-A and B-T connected

36.
Variable throttle valve,
hydraulically controlled, Travel brake valve located at the
pilot control port pressureless car body
= maximum restriction

37.
3/2 directional control solenoid
valve, seat design = leak oil free;
3/2 way solenoid valve,
neutral = ports P–A connected

SHOP-10 06279-xD-GB-1 PC3000-6 14 - 9

Hydraulic symbols Hints for reading the hydraulic diagram

Valves, valve components

Item Symbol Description Used as / at / on

38.
4/3 direction control solenoid
valve, 4/3 solenoid valve; Ladder control,
in neutral position all ports service arm control
closed

39.

External pilot controlled PC3000 and PC4000 FSA:

proportional floating valve at stick and boom

40.

Main control valve with standard

function

Neutral position:
open pump flow (P–T),
control port flushing (T–a, T–b), Standard control valve for bidi-
closed pressure ports A and B. rectional motors and double-act-
Position b: ing cylinders
closed circulation port (P–T),
ports P–B and A–T connected.
Position a:
closed circulation port (P–T),
ports P–A and B–T connected.

41. Main control valve with

pressureless lowering function
(lowering function marked with
additional symbol " ")

Neutral position:
open pump flow (P–T), Control valve for pressureless
control port flushing (T–a, T–b), lowering.
closed pressure ports A and B. Used to assist the floating
Position b: function of boom and/or stick.
closed circulation port (P–T),
ports P–B and A–T connected.
Position a:
open pump flow P–T,
closed pressure port A,
ports B–T connected.

14 - 10 PC3000-6 SHOP-10 06279-xD-GB-1

Hints for reading the hydraulic diagram Hydraulic symbols

Valves, valve components

Item Symbol Description Used as / at / on

42. Main control valve with floating

function (floating function
marked with additional
symbol " ")
Neutral position:
open pump flow (P–T),
control port flushing (T–a, T–b),
closed pressure ports A and B. Floating valve for boom and/or
Position b: stick
closed circulation port (P–T),
ports P–B and A–T connected,
check valve prevents flow BP.
Position a:
open pump flow P–T and P–A,
ports B–A connected with check
valve to prevent flow TB.

43. Pressure reducing valve

assembly Pressure reducing valve to
Variable inlet pressure at port P provide reduced operating
and constant lower output pres- pressure for travel parking
sure at port A, adjustable output brakes and slew parking brakes
pressure (set to 35 bar)

44.
Pressure relief valve,
Safety valve in ladder
directly controlled
control circuit
and adjustable

45.

Pressure relief valve with

anti-cavitation valve Secondary relief valve
(check valve) assembly, at main control blocks
external drain at port Y

46.
Throttle check valve with
secondary relief valve, Distribution manifold normally in
throttle and secondary valve the line to the cylinder, piston
mechanically adjustable, exter- side
nal drain at port Y

47.
Pressure increasing valve,
pressure relief valve with
Slew brake valve block,
variable setting, pilot pressure
track tensioning system
controlled via port X, low pilot
pressure = low relief pressure

SHOP-10 06279-xD-GB-1 PC3000-6 14 - 11

Hydraulic symbols Hints for reading the hydraulic diagram

Valves, valve components

Item Symbol Description Used as / at / on

48.
Proportional pressure valve,
to reduce the supply pressure P Remote control valves,
at port A proportional to the pump regulation
solenoid current

49.

4-port proportional valve,

Pump regulation
directly operated by a solenoid

50.

Pressure relief valve,

mechanically and hydraulically
Radiator and oil cooler fan drive
adjustable via pilot port X,
pilot valve drain port Y

Table 14-3 Symbols for valves and valve components

14.2.5 PUMP, MOTOR, CYLINDER

Pump, motor cylinder

Item Symbol Description Used as / at / on

51.
Single-acting cylinder,
only moving n one direction
Track tensioning system
when pressurized,
returning by external forces

52.
Double-acting cylinder, operated
in both directions by pressurized Attachment
oil

53.

Drive shaft of a motor or pump

Main pumps
with one direction

14 - 12 PC3000-6 SHOP-10 06279-xD-GB-1

Hints for reading the hydraulic diagram Hydraulic symbols

Pump, motor cylinder

Item Symbol Description Used as / at / on

54.
Hydraulic pump, Pilot pump, engine coolant fan,
fixed volume per REV, oil cooler fan, PTO lubrication
suction port S, pressure outlet P pump

55.
Hydraulic pump,
variable output volume per REV Main pump
with external case drain

56.

Variable hydraulic pumps with

external case drain combined Main pump (tandem pump)
with charge pump (impeller)

57.

Hydraulic motor
can be used in both directions, Oil cooler fan motors
with external case drain L

58.

Motor with disc brake,

disc brake spring loaded:
Travel motor, slew motor
pressureless pilot line =
maximum brake torque

SHOP-10 06279-xD-GB-1 PC3000-6 14 - 13

Hydraulic symbols Hints for reading the hydraulic diagram

Pump, motor cylinder

Item Symbol Description Used as / at / on

59.

Lubrication pump drive, Lubrication pump station for

differential cylinder with central lubrication system and
integrated control valves slew circle lubrication system

60.

Slew brake valve assembly

Acts as a hydraulically back

pressure system parallel to
Slew service brake system
a slew motor with variable
on top of the slew motor
pressure setting and indepen-
dent pressure side. Input port A
or B and outlet on the opposite
side, relieve port T

61.
Rotary joint,
upper part with connections to Hydraulically connection
the superstructure hydraulic, between superstructure
and lower part with connections and car body
to the car body

62.
Travel brake valve block
with secondary pressure relief
valve in the line to the travel Mounted in the supply line to the
motors. The return oil flow is travel motors
restricted according to the
pressure inlet.

63.
Hydraulic oil tank
with leak and return oil filter,
Main hydraulic oil tank
back pressure valve and
sensors

14 - 14 PC3000-6 SHOP-10 06279-xD-GB-1

Hints for reading the hydraulic diagram Hydraulic symbols

Pump, motor cylinder

Item Symbol Description Used as / at / on

64.

Main pump (tandem pump)

with charge pump (impeller),
variable displacement individual Main pumps
for each pump, controlled via
proportional solenoid valve

Table 14-4 Symbols for pumps, motors and cylinders

SHOP-10 06279-xD-GB-1 PC3000-6 14 - 15

Hydraulic symbols Hints for reading the hydraulic diagram

Please continue reading on the next page.

14 - 16 PC3000-6 SHOP-10 06279-xD-GB-1

Hints for reading the electric wiring diagram

15 HINTS FOR READING

THE ELECTRIC WIRING
DIAGRAM

SHOP-10 06279-xD-GB-1 PC3000-6 15 - 1

General Hints for reading the electric wiring diagram

15.1 GENERAL
In this chapter you’ll find information about:

– the (new) designation of electrical components (reference code)

– the graphical symbols used
– the layout of the electric wiring diagram
– hints for a fast look-up of electrical components in the electric wiring diagram

REMARKS: The electric wiring diagram is solely intended for wiring purposes. For information on operating
sequences or the process logic, refer to the CoDeSys visualization software.

15 - 2 PC3000-6 SHOP-10 06279-xD-GB-1

Hints for reading the electric wiring diagram Reference code of the electrical components

15.2 REFERENCE CODE OF THE ELECTRICAL

COMPONENTS
Each electrical component is well-defined by a code containing two single reference designations, see following
table.

Code "aabcdd–x" Meaning Remarks

aabcdd–x aa : Area code (location reference designation) See section "Area code" for
details
aabcdd–x b : Product reference designation, See section "Component iden-
component identifying letter acc. to IEC 61346-2 tifying letter" on page 15-5 for
details
aabcdd–x c : 2 = Pre-heating / 3 = CAN bus / 5 and 6 = valves
aabcdd–x dd : Further product reference designation
aabcdd–x –x : Powertrain (–1 and –2)

Table 15-1 Reference designations

Because this reference designation was just introduced at KMG, and differs from the previously used designation,
this chapter also contains a table with the new and old component designation are listed side by side, refer to sec-
tion on page 15-19.

15.2.1 AREA CODE

The first two letters of the product code of the electrical components indicate its location, see following table:

Area code Location

10 Cab base
11 ELV board (DC / 0…60 V)
12 Low voltage board (AC / 60…400 V)
13 Cab base bottom compartment
14 —
15 Customer board in the cab base
16 Switch board, pre-heating hydraulic oil
17 Air condition at cab base
18 Air condition switch board, HV cabinet
19 Air condition switch board, LV cabinet
20 Cab
21 Customer board in the cab

30 Drive
31 Fuel tank
32 High voltage cabinet (400 V and up)
33 Low voltage in the high voltage cabinet
34 Air condition at the high voltage cabinet

SHOP-10 06279-xD-GB-1 PC3000-6 15 - 3

Reference code of the electrical components Hints for reading the electric wiring diagram

Area code Location

40 Hydraulic oil tank
41 Oil cooler (hydraulic)

50 Machinery house
51 Engine / motor room
52 Engine / motor

54 Counterweight
55 Service arm
56 Pump compartment
57 Control panel, PTO

59 Suction tank
60 Superstructure
61 Control blocks, remote control valves
62 Lubrication system
63 Reserve oil tank, engine

65 Engine coolant pre-heating

67 Crane
68 Compressor

70 Stairs, access ladder

71 Battery box

80 Loader attachment

90 Undercarriage
91 Cable drum
92 Rotary joint
93 Slip ring
94 Junction box, cable drum
Table 15-2 Aerea codes / locations at the machine

15 - 4 PC3000-6 SHOP-10 06279-xD-GB-1

Hints for reading the electric wiring diagram Reference code of the electrical components

15.2.2 COMPONENT IDENTIFYING LETTER

According to IEC 61346-2, it is now the function / purpose of the electrical component within the circuit that
determines its identifying letter in the reference designation (refer to section 15.2 on page 15-3).

Letter Component function / purpose Examples

A Double function (basic functions are equivalent) KOMTRAX Plus display, multi-monitor
Converting physical values into processable End switch, binary or analog sensor, transducer,
B
signals camera
C Saving/storing of energy, information, or material Battery, data memory
E Supplying rays, heat, or coldness Heater, lamp
Fuse, circuit breaker, power circuit breaker, emer-
gency shut-off switch, safety lock switch, insulation
F Protective devices
monitor, motor overload switch, ground fault circuit
interruptor
Initiate energy signals, material flow signals,
G Battery, generator
reference signals
K Information processing (without F) Relay, time relay, controller, phase protective relay
M Supply mechanical energy (linear or rotating) E-motor, actuation coil
Display, signal transducer, gauge, clock, counter
P Exposition of information or operating hours, LED, printer, counter, seven-
segment display
Switching or modifying material flow or energy flow Contactor, power relay, battery main switch,
Q
(without F) disconnecting switch, starter, power switch
Limiting, damping, stabilizing, blocking of energy, "Z-diode, diode, throttle, resistance, series
R
information, or material resistance, capacitor module, cut-in unit
Converting manual mechanical signals into Switch, button, selector switch, setpoint sensor/
S
processable signals transmitter
Converting energy or information without modifica- Current transformer, voltage transformer, amplifier,
T tion of the kind of energy and the information aerial, measurement transformer, transformer rec-
content tifier, charger, inverter
Supporting, retaining, carrying, holding up of Isolator, cable duct, switchboard, wiring rack, cable
U
objects drum
V Processing material, energy, information signals Mains filter, frequency filter
Guiding, channeling, transferring energy, material, Conductor, wiring, rail, bus, fiber optic cable, slip-
W
information ring
Terminal, terminal block, terminal strip, connector,
X Connecting objects
socket, cable connector

Table 15-3 Component identification letters

SHOP-10 06279-xD-GB-1 PC3000-6 15 - 5

Graphical symbols Hints for reading the electric wiring diagram

15.3 GRAPHICAL SYMBOLS

The circuit symbols used in the wiring diagram are based upon IEC (International Electrical Commission) standard
IEC 60617, which differ from the symbols in accordance with the standards NEMA ICS 19-2002 (R2007),
ANSI Y32.2/IEEE 315/315A, CSA Z99 for the North American market.

The symbols shown in the table below only present an excerpt of the standards, not an exhaustive list of all
symbols relating to the standards.

Description Symbol acc. to IEC Symbol acc. to NEMA ICS/ANSI/IEEE

Junction of conductors
or or
Connection of conductors (node)

Terminal

Line of effect, general symbol

Line of effect, denoting small interval

Line of separation between functional units

Shielding

Earth, general symbol ’Ground’, general sym-

bol

Protective earth / Protective ground

Connector with plug and socket

or

Isolating point, lug, closed

Passive components

Resistor, general symbol

or or

Variable resistor, general

Resistor with sliding contact, potentiometer

Winding, inductance, general

or

Capacitor, general symbol

or or

Variable capacitor

Visual indicator, general symbol

(* with color indication)

Indicator light, general symbol

or or

Buzzers

15 - 6 PC3000-6 SHOP-10 06279-xD-GB-1

Hints for reading the electric wiring diagram Graphical symbols

Description Symbol acc. to IEC Symbol acc. to NEMA ICS/ANSI/IEEE

Horn, claxon

Drives

Manual operation, general use

Operated by pushing

Operated by pulling

Operated by turning

Operated by key

Operated by rollers, sensors

Stored energy mechanism, general symbol

Operated by motor

Emergency switch

Operated by electromagnetic overcurrent

protection

Operated by thermal overcurrent protection

Electromagnetic operation

Control by fluid level

Electromechanical, electromagnetic operating devices

Electromechanical operating device, general
symbol,
relay coil, general symbol
Electromechanical operating device with ON-
delay
or or
(× : device code letter)
Electromechanical device with OFF-delay

Electromechanical device with ON- and OFF-

delay

Electromechanical device of a thermal relay

or
Contacts

N/O contact
or or

N/C contact
or

Changeover contact with interruption

or

SHOP-10 06279-xD-GB-1 PC3000-6 15 - 7

Graphical symbols Hints for reading the electric wiring diagram

Description Symbol acc. to IEC Symbol acc. to NEMA ICS/ANSI/IEEE

TC or TDC
Early-make N/O contact of a contact assembly

TO or TDO
Late-break N/C contact of a contact assembly

N/O contact, delayed when closing

or

N/C contact, delayed when reclosing

or
Control devices

Push-button (not stay-put)

Spring-return switches with N/C contact, man-

ually operated by pushing, e.g. push-button
Spring-return switches with N/O and
N/C contact, manually operated by pushing
Spring-return switches with latching position
and one N/O contact, manually operated by
pushing
Spring-return switches with latching position
and one N/C contact, manually operated by
striking (e.g. mushroom button)
Position switches (N/O contacts),
limit switches (N/O contacts)
Position switches (N/C contacts),
limit switches (N/C contacts)
Proximity switches (N/C contacts), actuated by
the proximity of iron

Proximity switches, inductive, N/O contacts

Proximity switches, block diagram

Under-pressure relays, N/O contacts

or

Pressure switches, N/C contact

or

Float switches, N/O contact

Float switches, N/C contact

Switchgear

Contactors (N/O contacts)

(× : code letter)

Three-pole switch-disconnector

Three-pole circuit-breaker

Fuse, general symbol

15 - 8 PC3000-6 SHOP-10 06279-xD-GB-1

Hints for reading the electric wiring diagram Graphical symbols

Description Symbol acc. to IEC Symbol acc. to NEMA ICS/ANSI/IEEE

Transformers, current transformers

Transformers with two windings

or

Current transformer
or or
Machines

Generator
or

Motor, general symbol

or

DC motor, general symbol

AC motor, general symbol

Three-phase asynchronous motor with squir-

rel-cage rotor or

Three-phase asynchronous motor with slip-

ring rotor

Semiconductor components

Semiconductor diode, general symbol

Limiting diode Zener diode

Light-emitting diode (LED), general symbol

Bi-directional diode, diac

Thyristor, general symbol

Table 15-4 Graphical symbols

SHOP-10 06279-xD-GB-1 PC3000-6 15 - 9

Drawing concept Hints for reading the electric wiring diagram

15.4 DRAWING CONCEPT

Fig. 15-1 Cover page of the KMG electric wiring diagram

15 - 10 PC3000-6 SHOP-10 06279-xD-GB-1

Hints for reading the electric wiring diagram Drawing concept

Komatsu wiring diagrams

Each page of the wiring diagram has the following information in the bottom right hand corner:

– Diagram number (Fig. 15-1, Pos. 5); – example: 942 123 40 d

– Machine type (Fig. 15-1, Pos. 6) – example: PC4000-6D
– Machine number(s), the diagrams are valid for (Fig. 15-1, Pos. 7) – example: 08210 and following
– Diagram title (Fig. 15-1, Pos. 8) and contents – example: "Elektroplan" [German for "electric wiring diagram"]
and "Table of contents"
– Current page number and total number of pages (Fig. 15-1, Pos. 4) – example: 01/175
Each page is numbered from 8 (at the left corner) to 1 (at the right corner) along the top and bottom lines, and
lettered down from F (at the top) to A (at the bottom) along the left and right side lines (see Fig. 15-1, Pos. 3).
This coordinate system allows to indicate the location of components, as well as to locate a component on a given
page more easily.

Table of contents

In the table of contents on the first pages, the pages (Fig. 15-1, Pos. 1) are listed in ascending order, for each page
the title (Fig. 15-1, Pos. 2, with area code relating to the units presented on the page, where applicable) is listed.
The english version of the table of contents is to be found following the german version.

Example: "103 51 bus connector node 17, 18, 19"

 On page 103, the bus connectors for nodes 17, 18, and 19, to be found in the engine / motor room
(area code 51), are shown.

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Drawing concept Hints for reading the electric wiring diagram

Cross reference list

The pages following the table of contents contain the cross reference list.

Fig. 15-2 Cross reference list

In the cross reference list, all electrical parts/components are listed in alphabetical order (Fig. 15-2, Pos. 2 and 3).
In front of the components’ designation, the relevant page number (Fig. 15-2, Pos. 1) on which the component is
drawn, is given.

REMARKS: Following the cross reference list, but still in front of the wiring diagram pages, you’ll find:
– the FAQ (about how information is represented in the diagrams)
– information about the structure of the reference designations.

REMARKS: The underscore in cross references like "40X_41.5" stands for a connection to a terminal block.

15 - 12 PC3000-6 SHOP-10 06279-xD-GB-1

Hints for reading the electric wiring diagram Drawing concept

Please continue reading on the next page.

SHOP-10 06279-xD-GB-1 PC3000-6 15 - 13

Drawing concept Hints for reading the electric wiring diagram

Electrical wiring diagrams – explanations

The following illustrations shall show up some basics about the wiring diagrams and how information is presented.

Fig. 15-3 Wiring diagram (example)

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Hints for reading the electric wiring diagram Drawing concept

Legend for Fig. 15-3:

(1) Phase / wire designation

(2) Cross reference to further connection (e.g. "158.1" : continuation on page 158, column 1)

(3) Notation of temperature switch (63B204: pre-heating reserve oil tank)

(4) Notation of circuit breaker (12F206a: heater in cab support)

(5) Required wire cross-section area in mm² (e.g.: 2.5 mm² = AWG 14)

(6) Separation line for an electrical module / assembly group

(7) Cable connector designation and pin number

(8) Connection to a terminal block (e.g. pin 19 of terminal block 11X_51)

(9) Contacts of relay 12K201 (Fig. 15-3, Pos. 10).

The switching contacts are always drawn at the bottom below the associated relay.
For switching contacts in usage, a cross reference is given alongside; for contacts not used, only ":" is
shown.
In the example, only the switching contacts 43 an 44 are used, the contacts are shown in detail on
page 69, section/column 1.

(10) Relay coil

(11) Notation of heating resistor (e.g.: 63E212)

(12) Functional unit’s name for the wiring diagram sector shown above

(13) Protective earthing (PE)

(14) Ground wire / machine ground (e.g.: 12GND)

(15) Designation for optional design (e.g.: TT = low-temperature design)

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Drawing concept Hints for reading the electric wiring diagram

Fig. 15-4 Wiring diagram (example)

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Hints for reading the electric wiring diagram Drawing concept

Legend for Fig. 15-4:

(1) Designation of CAN-bus node

(2) Separating line for functional unit (40K311, ICN-D, CAN-bus node 11)

(3) Notation of input resistance of CAN-bus node ICN-D (at socket 3, pin 8)

(4) Identification for logic input signal also used in the flowchart (first line),
first letter in second line identifying type of port (SB_… : input / OB_… : output)

(5) Notation of pressure switch (40B024: filter monitoring of air filter at the hydraulic tank)

(6) Functional unit’s name for the wiring diagram sector shown above

(7) Color code of connecting line (e.g.: "BN" = brown), refer to cable color identification table below.

(8) Connector identification

(9) Cross reference/location of the complete assembly group, if only a part of the group is shown here.
In the example, only the relevant resistor between pins 9 and 10 of the resistor array 40R008 is shown
in the drawing for the functional unit (hydraulic oil tank monitoring); the complete resistor array is
shown on page 143, section/column 2.

(10) Cross reference/location of the complete assembly group, if only a part of the group is shown here.
In the example, only the relevant diode between pins 1 and 2 of the diode array 40R014 is shown in
the drawing for the functional unit (hydraulic oil tank monitoring); the complete diode array is shown on
page 143, section/column 1.

REMARKS: All circuits are shown without current, and all relays and switches in neutral position.

Cable color identification

Refer to the following table if the identification of cable colors in wiring diagrams may be unclear due to different
existing systems of color codes.

Color Color code

English German Standard IEC 60757* German (current) German (previous)

Black Schwarz BK SW sw
Brown Braun BN BR br
Red Rot RD RT rt
Orange Orange OG OR or
Yellow Gelb YE GE ge
Green Grün GN GN gn
Blue Blau BU BL bl
Violet Violett VT VI vi
Grey Grau GY GR gr
White Weiß WH WS ws
Pink Rosa PK RS rs
Turquoise Türkis TQ TK tk

Table 15-5 Cable color identification

* IEC: International Electrotechnical Commission

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Drawing concept Hints for reading the electric wiring diagram

Search hints

In order to find the required information fast and easily, the following hints may be useful.

– A component at a certain location is to be looked-up in the wiring diagram, the component designation is
missing / unrecognizable:
– If needed, look-up the location reference designation (area code) for the relevant place of the machine in
the "List of location reference designations" following the FAQ.
– Look-up the page number the wiring diagram starts for the desired location in the table of contents.
– If the functional unit the component belongs to is identified, look-up the page number for the functional unit
in the table of contents for the entries for the relevant location reference code.
– Identify the electrical component on the specified page(s).
– The component’s product reference code is known / identifiable:
– Go to the cross reference list following the table of contents.
– Look-up the component’s product reference designation and the corresponding page number in the
alphabetically sorted list.
– Identify the electrical component on the specified page.

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Hints for reading the electric wiring diagram Cable marking

15.5 CABLE MARKING

On all blue wires there is a printed code approx. every 10 cm.

Fig. 15-5 Example for cable marking

The code next to the cable end shows where the cable end has to be connected, the code further away from the
end gives information about what is connected at the other end of the wire.

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Cable marking Hints for reading the electric wiring diagram

Please continue reading on the next page.

15 - 20 PC3000-6 SHOP-10 06279-xD-GB-1

KOMTRAX Plus

16 KOMTRAX PLUS

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General KOMTRAX Plus

16.1 GENERAL

Fig. 16-1 System layout - PC3000 CAN overview

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KOMTRAX Plus General

The KOMTRAX Plus System is an electronic on-board monitoring system which includes the functions
REAL TIME MONITOR, basic adjustments, and history reporting. Details are as follows:

– System and component monitoring based on fault code detection and storage of faults and other events, incl.
Trend Data, Snapshot Data etc.
– Selected subsystems and components, generation of trending, histogram, and cumulative data to be used as
a predictive maintenance aid.
– PC-based downloads via VHMS Technical Analysis Tool Box.
– Basic settings as for example system language.

Operating Principle

The KOMTRAX Plus system with a keyboard below the monitor allows comfortable operation and quick access to
all information about the machine status and maintenance calls.

Condition monitoring on the shovel systems is established by the KOMTRAX Plus controller. The KOMTRAX Plus
controller is equipped with a read & write memory and a Real Time Monitoring system.

The access to the KOMTRAX Plus controller is established via laptop and a serial interface, using the respective
software.

The control system components are connected as follows, also refer to Fig. 16-1 System Layout - CAN overview.

Additionally the ORBCOMM is included.

Exemplary view onto a KOMTRAX Plus monitor with key pad in

the dashboard.

Fig. 16-2 Dashboard with KOMTRAX Plus

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General KOMTRAX Plus

16.1.1 LOCATION OF KOMTRAX PLUS COMPONENTS IN CAB BASE

Fig. 16-3 Cab base - location of KOMTRAX Plus components

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KOMTRAX Plus General

Legend for Fig. 16-3:

(1) X2 switch board

(2) KOMTRAX switch box

[10K032] Electronic pump controller CR710

[11P046] KONTRAX Plus display MH801 in cab base (Multimonitor)

[14T058] ORBCOMM controller

[14K300] KOMTRAX Plus controller

The KOMTRAX Plus controller [14K300] is mounted inside the KOMTRAX switch box (Fig. 16-3, Pos. 2) behind
the ORBCOMM controller [14T058]. The KOMTRAX switch box is located at the cab base wall, next to the door.

The pump controller [10K032] is located at the cab base front wall and communicates with the KOMTRAX Plus
controller via CAN BUS #1, refer to section 16.9 on page 16-84.

The Multimonitor [11P046] is mounted inside the X2 switch board (Fig. 16-3, Pos. 1) and communicates with the
KOMTRAX Plus controller via CAN BUS #1, refer to section 16.9 on page 16-84.

REMARKS: For further information about the pump controller CR710 refer to section 9.4 on page 9-24.
For further information about the Multimonitor refer to section 9.5 on page 9-30.

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Specifications for operators KOMTRAX Plus

16.2 SPECIFICATIONS FOR OPERATORS

Fig. 16-4 KOMTRAX Plus operating controls and opening screen

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KOMTRAX Plus Specifications for operators

Legend for Fig. 16-4:

(1) The monitor displays the condition of the machine, the maintenance status, and messages for the
operator & the maintenance staff

(2) Buttons for changing the screens and for settings on the operator level

(3) Key pad for entering data and the Personal Identification Number (PIN)

(4) Main key switch on the dashboard

(5) Opening message

(6) Acknowledgement button for the opening message

16.2.1 OPENING SCREEN

The opening message (Fig. 16-4, Pos. 5) is a general safety information for the operator.

REMARKS: Press button F6 (Fig. 16-4, Pos. 6) to acknowledge this message.

The monitor will display the Main Gauge Screen 1, refer to Fig. 16-5 on page 16-8.

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Specifications for operators KOMTRAX Plus

16.2.2 MAIN GAUGE SCREENS 1 TO 2

Fig. 16-5 Main gauge screens 1 to 2

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KOMTRAX Plus Specifications for operators

Symbol explanation for Fig. 16-5:

Main Gauge Screen 1 of 2

°C Celsius, ambient temperature

1/min Engine speed

Time

Truck counter 1

Truck counter 2

Engine oil pressure

Engine coolant temperature

Hydraulic oil temperature

Fuel level

Main Gauge Screen 2 of 2

Battery charging current (A)

Board voltage (24V)

Engine oil temperature

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Specifications for operators KOMTRAX Plus

Definition of the gauge range colors

Green Normal operating range

Red Serious trouble, act immediately. Engine derate or shutdown may happen.

REMARKS: If the pointer of any gauge moves into a red range (upper or lower) the background colour of the
corresponding symbol will also turn to red. If this happens, in most cases an automatic message
display will inform the operator in plain text about the failure and the necessary action to be taken.
For a typical failure message display refer to section 16.2.8 on page 16-26.

Symbols and functions of the buttons F1 - F6

This button is used to scroll through the Main Gauge Screens 1 and 2.
F1
If other screens are selected, the function of this button changes accordingly.

This button switches to the Fuel Consumption Screen, for details refer to
F2
section 16.2.3 on page 16-12.

This button switches to the Failure Message Screen for the operator. The
colour of the icon above this button changes to yellow if a current message is
F3
pending in the Failure History. The icon remains yellow as long as the cause
for the message exists, even if the message was cancelled.

This button switches to the Main Gauge Screen for changing the display from
F4 Time to Service Meter Reading (SMR) or to Date and vice versa, refer to
section 16.2.5 on page 16-15.

This button switches to the Maintenance Monitor. The colour of the icon above
F5 this button changes to yellow or red if maintenance is due, for details refer to
section 16.2.6 on page 16-16.

This button switches to the main screen Settings for Operator, for details refer
F6
to section 16.2.7 on page 16-18.

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KOMTRAX Plus Specifications for operators

Please continue reading on the next page.

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Specifications for operators KOMTRAX Plus

16.2.3 FUEL CONSUMPTION SCREEN

Fig. 16-6 Fuel consumption screen

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KOMTRAX Plus Specifications for operators

Measuring the Fuel Consumption

Starting from one of the two Main Gauge Screens press button F2, the screen changes to Fuel Consumption
Screen (Fig. 16-6). The fields in the screen can be either blank or filled with the data of the last measurement.
If you want to start a new fuel consumption measurement, push the START button F1. The date and the local time
will be inserted into the Start Time frame and the START command above button F1 changes to STOP, refer to
screen (Fig. 16-6, Pos. 2).

Push the RETURN button F5 to go back to the Main Gauge Screen 1.

When the time period for fuel consumption measurement is over, for example after 10 hours, select the
Fuel Consumption Screen from any of the two Main Gauge Screens by pushing button F2.

The displayed Fuel Consumption Screen shows the starting date and time of the energy consumption
measurement. Push the STOP button F1. The current date and time is inserted into the Stop Time field and the
fuel consumption calculated during the previous time period is inserted into the Fuel Consumption Frame. The
STOP button F1 changes to START again, refer to screen (Fig. 16-6, Pos. 3).

Push the return button F5 to return to the Main Gauge Screen 1.

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Specifications for operators KOMTRAX Plus

16.2.4 FAILURE MESSAGE HISTORY FOR THE OPERATOR

Fig. 16-7 Main Gauge Screen 1/2 and Failure History for Operator

Failure Messages for the Operator

The Failure Message Screen (Fig. 16-7) can be selected from the Main Gauge Screens 1 or 2 by pressing button
F3. The colour of the icon above the button F3 changes to yellow if a current message is pending in the Failure
Message History for the operator.

Refer to Fig. 16-8:

F3 - Scroll down
Shifts down to the next message, if several messages are present

F4 - Scroll up
Shifts up to the previous message, if several messages are
present

F5 - Return
Switches back to the Main Gauge Screen
Fig. 16-8 Failure Message

If the cause for any failure message, which is shown on the Failure Message Screen for operators, does not exist
any longer, the message will be removed from the operator’s failure history.

The time and the date of the removed failure message are added to the already stored failure information in the
failure memory for the service level.

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KOMTRAX Plus Specifications for operators

16.2.5 MAIN GAUGE SCREENS - CHANGING OF TIME / SMR / DATE

Fig. 16-9 Changing Time, SMR, Date

If button F4 of the Main Gauge Screen is pressed, the center information in the headline changes in the sequence:
Time  Service Meter Reading (SMR)  Date  Time …

The selected information (Time, SMR, or Date) is shown in the headline of both Main Gauge Screens.

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Specifications for operators KOMTRAX Plus

16.2.6 MAINTENANCE MONITOR

Fig. 16-10 Maintenance Monitor

The Maintenance Monitor can be selected from the Main Gauge Screens 1 or 2 by pressing the maintenance
button F5. The colour of the icon background above the button changes to yellow if maintenance is due.
The colour will change to red if maintenance is overdue.

Fig. 16-10 shows a Maintenance Monitor of a new machine which has been operated for 10 hours only. There are
240 hours left before the 250 hour maintenance is due and 2990 hours before the 3000 hours maintenance is due.
To return to the Main Gauge Screen press button F5 on the Maintenance Monitor.

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KOMTRAX Plus Specifications for operators

Specifics to be observed

Higher maintenance also includes lower maintenance. (Lower maintenance must also be carried out!)

Maintenance Interval Overview

Maintenance interval Remark

250 h Includes maintenance: 50 h • 10 h

500 h Includes maintenance: 250 h • 50 h • 10 h

(750 h) Is a follow-up maintenance of 250 h

1000 h Includes maintenance: (750 h) • 500 h • 250 h • 50 h • 10 h

2000 h Includes: PM-CLINIC

3000 h Includes maintenance: 1000 h • 750 h • 500 h • 250 h • 50 h • 10 h

Exception: For the 3000 h maintenance it is not necessary to carry out the 2000 h maintenance also.
The maintenance cycles are rigidly linked to the running time meter. Only running time hours are taken into
consideration (no minutes or seconds).

The routine visual checks and inspections after every 10 and 50 operating hours are not called up on the
Maintenance Monitor. Carry out these checks and inspections according to the OPERATION & MAINTENANCE
MANUAL section 4. The motor maintenance has to be carried out according to the separate MOTOR OPERATION
& MAINTENANCE MANUAL filed in the volume 2 binder.

REMARKS: For detailed maintenance cycle information refer to the OPERATION & MAINTENANCE MANUAL,
section MAINTENANCE.

NOTE! On new machines an INITIAL SERVICE after the first 250 and 1000 operating hours is required in
addition to the periodic maintenance intervals displayed on the monitor. Carry out all maintenance
items according to the OPERATION & MAINTENANCE MANUAL, section 4.

Maintenance Confirmation by Service Personnel

Maintenance indicated with yellow or red background behind the icon above the maintenance button F5 should
be confirmed by service personnel in the Service Menu subsequent to the execution of the maintenance.
With each confirmation the actual maintenance number is increased by 1.

The message in the Service Menu for Maintenance Confirmation then turns to white instead of yellow.

For more information about the Maintenance Confirmation screen refer to section 16.5.8 on page 16-69.

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Specifications for operators KOMTRAX Plus

16.2.7 SETTINGS FOR OPERATOR

Fig. 16-11 Settings for operator

The user menu Settings for Operators can be selected from the Main Gauge Screens 1 or 2 by pressing the
button F6.

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KOMTRAX Plus Specifications for operators

Selection of the Setting Screens

The settings selection menu offers seven different setting screens, starting with USER ID and ending with the
Language selection. Use the buttons F3 and F4 to scroll through all the seven selection items. Select the desig-
nated setting item and push button F6 in order to open the selected setting screen. Button F5 switches back to the
Main Gauge Screen 1. The setting screens on the following pages appear in the same sequence as shown in the
Main Setting Screen.

16.2.7.1 USER ID SCREEN

Entering the USER ID (Operator Identification Number)

In order to personalize different operators, it is possible to enter

any up to 10-digits USER ID (Operator Identification Number) via
the key pad.

In order to acknowledge the USER ID press button F6.

The display then changes to the Main Setting Screen for
operators.

REMARKS: If 10 digits are entered, each further entry will be

ignored.

If any USER ID has been entered, the ID is saved together with

the continuous machine operation records in the K+ memory.

Fig. 16-12 Entering Operator User ID

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Specifications for operators KOMTRAX Plus

16.2.7.2 RESET TRUCK COUNTER 1 & 2

When the beside screen (Fig. 16-13, Pos. 1) is displayed,
press button F6 to reset Truck Counter 1 to zero.
The screen then changes to the Main Setting Screen
for operators.

If you don’t want to reset the Truck Counter, press button F5

to return to the Main Setting Screen for operators again.

The reset of Truck Counter 2 is performed analogously.

Fig. 16-13 Reset Truck Counter 1

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KOMTRAX Plus Specifications for operators

Please continue reading on the next page.

SHOP-10 06279-xD-GB-1 PC3000-6 16 - 21

Specifications for operators KOMTRAX Plus

16.2.7.3 SCREEN ADJUSTMENT DISPLAYS

Fig. 16-14 Screen adjustment

(1) Brightness (Night) adjustment

(2) Contrast (Night) adjustment

(3) Back Light (Night) adjustment

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KOMTRAX Plus Specifications for operators

Screen Adjustment

The Night Mode Screen (Fig. 16-14) will be displayed during the night when the main working lights are switched
ON.

The screen changes automatically to the Day Mode when the main working lights are switched OFF.

The adjustment of both screens is done in the same way.

The function of the buttons for Screen Adjustment (Fig. 16-14) is as follows:

F2 Select the DEFAULT setting (factory setting) of Brightness, Contrast, and Back Light

F3 Decrease Brightness, Contrast, or Back Light

F4 Increase Brightness, Contrast, or Back Light

F5 Leave the adjustment screen and return to the Main Setting Screen for operators

F6 Save the current adjustment and jump to the next adjustment item
(Brightness  Contrast  Back Light)

(1) Brightness adjustment

In the first display of the screen the brightness field is highlighted yellow. For increasing the brightness press
button F4 until the desired condition is obtained. For decreasing the brightness press button F3 until the desired
condition is obtained. Press button F6 in order to save the selected brightness adjustment and to change over to
the contrast adjustment.

(2) Contrast adjustment

The contrast field is now highlighted yellow. For increasing the contrast press button F4 until the desired condition
is obtained. For decreasing the contrast press button F3 until the desired condition is obtained. Press button F6 in
order to save the selected contrast adjustment and to change over to the back light adjustment.

(3) Back Light adjustment

The back light field is now highlighted yellow. For increasing the back light press button F4 until the desired
condition is obtained. For decreasing the back light press button F3 until the desired condition is obtained.
Press button F6 in order to save the selected back light adjustment and to return to the Main Setting Screen
for operators.

If you want to leave the above adjustment screens without saving any adjustment, press button F5 and return to
the Main Setting Screen for operators.

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Specifications for operators KOMTRAX Plus

16.2.7.4 DATE AND TIME ADJUSTMENT

Fig. 16-15 Date and time adjustment screen

(1) Date Adjustment

In the display of this adjustment screen Date is highlighted yellow and the year is highlighted orange, refer to
Fig. 16-15. Press button F3 (down) or F4 (up) in order to adjust the correct year. If button F1 is pressed one time,
the month is highlighted and can be adjusted, using the buttons F3 and F4 again. Press button F1 again in order to
change to the adjustment mode of the day.

Press button F6 in order to save the adjustment(s) of year, month, or day and to return to the Main Setting Screen
for operators. Press button F5 if you want to leave the adjustment screen.

(2) Time Adjustment

Time is highlighted yellow and the hours are highlighted orange, refer to Fig. 16-15. Press button F3 (down) or F4
(up) in order to adjust the correct hours.
If button F1 is pressed one time, the minutes are highlighted and can be adjusted, using the buttons F3 and F4
again. Press button F6 in order to save the adjustment(s) of the clock time and to return to the Main Setting Screen
for operators.

(3) Switching the Daylight Saving Time ON/OFF

If you are in the clock adjustment mode for minutes (the minutes are highlighted) press button F1.
Daylight Saving Time will be highlighted yellow.
Press button F3 or F4 in order to select the ON or OFF condition. The selected condition is highlighted green.
Press button F6 if you want to save the adjustment and to return to the Main Setting Screen for operators.

If you want to leave the above adjustment screens without saving any adjustment, press button F5 and return to
the Main Setting Screen for operators.

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KOMTRAX Plus Specifications for operators

16.2.7.5 LANGUAGE SELECTION

1. Select the desired language using button F3 or F4.

2. Press button F6 in order to save the language selection and

to return to the Main Setting Screen for operators.

REMARKS: If you want to leave the above selection screen with-

out saving any selection, press button F5 and return
to the Main Setting Screen for operators.

Fig. 16-16 Language selection screen

(exemplaric view)

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Specifications for operators KOMTRAX Plus

16.2.8 AUTOMATIC MESSAGES

Fig. 16-17 Messages with red and yellow background

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KOMTRAX Plus Specifications for operators

Legend for Fig. 16-17:

(1) Failure message - red level

(2) Failure message - yellow level

(3) Failure message - blue level

(4) Instruction Message - follow the displayed instructions

(5) Error Code

(6) Icon - depending on the error message

(7) Number of the currently displayed message / Total number of existing messages

F1 CANCEL button
When this button is pressed, the currently displayed message disappears and is listed in the failure
history for operators. The message will be displayed again if any different USER ID (operator
identification number) is entered.

F3 PAUSE button (green)

When this button is pressed, automatic rolling up of messages is stopped and the displayed message
will be frozen on the screen for two minutes. After that the button changes to RESET (red) and
automatic roll up of current messages starts again. A new message will overwrite a frozen message.

F4 JUMP button
This button switches to the previous displayed menu, normally to the Main Gauge Screen 1.
After two minutes the display jumps automatically back to the last displayed Automatic Message, and
rolling up of messages starts again. If any menu select button was pressed during the two minutes
standard period, the display will also jump back to Automatic Message when the two minutes are
over. A new message will overwrite any menu display and rolling up of messages starts again.

If any failure or information condition occurs during operation, the background of the exclamation mark (!) above
button F3 is coloured yellow. Then the present display is automatically replaced by an Automatic Message.

If there are several messages at the same time, the system displays these messages one after the other.
Each message is displayed for a few seconds.

The message text informs the operator about the type of failure and the action to be taken. Carry out the action
which is recommended on the screen.

The Top Messages have background colors which indicate the trouble condition as follows:

Shut-down - act immediately

RED
Refer to Fig. 16-17 for a typical message with red background.

Caution - inform service

YELLOW
Refer to Fig. 16-17 for a typical message with yellow background.

Informational message
BLUE
Refer to Fig. 16-17 for a typical message with blue background.

REMARKS: For all available Top Messages in the system refer to section 16.3 on page 16-28.
Trouble messages of the pump controller are displayed on the KOMTRAX Plus display and on the
Multimonitor in the cab base.

SHOP-10 06279-xD-GB-1 PC3000-6 16 - 27

Tables of all provided messages KOMTRAX Plus

16.3 TABLES OF ALL PROVIDED MESSAGES

16.3.1 TABLE OF CUMMINS TROUBLE CODES (TIER 2)

Explanation of the columns in the following Trouble Code chart

Column 1 Trouble Code C-Code number

1 = displayed once
Column 2 Display
2 = displayed at each occurrence

Column 3 Acoustic Signal 1 = an acoustic signal sounds if the relating trouble occurs

Colour Code of 0 = Red

Column 4
Top Message 1 = Yellow

Instruction Number of the Instruction Message, which is displayed together with

Column 5
Message No. the Trouble Code (numbers 1 - 58)

Column 6 Message Displayed text of the Trouble Code

Table of Cummins C-Codes:

Acoustic Signal

Message No.
Instruction
Display

Trouble
Color

Message
Code

CA115 1 1 0 34 Engine Speed Signal Lost

CB115 1 1 0 34 Engine Speed Signal Lost
CA135 Oil Press Ckt Failed High
CA141 Oil Press Ckt Failed Low
CA144 2 1 1 20 Coolant Temp Ckt Failed High
CA145 2 1 1 20 Coolant Temp Ckt Failed Low
CA146 1 1 1 40 Coolant Temp Above Normal
CA151 2 1 0 33 High Coolant Temp
CA153 Int Man Temp 1 Ckt Failed High
CA154 Int Man Temp 1 Ckt Failed Low
CA155 2 1 0 32 High Int Man Temp 1
CA156 Int Man Temp 2 Ckt Failed High
CA157 Int Man Temp 2 Ckt Failed Low
CA158 2 1 0 32 High Int Man Temp 2
CA159 Int Man Temp 3 Ckt Failed High
CA161 Int Man Temp 3 Ckt Failed Low
CA162 2 1 0 32 High Int Man Temp 3
CA163 Int Man Temp 4 Ckt Failed High
CA164 Int Man Temp 4 Ckt Failed Low

16 - 28 PC3000-6 SHOP-10 06279-xD-GB-1

KOMTRAX Plus Tables of all provided messages

Acoustic Signal

Message No.
Instruction
Display
Trouble

Color
Message
Code

CA165 2 1 0 32 High Int Man Temp 4

CA187 Sensor Supply 2 Ckt Failed Low
CB187 Sensor Supply 2 Ckt Failed Low
CA195 Coolant Level Ckt Failed High
CA196 Coolant Level Ckt Failed Low
CA197 Coolant Level Below Normal
CA212 Oil Temp Ckt Failed High
CA213 Oil Temp Ckt Failed Low
CA214 2 1 0 32 Engine Oil Temp too High
CA221 Ambient Air Press Failed High
CA222 Ambient Air Press Failed Low
CA223 Centinel Burn Valve Below Normal
CA224 Centinel Burn Valve Above Normal
CA227 Sensor Supply 2 Ckt Failed High
CB227 Sensor Supply 2 Ckt Failed High
CA228 2 1 0 32 Very Low Coolant Pressure
CA231 Coolant Press Ckt Failed High
CA232 Coolant Press Ckt Failed Low
CA234 2 1 0 32 Engine overspeed
CA235 2 1 0 31 Low Coolant Level
CA238 Sensor Supply 3 Ckt Failed Low
CB238 Sensor Supply 3 Ckt Failed Low
CA245 Fan Control Circuit Failed Low
CA263 Fuel Temp Ckt Failed High
CA265 Fuel Temp Ckt Failed Low
CA266 2 1 0 33 Very High Fuel Temp
CA271 1 1 40 Fuel Pump Press 1 Ckt Failed Low
CA272 1 1 40 Fuel Pump Press 1 Ckt Failed High
CA322 1 1 40 Injector Sol Driver Cyl 1 Below Normal
CA323 1 1 40 Injector Sol Driver Cyl 5 Below Normal
CA324 1 1 40 Injector Sol Driver Cyl 3 Below Normal
CB325 1 1 40 Injector Sol Driver Cyl 6 Below Normal
CA331 1 1 40 Injector Sol Driver Cyl 2 Below Normal
CB332 1 1 40 Injector Sol Driver Cyl 4 Below Normal

SHOP-10 06279-xD-GB-1 PC3000-6 16 - 29

Tables of all provided messages KOMTRAX Plus

Acoustic Signal

Message No.
Instruction
Trouble Display

Color
Message
Code

ECM Hardware Issue Non Mission

CA343
Disabling
ECM Hardware Issue Non Mission
CB343
Disabling
CA351 1 0 34 Injector Power Supply Failed
CB351 1 0 34 Injector Power Supply Failed
CA352 Sensor Supply 1 Ckt Failed Low
CB352 Sensor Supply 1 Ckt Failed Low
CA386 Sensor Supply 1 Ckt Failed High
CB386 Sensor Supply 1 Ckt Failed High
CA415 2 1 0 32 Very Low Oil Pressure
CA418 1 1 31 WIF Indicator Warning
CA421 1 1 1 40 Engine Oil Temp Above Normal
CA441 1 1 1 31 Low Battery Voltage
CB441 1 1 1 31 Low Battery Voltage
CA442 1 1 1 31 High Battery Voltage
CB442 1 1 1 31 High Battery Voltage
CA449 2 1 0 31 High Rail Pressure
CA451 Rail Press Ckt Failed High
CA452 Rail Press Ckt Failed Low
CA488 1 1 31 High Intake Manifold Temp
CA527 Dual Output A Failed High
CA529 Dual Output B Failed High
CA546 Fuel Del Pressure Ckt Failed High
CA547 Fuel Del Pressure Ckt Failed Low
CA556 2 1 0 32 High Crankcase Pressure
CA559 1 1 40 Rail Pressure 1 Below Normal
CA689 1 1 40 Engine Crankshaft Speed Erratic
CB689 1 1 40 Engine Crankshaft Speed Erratic
CA731 Engine Speed Cam/Crank Misalignment
CB731 Engine Speed Cam/Crank Misalignment
CA783 2 1 0 32 Rapid rise int man temp 1
CA1117 Power Lost with Ignition On
CB1117 Power Lost with Ignition On
CA1357 1 1 31 Remote Oil Level Below Normal

16 - 30 PC3000-6 SHOP-10 06279-xD-GB-1

KOMTRAX Plus Tables of all provided messages

Acoustic Signal

Message No.
Instruction
Display
Trouble

Color
Message
Code

CB1362 1 1 31 High Lube Oil Filter Restriction

CA1363 1 1 40 Int Man Press 1 Below Normal
CB1367 Pre Filter Oil Press Ckt Failed High
CB1368 Pre Filter Oil Press Ckt Failed Low
CA1373 Ether Injection Ckt Failed
CA1383 Int Man Press 1 Failed High
CA1384 Int Man Press 1 Failed Low
CB1385 Int Man Press 2 Failed High
CB1386 Int Man Press 2 Failed Low
CA1387 2 1 0 34 J1939 Engine Commanded Shutdown
CA1517 1 0 31 ECM Detects Most Severe Fault
CA1542 Engine oil level sensor Ckt Failed High
CA1543 Engine oil level sensor Ckt Failed Low
CB1548 40 Injector Sol Driver 7 Below Normal
CA1549 40 Injector Sol Driver 8 Below Normal
CA1551 40 Injector Sol Driver 10 Below Normal
CA1552 40 Injector Sol Driver 11 Below Normal
CB1553 40 Injector Sol Driver 12 Below Normal
CB1622 Injector Sol Driver 9 Below Normal
CA1638 1 1 40 Int Man Press 2 Below Normal
CA1843 Crankcase Press Ckt Failed High
CA1844 Crankcase Press Ckt Failed Low
CA1845 WIF Indicator Ckt Failed High
CA1846 WIF Indicator Ckt Failed Low
CA1852 1 1 31 WIF Indicator Above Normal
CA1891 Engine Oil Change Interval Exceeded
CA1984 1 1 31 Int Man Temp 2 Above Normal
CA1985 1 1 31 Int Man Temp 3 Above Normal
CA1986 1 1 31 Int Man Temp 4 Above Normal
CA2157 2 1 0 32 Rapid Rise Int Man Temp 2
CA2158 2 1 0 32 Rapid Rise Int Man Temp 3
CA2159 2 1 0 32 Rapid Rise Int Man Temp 4
CA2185 Sensor Supply 4 Ckt Above Normal
CB2185 Sensor Supply 4 Ckt Above Normal
CA2186 Sensor Supply 4 Ckt Below Normal

SHOP-10 06279-xD-GB-1 PC3000-6 16 - 31

Tables of all provided messages KOMTRAX Plus

Acoustic Signal

Message No.
Instruction
Trouble Display

Color
Message
Code

CB2186 Sensor Supply 4 Ckt Below Normal

CA2215 1 1 40 Fuel Pump Pressure Below Normal
CA2261 1 1 31 Fuel Pump Del Pressure Above Normal
CA2262 1 1 40 Fuel Pump Del Pressure Below Normal
CA2265 Lift Pump Supply Ckt Failed High
CA2266 Lift Pump Supply Ckt Failed Low
CA2311 Fuel Injection Valve Ckt Error
CA2377 Fan Control Ckt Failed High
CA2474 Turbocharger 1 Speed - Data Erratic
Accelerator pedal Idle validation Ckt
CA2697
failed
CA2727 J1939 between Parent and Child Error
CA2734 1 1 31 Ether Bottle Empty
CA2963 1 1 33 Engine Coolant Temp Above Normal
CA2964 1 1 33 Int Man Temp 1 Above Normal

Table 16-1 Table of Cummins C-Codes

16 - 32 PC3000-6 SHOP-10 06279-xD-GB-1

KOMTRAX Plus Tables of all provided messages

16.3.2 TABLE OF KOMTRAX PLUS TROUBLE CODES

Explanation of the columns in the following Trouble Code chart

Column 1 Trouble Code G-Code number

1 = displayed once
Column 2 Display 2 = displayed at each occurrence
0 = NOT displayed

Column 3 Acoustic Signal 1 = an acoustic signal sounds if the relating trouble occurs

Column 4 7 segments LED Short-code of the displayed Trouble Code

0 = Red
Colour Code of 1 = Yellow
Column 5
Top Message 2 = Green
3 = Blue

Instruction Number of the Instruction Message, which is displayed together with

Column 6
Message No. the Trouble Code (numbers 1 - 58)

The error/message is saved in a History Memory:

1 = Service & Operator History
Column 7 Memory 2 = Service History
3 = Operator History
4 = KOMTRAX PlusHistory

Column 8 Message Displayed text of the Trouble Code

Table of KOMTRAX Plus Trouble Codes:

7 segments LED
Acoustic Signal

Message No.
Instruction

Memory
Display

Trouble
Color

Message
Code

G00001 2 M481 0 1 1 Trouble Shut-Off (gate) valve

Test speed 1800 1/min
G00002 2 M231 3 37 3
engine 1
G00007 2 M581 0 2 1 Trouble hydraulic oil level
Central lubrication system
G00012 1 M541 1 17 3
grease level too low
Slew ring gear lubr. system
G00013 1 M542 1 17 3
grease level too low
G00031 2 1 M232 3 0 3 Set engine to low idle
G00060 2 M492 0 6 1 Fire in the power house
G00065 1 M582 1 2 1 Very low hydraulic oil level
Trouble
G00066 2 M590 1 2 1
hydraulic oil temperature
Trouble battery voltage
G00067 1 M991 1 2 1
too high

SHOP-10 06279-xD-GB-1 PC3000-6 16 - 33

Tables of all provided messages KOMTRAX Plus

7 segments LED
Acoustic Signal

Message No.
Instruction

Memory
Trouble Display

Color
Message
Code

Trouble oil temperature

G00070 2 1 M591 1 2 1
gear (PTO 1)
Trouble gear lubrication
G00071 2 1 M592 1 2 1
(PTO 1)
G00091 2 M593 3 9 3 Pilot control cut out
Emergency shut-down
G00092 2 M482 0 10 3
at access ladder
Emergency shut-down
G00093 2 M594 0 10 1
at valve block
Emergency shut-down
G00095 2 M483 0 10 3
in cabin
Emergency shut-down
G00097 2 M484 0 10 3
at counterweight
G00100 2 MA01 3 11 3 Maintenance Safety Switch
G00104 2 1 M995 1 15 1 Trouble battery current
Trouble battery charging
G00105 2 1 M996 1 16 1
current too low
G00164 1 M485 1 17 1 Trouble air cleaner 1
Trouble breather filter
G00165 1 M595 1 17 1
hydraulic oil tank
G00166 1 M596 1 17 1 Trouble oil filter gear (PTO 1)
Trouble return oil filter
G00169 1 M597 1 17 1
hydraulic oil tank
Trouble leak oil filter
G00170 1 M598 1 17 1
hydraulic oil tank
Trouble battery voltage
G00176 1 M992 1 17 1
too low
Trouble battery charging
G00177 1 M997 1 17 1
circuit
Trouble battery charging
G00178 1 M998 1 17 1
current too high
Central lubrication
G00184 1 1 M538 1 20 1
system empty
Trouble central lubrication
G00185 1 1 M536 1 20 1
system
Slew ring gear lubrication
G00187 1 1 M539 1 20 1
system empty
Trouble slew ring gear
G00188 1 1 M537 1 20 1
lubrication system
Engine remote oil-tank 1
G00207 1 1 M233 1 2 1
empty

16 - 34 PC3000-6 SHOP-10 06279-xD-GB-1

KOMTRAX Plus Tables of all provided messages

7 segments LED
Acoustic Signal

Message No.
Instruction

Memory
Display
Trouble

Color
Message
Code

Load limiting
G00222 2 1 M486 1 2 1
clam defective
G00243 1 1 M487 3 23 3 Fill up fuel tank
Engine shutdown from
G00245 2 M234 0 24 1
ground
G00256 2 MA02 3 45 3 Operator warning system
Trouble screen at hydr.
G00262 1 1 M599 1 20 1
cooler entry clogged
G00422 2 1 M801 1 2 1 Can-net sys (J1939)
Communication failure
G00491 2 1 1 2 1
MH800 <=> KOMTRAX Plus Controller
Communication failure
DBBQKR 2 1 M802 1 2 2
CR710 <=> KOMTRAX Plus Controller
Abnormality in VBAT voltage
DBB3KK 2 1 M905 1 2 2
(KOMTRAX Plus VBAT<10V)

DBB0KK 2 1 M901 1 2 2 KOMTRAX Plus source voltage Error

DBB0KQ 2 1 MF11 1 2 2 KOMTRAX Plus Connector Mismatch

DGH2KA 1 M521 1 2 2 Hyd. Oil Temp. Sensor Failure

DGH2KB 1 M522 1 2 2 Hyd. Oil Temp. Sensor Failure
J100KA 1 M511 1 17 2 Pilot Press. Sensor Failure
J100KB 1 M512 1 17 2 Pilot Press. Sensor Failure
J100L6 1 M571 1 17 2 Abnomal Pilot Pump press

DGE5KA M401 2 Ambient air temp Sensor Failure

DGE5KB M402 1 2 Ambient air temp Sensor Failure

Trouble High Exhaust Temperature

F@DANS 2 1 M651 0 32 2
Cylinder RB1
Trouble High Exhaust Temperature
F@DBNS 2 1 M652 0 32 2
Cylinder RB2
Trouble High Exhaust Temperature
F@DCNS 2 1 M653 0 32 2
Cylinder RB3
Trouble High Exhaust Temperature
F@DDNS 2 1 M654 0 32 2
Cylinder RB4
Trouble High Exhaust Temperature
F@DENS 2 1 M655 0 32 2
Cylinder RB5
Trouble High Exhaust Temperature
F@DFNS 2 1 M656 0 32 2
Cylinder RB6
Trouble High Exhaust Temperature
F@DGNS 2 1 M641 0 32 2
Cylinder LB1

SHOP-10 06279-xD-GB-1 PC3000-6 16 - 35

Tables of all provided messages KOMTRAX Plus

7 segments LED
Acoustic Signal

Message No.
Instruction

Memory
Trouble Display

Color
Message
Code

Trouble High Exhaust Temperature

F@DHNS 2 1 M642 0 32 2
Cylinder LB2
Trouble High Exhaust Temperature
F@DJNS 2 1 M643 0 32 2
Cylinder LB3
Trouble High Exhaust Temperature
F@DKNS 2 1 M644 0 32 2
Cylinder LB4
Trouble High Exhaust Temperature
F@DLNS 2 1 M645 0 32 2
Cylinder LB5
Trouble High Exhaust Temperature
F@DMNS 2 1 M646 0 32 2
Cylinder LB6
Trouble monitoring Exhaust Temp
DGTAKX 1 M721 1 31 2
Cylinder RB1
Trouble monitoring Exhaust Temp
DGTBKX 1 M722 1 31 2
Cylinder RB2
Trouble monitoring Exhaust Temp
DGTCKX 1 M723 1 31 2
Cylinder RB3
Trouble monitoring Exhaust Temp
DGTDKX 1 M724 1 31 2
Cylinder RB4
Trouble monitoring Exhaust Temp
DGTEKX 1 M725 1 31 2
Cylinder RB5
Trouble monitoring Exhaust Temp
DGTFKX 1 M726 1 31 2
Cylinder RB6
Trouble monitoring Exhaust Temp
DGTGKX 1 M671 1 31 2
Cylinder LB1
Trouble monitoring Exhaust Temp
DGTHKX 1 M672 1 31 2
Cylinder LB2
Trouble monitoring Exhaust Temp
DGTJKX 1 M673 1 31 2
Cylinder LB3
Trouble monitoring Exhaust Temp
DGTKKX 1 M674 1 31 2
Cylinder LB4
Trouble monitoring Exhaust Temp
DGTLKX 1 M675 1 31 2
Cylinder LB5
Trouble monitoring Exhaust Temp
DGTMKX 1 M676 1 31 2
Cylinder LB6
DJF1KX 1 M580 1 17 2 Trouble monitoring fuel level

Table 16-2 Table of KOMTRAX Plus Trouble Codes

16 - 36 PC3000-6 SHOP-10 06279-xD-GB-1

KOMTRAX Plus Tables of all provided messages

16.3.3 TABLE OF PUMP-CONTROLLER-CODES (MULTI MONITOR)

Trouble messages of the pump controller are displayed on the KOMTRAX Plus display and on the Multimonitor in
the cab base.

Explanation of the columns in the following Trouble Code chart

Column 1 Trouble Code Code number

1 = displayed once
Column 2 Display 2 = displayed at each occurrence
0 = NOT displayed

Column 3 Acoustic Signal 1 = an acoustic signal sounds if the relating trouble occurs

Column 4 7 segments LED Short-code of the displayed Trouble Code

0 = Red
Colour Code of
1 = Yellow
Column 5 Top Message
2 = Green
(K+ display only)
3 = Blue

Instruction Number of the Instruction Message, which is displayed together with

Column 6
Message No. the Trouble Code (numbers 1 - 58)

The error/message is saved in a History Memory:

1 = Service & Operator History
Column 7 Memory 2 = Service History
3 = Operator History
4 = KOMTRAX Plus History

Column 8 Message Displayed text of the Trouble Code

Table of Pump-Controller-Codes:
Color on (K+ only)
7 segments LED
Acoustic Signal

Message No.
Instruction

Memory
Display

Trouble-
Message
Code

DXAAKA 1 1 1 40 2 Solenoid-1(Pump-1) open circuit

DXAAKB 1 1 1 40 2 Solenoid-1(Pump-1) short circuit
DXABKA 1 1 1 40 2 Solenoid-2(Pump-2) open circuit
DXABKB 1 1 1 40 2 Solenoid-2(Pump-2) short circuit
DXACKA 1 1 1 40 2 Solenoid-3(Pump-3) open circuit
DXACKB 1 1 1 40 2 Solenoid-3(Pump-3) short circuit
DXADKA 1 1 1 40 2 Solenoid-4(Pump-4) open circuit
DXADKB 1 1 1 40 2 Solenoid-4(Pump-4) short circuit
DXAEKA 1 1 1 40 2 Solenoid-5(Pump-5) open circuit
DXAEKB 1 1 1 40 2 Solenoid-5(Pump-5) short circuit
DXAFKA 1 1 1 40 2 Solenoid-6(Pump-6) open circuit

SHOP-10 06279-xD-GB-1 PC3000-6 16 - 37

Tables of all provided messages KOMTRAX Plus

Color on (K+ only)

7 segments LED
Acoustic Signal

Message No.
Instruction

Memory
Display
Trouble-
Message
Code

DXAFKB 1 1 1 40 2 Solenoid-6(Pump-6) short circuit

DHPEMA 1 1 1 40 2 Pump-1/2 pressure sensor abnormality
DHPGMA 1 1 1 40 2 Pump-3/4 pressure sensor abnormality
DHPJMA 1 1 1 40 2 Pump-5/6 pressure sensor abnormality
DLE2MA 1 1 1 40 2 Engine speed sensor abnormality
DA25KP 1 1 1 40 2 5V sensor1 power abnormality
DA22KK 1 1 1 40 2 Pump Solenoid Power Low Error
DA29KQ 1 1 1 40 2 Model Selection Abnormality

Table 16-3 Table of Pump-Controller-Codes

16 - 38 PC3000-6 SHOP-10 06279-xD-GB-1

KOMTRAX Plus Tables of all provided messages

16.3.4 TABLE OF AVAILABLE INSTRUCTION MESSAGES

Message
Instruction Message
No.

Engine stopped because of main Shut-Off

(gate) valve.
1
- Open the Shut-Off (gate) valve.
- If failure exist further, inform service.

2 Inform service.

Stop the engine.

3
- Inform service.

Start blocked because of main Shut-Off

(gate) valve.
4
- Open the Shut-Off (gate) valve.
- If failure exist further, inform service.

Start blocked
5
- Inform service.

The fire suppression system has been actuated.

- Inform the fire brigade.
6 - Evacuate endangered persons.
- Fight the fire.
- Inform service.

Bucket motion switched off.

7
- Inform service.

No 24V at circuit breaker 11F013

8
- If failure exist further, inform service.

Ladder end switch or lock lever contact open

9 or service arm down or unlock.
- If failure exist further, inform service.

Emergency shut-down switch was

actuated.
10
- Unlock before restarting.
- If failure exist further, inform service.

Engine switched off by

11 Maintenance Safety Switch
in the engine room.

12 Operate the machine into the parking position.

13 Please wait! No high idle !

Enable switch for refilling arm active

14
- If failure exist further, inform service.

Load of the batteries too high.

15
- Inform service.

Batteries are not being charged.

16
- Inform service.

17 Inform service till end of shift and then press cancel button.

SHOP-10 06279-xD-GB-1 PC3000-6 16 - 39

Tables of all provided messages KOMTRAX Plus

Message
Instruction Message
No.

Slew ring gear house brake OFF

18 - Inform service till end of shift and then
press cancel button.

Travel gear house brake OFF

19 - Inform service till end of shift and then
press cancel button.

20 Inform service and then press cancel button.

Hydraulic oil far below operating

temperature !
21
- Pre-heat hydraulic oil or warm up at
low idle speed and reduced power.

22 Engine runs (starter motor inactive).

A fuel reserve only is still in the tank

23
- Order tanker.

Engine shutdown has been actuated from

24
ground man.

Hydraulic oil below operating

25 temperature.
- Operate with reduced power !

26 Slew ring gear house brake ON

27 Hydraulic oil overheat - engine power derated

The VHMS is by-passed.

28
- Reset by-pass switch.

Engine shutdown by keyswitch before proper

engine cool down.
29
- Before you switch off the engine, cool down
the engine in the low idle for 2-3 minutes.

Hydraulic oil far below operating

temperature !
30
- Pre-heat hydraulic oil or warm up at
low idle speed and reduced power.

31 Continue shift but advise service.

32 Stop engine call service.

Derate active, continue to work.

33 Later shutdown possible.
Inform service.

34 Call service because of shutdown.

Interrupt work and inform service about

35
Speed Derate .

Continue work until next PM

36
(Schedule work for next PM)

Switch Testspeed in cab base forces the

37
engine to run constantly 1800 1/min.

16 - 40 PC3000-6 SHOP-10 06279-xD-GB-1

KOMTRAX Plus Tables of all provided messages

Message
Instruction Message
No.

38 If failure exist further, inform service.

Inform service
39
if attachment in defined position.

Continue to work and inform service about

40
Power Derate.

Cable Drum at limit.

41
- Move the shovel in an other direction.

Motor overheated. Wait until cooldown.

42
- If failure exists further, inform service.

Switch off and restart motor

43
- If failure exists further, inform service.

Switch off and restart motor

44 (It may be necessary to wait for cool down)
- If failure exists further, inform service.

Switch off windscreen wiper

46
and call service.

Only upper windscreen wiper!

47
Inform service.

No 24V at circuit breaker 11F013a

48
- If failure exist further, inform service.

Only lower windscreen wiper!

49
Inform service.

Reverse travel cut out by

50
cable drum.

Cable drum-motor temperature

51 too high.
Allow motor to cool down.

Permanently switch off by

52 device overheating.
Inform service.

53 Temporary switch off by

heating-air overheating.
Inform service.

54 Wait during one minute after

last start of motor.

55 Risk of collision with the cable drum!

56 Key switch off and back on !

57 Cool down period !

58 Travel gear house brake ON

Table 16-4 Table of message instructions

SHOP-10 06279-xD-GB-1 PC3000-6 16 - 41

Flow charts (1-4) of KOMTRAX Plus main screens KOMTRAX Plus

16.4 FLOW CHARTS (1-4) OF KOMTRAX PLUS MAIN

SCREENS

Fig. 16-18 Main screen flow chart for the Operator Level (1 of 4)

16 - 42 PC3000-6 SHOP-10 06279-xD-GB-1

KOMTRAX Plus Flow charts (1-4) of KOMTRAX Plus main screens

Fig. 16-19 Main screen flow chart for the Service Level (2 of 4)

SHOP-10 06279-xD-GB-1 PC3000-6 16 - 43

Flow charts (1-4) of KOMTRAX Plus main screens KOMTRAX Plus

Fig. 16-20 Main screen flow chart for the Service Level (3 of 4)

16 - 44 PC3000-6 SHOP-10 06279-xD-GB-1

KOMTRAX Plus Flow charts (1-4) of KOMTRAX Plus main screens

Fig. 16-21 Main screen flow chart for the Service Level (4 of 4)

SHOP-10 06279-xD-GB-1 PC3000-6 16 - 45

KOMTRAX Plus service level KOMTRAX Plus

16.5 KOMTRAX PLUS SERVICE LEVEL

Fig. 16-22 Entering the Service Level

(1) Keep key 4 pressed

(2) Enter digits 123 and release key 4

16 - 46 PC3000-6 SHOP-10 06279-xD-GB-1

KOMTRAX Plus KOMTRAX Plus service level

The Service Level can be activated from both Main Gauge Screens in the operator mode only.

If one of the Main Gauge Screens is open, keep key 4 of the key pad pressed and simultaneously enter the digits
1, 2, 3. Then release key 4. Refer to Fig. 16-22.

The screen shown in Fig. 16-23 will appear.

Enter the Service ID number and press F6 to confirm.

Fig. 16-23 Input Service ID (1/3)

REMARKS: The Service ID number 0300006279 (exemplary,

machine serial number) is programmed ex factory.

Fig. 16-24 Input Service ID (2/3)

If the entered Service ID was not correct, the display changes to

the screen shown in Fig. 16-25.

Enter the correct Service ID and press F6 to confirm.

The number of attempts to enter the Service ID is not limited.

REMARKS: If you are unsure about the correct Service ID

number, please contact your supervisor.

Fig. 16-25 Input Service ID (3/3)

SHOP-10 06279-xD-GB-1 PC3000-6 16 - 47

KOMTRAX Plus service level KOMTRAX Plus

16.5.1 EXPLANATION OF THE BUTTON SYMBOLS (SERVICE LEVEL)

REMARKS: The function of the buttons depends on the menu context.

Functions of the buttons F1 to F6

F1 Go to the next screen.

F2 Go to the previous screen.

Move the cursor down or left in a

F3
menu.

Move the cursor up or right in a

F4
menu.

Leave the sub-menu and go back to

F5
the previous main menu.

Confirm any setting, or switch any

F6
function ON or OFF (1 or 0).

16 - 48 PC3000-6 SHOP-10 06279-xD-GB-1

KOMTRAX Plus KOMTRAX Plus service level

16.5.2 SERVICE MENU SELECT SCREEN

After the log-in with the Service ID, the following 8 options of the SERVICE MENU SELECT screen are available:

Fig. 16-26 Service Menu selection screen - items 01 - 08

01 Real Time Monitor

Shifts to the menu which allows to display real-time controller data,
refer to section 16.5.3 on page 16-50.

02 PM-Clinic
Shifts to the menu which displays PM-Clinic data, refer to section 16.5.4 on page 16-62.

03 Serial/GCC No. Setting

Registers the serial numbers of the excavator model, the engine, and ORBCOMM,
refer to section 16.5.5 on page 16-65.

04 Memory Clear
Shifts to the menu which allows to clear the records in the KOMTRAX Plus memory,
refer to section 16.5.6 on page 16-66.

05 Failure History
Shifts to the screen which displays the event and error history for service,
refer to section 16.5.7 on page 16-68.

06 Maintenance
Shifts to the menu which allows to manage the data of the Maintenance Monitor,
refer to section 16.5.8 on page 16-69.

07 Snapshot
Shifts to the menu which allows to manage the saving options of machine data in manual snapshots,
refer to section 16.5.9 on page 16-70.

08 Setting
Shifts to the menu which allows to manage specific settings of machine data,
refer to section 16.5.10 on page 16-72.

SHOP-10 06279-xD-GB-1 PC3000-6 16 - 49

KOMTRAX Plus service level KOMTRAX Plus

16.5.3 REAL TIME MENU SELECT SCREEN

REMARKS: For entering the Service Menu refer to section 16.5

on page 16-46.

Use the two REAL TIME MENU SELECT screens to open the
sub-screens for all 15 options.
The sub-screens are called REAL TIME MONITOR.

Press F3 or F4 to toggle the REAL TIME MENU SELECT

screens.

Fig. 16-27 Real Time Menu

The following REAL TIME MONITOR screens display all relevant controller data in real-time.
Use the real-time data for testing & adjustment work and for troubleshooting.

16 - 50 PC3000-6 SHOP-10 06279-xD-GB-1

KOMTRAX Plus KOMTRAX Plus service level

16.5.3.1 REAL TIME MENU, OPTION: 01 ENGINE 1

Press F3 or F4 to move up or down in the menu.

Select menu option 01 Engine 1 and press button F6.

Fig. 16-28 Real Time Menu, selection 01

Press F1 or F2 to toggle the screens.

Fig. 16-29 Real Time Monitor - Engine 1, screens 1 - 5

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16.5.3.2 REAL TIME MENU, OPTION: 02 PTO 1

Press F3 or F4 to move up or down in the menu.

Select menu option 02 PTO 1 and press button F6.

Fig. 16-30 Real Time Menu, selection 02

Fig. 16-31 Real Time Monitor - PTO 1, screen 1

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16.5.3.3 REAL TIME MENU, OPTION: 03 HYDRAULIC

Press F3 or F4 to move up or down in the menu.

Select menu option 03 Hydraulic and press button F6.

Fig. 16-32 Real Time Menu, selection 03

Press F1 or F2 to toggle the screens.

Fig. 16-33 Real Time Monitor - Hydraulic, screens 1 - 3

Screen 1/3 components 61B158a ~ 61B158c:

Pressure sensors for the electronic pump control (CR 710) of main pumps 1 ~ 3.

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16.5.3.4 REAL TIME MENU, OPTION: 04 ELECTRICAL EQUIPMENT

Press F3 or F4 to move up or down in the menu.

Select menu option 04 Electrical Equipm. and press button F6.

Fig. 16-34 Real Time Menu, selection 04

Fig. 16-35 Real Time Monitor - Electrical Equipment, screen 1

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16.5.3.5 REAL TIME MENU, OPTION: 05 EMERGENCY STOP

Press F3 or F4 to move up or down in the menu.

Select menu option 05 Emergency Stop and press button F6.

Fig. 16-36 Real Time Menu, selection 05

Fig. 16-37 Real Time Monitor - Emergency Stop, screen 1

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16.5.3.6 REAL TIME MENU, OPTION: 06 MANUAL SWITCH

Press F3 or F4 to move up or down in the menu.

Select menu option 06 Manual Switch and press button F6.

Fig. 16-38 Real Time Menu, selection 06

Fig. 16-39 Real Time Monitor - Manual Switch, screen 1

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16.5.3.7 REAL TIME MENU, OPTION: 07 CENTRAL LUBE SYSTEM 1

Press F3 or F4 to move up or down in the menu.

Select menu option 07 Central Lube System 1 and press

button F6.

Fig. 16-40 Real Time Menu, selection 07

Fig. 16-41 Real Time Monitor - Central Lube System 1, screen 1

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16.5.3.8 REAL TIME MENU, OPTION: 08 SLEW RING GEAR LUBE SYSTEM

Press F3 or F4 to move up or down in the menu.

Select menu option 08 Slew Ring Gear Lube System and press
button F6.

Fig. 16-42 Real Time Menu, selection 08

Fig. 16-43 Real Time Monitor - Slew Ring Gear Lube System, screen 1

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16.5.3.9 REAL TIME MENU, OPTION: 09 PILOT CONTROL

Press F3 or F4 to move up or down in the menu.

Select menu option 09 Pilot Control and press button F6.

Fig. 16-44 Real Time Menu, selection 09

Fig. 16-45 Real Time Monitor - Pilot Control, screen 1

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16.5.3.10 REAL TIME MENU, OPTION: 10 OTHER ITEMS

Press F3 or F4 to move up or down in the menu.

Select menu option 10 Other Items and press button F6.

Fig. 16-46 Real Time Menu, selection 10

Press F1 or F2 to toggle the screens.

Fig. 16-47 Real Time Monitor - Other Items, screen 1

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16.5.3.11 REAL TIME MENU, OPTION: 11 OUTPUT SIGNALS

Press F3 or F4 to move up or down in the menu.

Select menu option 11 Output Signals and press button F6.

Fig. 16-48 Real Time Menu, selection 11

Press F6 to toggle (ON/OFF).

(ON = 1 / OFF= 0)

Fig. 16-49 Real Time Monitor - Output Signals, screens 1

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16.5.4 PM-CLINIC

REMARKS: For entering the Service Menu refer to section 16.5 on page 16-46.

The PM-Clinic Menu provides the following features:

– General data of the machine and operating conditions are displayed, refer to Fig. 16-51.
– Power Check relevant data can be frozen and also displayed by actuating:
– Button F4 in Fig. 16-53.
– Push button 20S082 (RH control lever), which is normally used as truck counter.
– The frozen data can be stored 3 times.

16.5.4.1 GENERAL

Press F3 or F4 to move up or down in the menu.

Select 02 PM-Clinic and press F6.

Fig. 16-50 Service Menu - 02 PM-Clinic

Press F1 or F2 to toggle the screens.

Fig. 16-51 PM-Clinic - General, screens 1 - 2

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Press F6 to get into the second PM-CLINIC menu POWER CHECK.

In case data are already stored in the Menu POWER CHECK

(Fig. 16-53) the screen shown in Fig. 16-52 appears before
screen POWER CHECK opens.

If you want to save the current PM-Clinic data, delete the

previously saved data by pressing button F6.

If you don’t want to delete all PM-Clinic data, press button F5 in

order to open the following screens of PM-Clinic POWER
CHECK.

Fig. 16-52 Delete PM-Clinic data - Yes/No

16.5.4.2 POWER CHECK

The POWER CHECK screens should assist you if you want to check or identify:

(a) Engine performance/engine output power

(b) Pressure adjustment/hydraulic system problems

There are 3 screens POWER CHECK (Fig. 16-53) for freezing data under different conditions.

REMARKS: In order to obtain a complete POWER CHECK, the F6 button should only be pressed after the 3rd
screen POWER CHECK 3/3 has been frozen.

It is possible to store the values of 3 different POWER CHECKS in the screens 1/3, 2/3, and 3/3.

Press button F1 or F2 to monitor the POWER CHECK data of all 3 screens.

Fig. 16-53 PM-Clinic - POWER CHECK, screens 1 - 3

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If you want to freeze the data, press button F4 to move the yellow
mark to Hold, at the bottom of the display.

If Hold is highlighted yellow (Fig. 16-54), press button F6 to freeze

the current PM-CLINIC data.

To show the current data again, press button F3.

The yellow mark moves to Monitoring again.

Fig. 16-54 POWER CHECK - Hold activated

After pressing button F6 in screen POWER CHECK 3/3

(Fig. 16-54) the screen shown in Fig. 16-55 appears.

Press button F6 if you want to record the data.

Press button F5 for exit if you don’t want to record the data.
The system returns to the POWER CHECK screen.

Fig. 16-55 Record PM-Clinic data - Yes/No

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16.5.5 SERIAL/GCC NO. SETTING

REMARKS: For entering the Service Menu refer to section 16.5 on page 16-46.

Use this option to display the serial number of:

(a) the excavator

(b) the engine

(c) the satellite communication setup (GCC)*

* The GCC code for ORBCOMM can only be set with the VHMS Setting Tool.

Press F3 or F4 to move up or down in the menu.

Select 03 Serial/GCC No. Setting and press F6.

NOTE! For GCC selection refer to the ORBCOMM manual.

Fig. 16-56 Service Menu - item 03 selected

Fig. 16-57 Screen SERIAL NO. SETTING

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16.5.6 MEMORY CLEAR

REMARKS: For entering the Service Menu refer to section 16.5 on page 16-46.

16.5.6.1 INPUT MEMORY CLEAR ID

Use this option to enter the Memory Clear ID, which enables the user to delete memory data. With this function it
is made sure that only authorized service personnel may delete saved data.

Press F3 or F4 to move up or down in the menu.

Select 04 Memory Clear and press F6.

Fig. 16-58 Service Menu - item 04 selected

Entry of the Identification Number

If 04 Memory Clear is selected in the Service Menu Selection

screen, the display changes to the Input Memory Clear ID screen
(Fig. 16-59).

The ID number entry is done via the key pad. The ID number is
a number with up to 10 digits (same as the Service ID number).
The entered number is compared with the number which is
registered in the KOMTRAX Plus controller.

If the check result is correct, the display changes to the

MEMORY CLEAR screen (Fig. 16-62), refer to section 16.5.6.2
on page 16-67. Fig. 16-59 Input Memory Clear ID

Enter the Identification Number (ID) for clearing the memory and
press F6 to confirm.

Fig. 16-60 Memory Clear ID is typed in

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If the entered ID is not correct, the display changes to the screen

shown in Fig. 16-61.

Enter the ID number again.

Fig. 16-61 Enter Memory Clear ID again

16.5.6.2 MEMORY CLEAR SCREEN

REMARKS: For entering the Memory Clear ID refer to section 16.5.6.1 on page 16-66.

After the correct Memory Clear ID is entered, the following MEMORY CLEAR menu will open.

Press button F3 or F4 to move up or down in the menu and select

the requested data set (01 - 06) which should be cleared in the
memory.

Fig. 16-62 Memory Clear Menu

Press button F6 to confirm the deletion of the selected data or

press F5 to exit.

REMARKS: The deletion procedure is the same for all 6 entries

in the MEMORY CLEAR menu (Fig. 16-62).

Fig. 16-63 Memory Clear - confirmation for

deletion

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16.5.7 FAILURE HISTORY

REMARKS: For entering the Service Menu refer to section 16.5 on page 16-46.

Press F3 or F4 to move up or down in the menu.

Select 05 Failure History and press button F6.

Fig. 16-64 Service Menu - selection 05

Fig. 16-65 Screen FAILURE HISTORY (for Service)

(1) Frame which indicates the selected failure message (using buttons F3 and F4)

(2) Failure detection start time

(3) – Number in the failure history chart

– Failure code (DBBQKR)
– Failure text message (Communication failure CR710 <=> KOMTRAX Plus controller)

(4) Occurrences of the same failure

(5) Total number of saved failure messages in this failure history

(6) No failure detection end time - failure still pending

(6) Failure detection end time - failure no longer present

The chart FAILURE HISTORY (for Service) is displayed in the reverse order of the failure occurrence.
The failure message which was saved lastly, is shown at the top of the displayed chart.
As long as any listed failure is not rectified, the failure detection end time is not displayed.

If you want to delete any failure record from the displayed chart:

1. Press button F3 or F4 to select any failure record.

2. Press F6 to delete the selected failure record.

If you want to delete more failure records from the chart, proceed analogously.

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16.5.8 MAINTENANCE MONITOR

REMARKS: For entering the Service Menu refer to section 16.5 on page 16-46.

Press F3 or F4 to move up or down in the menu.

Select 06 Maintenance and press F6.

Fig. 16-66 Service Menu - item 06 selected

Maintenance Confirmation by the Service Personnel

Maintenance indicated with yellow or red background colour

should be confirmed by service personnel in the Service Menu
subsequent to the execution of the respective maintenance.
After that the selection in the Service Menu, used for mainte-
nance confirmation, is without any function. The confirmation
of the maintenance is stored in the KOMTRAX Plus controller.

Example: 250 h maintenance is required (yellow marked),

service meter reading is -2 hours (red marked).
Fig. 16-67 Maintenance Monitor - overview

Press F6 to reset the selected service meter.

Fig. 16-68 Maintenance Monitor - reset

function

REMARKS: In this section only the selection of the 250 h Maintenance is described as an example.
The procedure is the same for all remaining Maintenance entries on the MAINTENANCE MONITOR
(Fig. 16-67).

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16.5.9 SNAPSHOT

REMARKS: For entering the Service Menu refer to section 16.5 on page 16-46.

Press F3 or F4 to move up or down in the SERVICE MENU.

Select 07 Snapshot and press F6.

Press the START button F1 in order to save the (manual) SNAPSHOT data in the KOMTRAX Plus controller.

Fig. 16-69 Service Menu - 07 Snapshot selected Snapshot - Start Monitor

Fig. 16-70 Snapshot running

After the snapshot procedure has been started the progress bar begins to fill up (Fig. 16-70, Pos. 1 + 2).
Data capturing is completed when the progress bar is completely filled (Fig. 16-70, Pos. 3).

2 seconds after data capturing is completed the screen changes back to the SNAPSHOT START monitor.

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Download the saved snapshot data

For any analysis of the manual SNAPSHOT data it is necessary to download these data onto a laptop.
For download and analysis the KOMTRAX Plus-Setting Tool and the KOMTRAX Plus-Analyzing Tool are required.

REMARKS: If certain troubles occur, machine data at the time of the failure occurrence are saved automatically
(automatic Snapshot).

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16.5.10 SETTINGS

REMARKS: For entering the Service Menu refer to section 16.5 on page 16-46.

This option allows you to determine the basic operating and system conditions (settings) via the KOMTRAX Plus
system.

Press F3 or F4 to move up or down in the menu.

Select 08 Setting and press F6.

Fig. 16-71 Service Menu - item 08 selected

16.5.10.1 CENTRAL LUBRICATION SYSTEM (CLS 1), SCREEN 1/4

Press button F1 or F2 to monitor the SETTINGS screens 1-4.

CLS 1 Lubrication Cycle Counter Setting

Options on screen CLS 1 SETTINGS 1/4 (Fig. 16-72):

Press button F6 to enter the Lubrication Cycle Counter Setting

screen.

REMARKS: It is recommended to keep the counter reading over

the live-time of the machine.
If necessary enter the number of the last download.

Fig. 16-72 Settings 1/4 - CLS 1 Settings

Enter the cycle counting via the key pad, for example: 238.

Press button F6 to confirm the entered value.

Fig. 16-73 Enter CLS 1 PAUSE TIME

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16.5.10.2 SLEW LUBRICATION SYSTEM (SLS), SCREEN 2/4

SLS Lubrication Cycle Counter Setting

Options on screen SLS SETTINGS 2/4 (Fig. 16-74):

Press button F6 to enter the Lubrication Cycle Counter Setting

screen.

REMARKS: It is recommended to keep the counter reading over

the live-time of the machine.
If necessary enter the number of the last download.

Fig. 16-74 Settings 2/8 - SLS Settings

Enter the cycle counting via the key pad, for example: 218.

Press button F6 to confirm the entered value.

Fig. 16-75 Enter SLS Settings

16.5.10.3 OTHER SETTINGS 1/2, SCREEN 3/4

Press F3 or F4 to move up or down in the menu.

REMARKS: This screen only displays current information

without any option for settings.

For changing the settings of e.g. Language, Date,

Time, and Daylight saving time refer to
section 16.2.7 on page 16-18
("Settings for operator").

Fig. 16-76 Settings 3/4, Other Settings (1/2)

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16.5.10.4 OTHER SETTINGS 2/2, SCREEN 4/4

Press button F3 or F4 to move up or down in the menu, and press

button F6 to open the selected submenu.

Fig. 16-77 Settings 4/4, Other Settings (2/2)

Hydraulic Oil Viscosity

Use this option to save the specification of the used hydraulic oil for the ORBCOMM transmissions.

REMARKS: This saved information does not have any effect on the machine, the oil viscosity is set at the temper-
ature converter relays for the pump regulation, refer to section 9.3.4 on page 9-22.

Select Oil viscosity hydraulic and press button F6.

Press button F1 or F2 to toggle the 5 screens.

Press button F3 or F4 to select the required hydraulic oil

specification on the screen (Fig. 16-78) and press button F6
for confirmation.

Fig. 16-78 Hydraulic oil selection chart

Messages ON/OFF

Use this option to avoid and eliminate unnecessary failure messages during certain service activities.

In the state Messages OFF setting works are not interrupted by accidentally generated messages and the memory
will not be filled with messages caused by testing operations. Control and monitoring functions remain active.

Every setting modification of the function Messages ON/OFF is saved in the service memory.

Press button F3 or F4 to move up or down in the menu.

If the option Messages ON/OFF is selected, press button F6

to deactivate messages (= OFF).

After testing or service work is finished, activate the messages

again by switching Messages ON/OFF to ON again.

Optionally switch off the main key switch (20S001) until the con-
troller is totally shut down (all LEDs OFF), in order to cause a
reset. After such a reset the function Messages ON/OFF is set to
ON again by the system.
Fig. 16-79 Message OFF selected

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Interface-Connection KOMTRAX Plus controller KOMTRAX Plus

16.6 INTERFACE-CONNECTION KOMTRAX PLUS

CONTROLLER

Fig. 16-80 Interface connection KOMTRAX Plus controller

(1) Interface panel on the side wall of the operator’s console

(2) operator’s console

[20S053] Enable switch for QUANTUM diagnostic:

– Download of engine data

– Programming QUANTUM controller
– Activation of the engine service lamps at the X2 board (11P094, 11P095, 11P096)

[20X027a] Socket for:

– VHMS Setting Tool

– VHMS Analysis Tool

[20X052-1] Data link connector for the QUANTUM service tool.

[20X336] Data link connector for programming the KOMTRAX Plus monitor.

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16.6.1 KOMTRAX PLUS CONTROLLER

The KOMTRAX Plus controller [14K300] provides interfaces and options for the user as follows:

– Data link to the KOMTRAX Plus monitor in the operator’s cab

– Data link to the Multimonitor
– Data link to QUANTUM (engine control)
– KOMTRAX Plus programming
– Reading out machine trouble codes
– Download of snapshot data
– Download of KOMTRAX Plus memory data
– Trouble shooting features & assistance
– Service link to QUANTUM (engine control)

REMARKS: Data cables, hardware devices, and software tools for data exchange via the KOMTRAX Plus
interface connections are optional equipment, refer to the TOOLS & ACCESSORIES catalogue.

For detailed information about the KOMTRAX Plus software refer to chapter 40 Troubleshooting
in this SHOP MANUAL.

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7-segment error code indication KOMTRAX Plus

16.7 7-SEGMENT ERROR CODE INDICATION

(1) KOMTRAX Plus controller

(2) 7-segment LED display

(3) 7-segment digit

If certain errors occur on the machine, the trouble messages are

not only displayed on the K+ monitor - special fault codes are also
displayed via 7-segment LED at the K+ controller.

The 7-segment fault code exists of the letter M and 3 figures.

Example:

M901 for message Source voltage error

Fig. 16-1 7-segment display

As the 7-segment system can not display letter "M" it displays

letter "n" instead.

The 7-segment system can display 2 figures only.

Therefore the 4-digit fault code is split.
For example M901 is displayed as "n9" and "01" alternately.

The alternating indication of the split fault code is repeated,

as long as the error exists.

Fig. 16-1 7-segment fault code M901

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Wiring of the KOMTRAX Plus controller KOMTRAX Plus

16.8 WIRING OF THE KOMTRAX PLUS CONTROLLER

Fig. 16-2 KOMTRAX Plus controller connectors

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Legend for Fig. 16-2:

(1) KOMTRAX Plus controller (14K300)

Mounted in the cab base

(2) 7-segment LED display

During standard operation the controller is continuously counting up a loop of digits.
In case of any malfunction the counting loop is stopped.

(3) Type label

(4) Connector panel

(5) Supply voltage indicator

(6) LED green

ON = supply voltage (24 V) OK

(7) LED yellow

ON = supply voltage (24 V) ERROR

Pin layout in the sockets at the KOMTRAX Plus controller:

CN1 (white) CN2-A (green)

1 LB1 1 X2 Pressure

6 Batt direct (24V) 2 RB5

7 Batt direct (24V) 3 RB5

8 Key switch 24V+ 4 Pow batt voltage

9 Key switch 24V+ 5 Exh. temp LB2

10 Exh. temp RB1 6 Exh. temp LB3

11 GND 7 Exh. temp LB4

12 GND 8 Level fuel tank

13 SLS Pump on 10 Ambient temperature

14 CLS Pump on 11 Hydr. oil temperature

15 ORBCOMM GND 12 Analog GND

16 Acoustic signal (output) 13 Analog GND

18 Flash_write 15 Battery charge/discharge current

19 GND 16 Exh. temp LB6

20 GND 17 Wake up for ORBCOMM

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Wiring of the KOMTRAX Plus controller KOMTRAX Plus

CN2-B (green) CN3-A (white)

Pin Function Pin Function

1 V5 1 Hour meter active

2 Start enable 3 PTO oil temp. too high

3 Hydraulic oil not cold 4 RS232 TX2

4 Exh. temp RB3 5 Engine speed high/low idle

5 Exh. temp RB4 7 Exh. temp LB5

7 Diesel engine running 9 GND (connection check 2)

8 Engine test speed 1800 1/min 10 Truck counter 1

9 Analog GND 11 Truck counter 2 RESERVE

10 Distributor strainer - oil cool. 12 RS232 RX2

11 Exh. temp RB6 13 RS232 GND

14 PTO lub. filter - pressure

15 Pilot control cut off

16 Engine oil tank empty

CN3-B (white) CN4-A (white)

Pin Function Pin Function

1 Hydraulic oil temperature too high 4 CAN 1 +

2 SLS Grease empty 5 CAN 0 Shield

3 SLS Grease fault 6 CAN 0 +

4 Leak oil filter - pressure 9 RS232 GND

5 Return oil filter - pressure 10 RS232 RX0

6 Oil tank breather - filter pressure 11 RS232 TX0

7 Engine air filter - pressure 12 CAN 1 -

8 PTO lubrication pressure 13 CAN 1 Shield

9 Digital GND 14 CAN 0 -

10 CLS Grease empty

11 CLS Grease fault

12 GND (connection check 3)

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CN4-B (white) CN5 (black)

Pin Function Free - not used

4 RS232 TX1

9 RS 232 GND (shield)

10 RS232 RX1

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Global layout of the internal CAN BUS KOMTRAX Plus

16.9 GLOBAL LAYOUT OF THE INTERNAL CAN BUS

16.9.1 GENERAL INFORMATION ON A CAN BUS SYSTEM

Fig. 16-1 System layout - PC3000 CAN overview

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16.9.1.1 GENERAL CAN BUS DESCRIPTION

REMARKS: The acronym CAN means: Controller Area Network.

The comparison of the wiring in a conventional control circuit and in a control circuit with CAN bus shows that the
total length of the wiring between the controller and the electrical components in the CAN bus system is visibly
shorter.

Also the number of connectors is reduced, as several cable sections in the wiring between the controller and the
machine components are no longer needed.

In a CAN bus system all system components (input & output) are connected to a common data line via short
branch lines. Therefore the system wiring is reduced and additional components may be connected easily.

However, the data flow must be controlled by an access method (protocol) in order to manage the well organized
data transfer in one common data line.

The status information from the electrical components are not continuously present in the CAN bus cable. Status
information and control signals of each component are packed in data packages which are called Data Frames.
These Data Frames are sent through the CAN bus periodically in small fractions of a second.

The main components KOMTRAX Plus controller, Quantum ECM and pump controller CR710 can send and
receive the Data Frames. Also they organize and manage a safety system, to make sure that defined and com-
plete information packages are received by the designated components.

Each Data Frame contains a protocol for its identification.

A CAN bus cable consists of only 3 wires, which are:

– CAN high (H)

– CAN low (L)
– Shield
In a CAN bus system 2 voltages are present. Depending on the kind of system the CAN high voltage is in a range
of up to approx. 6 V. The CAN low voltage is up to approx. 3.5 V.

A CAN bus does not build a closed wiring circuit as a conventional electrical circuit system in general does.

As a result there are two "open" ends. At these ends the wires CAN high and CAN low must be connected to an
End Resistor.

16.9.1.2 CAN BUS TROUBLESHOOTING

The CAN bus system is equipped with effective self-diagnosis tools.
CAN troubles are displayed via the KOMTRAX Plus monitor.

For appropriate and qualified troubleshooting procedures refer to part 40 TROUBLESHOOTING

in this SHOP MANUAL.

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Global layout of the internal CAN BUS KOMTRAX Plus

16.9.2 CAN BUS WIRING

Fig. 16-2 Detail of the CAN bus wiring1

1 For the entire overview refer to the complete Wiring Diagrams of the respective machine.

(1) CAN bus wire CAN high (H)

(2) CAN bus wire CAN low (L)

(3) CAN bus wire shield

(4) CAN bus branch connector

(5) CAN bus End Resistor

(6) Annotation in the Wiring Diagram: Length of branch cable max. 0.5 m

(7) View onto a standard CAN bus connector (male & female)

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16.9.2.1 CAN BUS END RESISTOR

A CAN bus does not build a closed wiring circuit as a conventional electrical circuit system in general does.

As a result there are two "open" ends. At these ends the wires CAN high and CAN low must be connected to an
End Resistor. The resistance of these End Resistors is 120 Ω each. A CAN bus can be split, and in this case an
End Resistor needs to be connected to each end of the split CAN bus.

The following chart gives an overview of the fitted End Resistors on your machine.

End Resistors - Overview

Location Component
CAN bus Description
Code1 Code2

CAN bus between KOMTRAX Plus controller and KOMTRAX

14 0 [14R101]
Plus monitor

CAN bus between KOMTRAX Plus controller and diagnostic

20 0 [20R102]
connector (20X052-1) for the engine

1, 2
For a detailed explanation of the Location Code & Component Code definition refer to section
16 HINTS FOR READING THE ELECTRIC WIRING DIAGRAM.

View onto End Resistors

Fig. 16-3 View onto 2 different types of End Resistor

SHOP-10 06279-xD-GB-1 PC3000-6 16 - 87

Global layout of the internal CAN BUS KOMTRAX Plus

Please continue reading on the next page.

16 - 88 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system

17 LUBRICATION SYSTEM

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 1

General overview (SLS & CLS) Lubrication system

17.1 GENERAL OVERVIEW (SLS & CLS)

Fig. 17-1 General overview SLS & CLS

(1) Lubrication station (4) Slew circle

(2) Attachment (FSA / BHA) (5) Superstructure

(3) Slew gear box (6) Lube pinion (dummy wheel)

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Lubrication system General overview (SLS & CLS)

17.1.1 GENERAL DESCRIPTION

For maximum machine reliability and maximum lifetime, the principal bearing points must be frequently lubricated
with a sufficient amount of specified lubricant.

For best lubricating reliability with minimum maintenance, there are automatic lubrication systems which are con-
trolled by timing relays. They lubricate all connected lubricating points within adjustable time intervals and with the
required amount of lubricant. The automatic lubrication starts as soon as the engine is running.

The excavator is equipped with 2 independent lubrication systems:

– SLS
The SLS (Slew circle gear Lubrication System) supplies the open gear of the slew circle teeth over the lube
pinion (Fig. 17-1, Pos. 6) with grease.
– CLS
CLS (Central Lubrication System) supplies all pins and bearings of the attachment (Fig. 17-1, Pos. 2), the
bearings of the slew circle (Fig. 17-1, Pos. 4) as well as the pins and bearings at the superstructure (Fig. 17-1,
Pos. 5) and the lower bearings of the slew gear box (Fig. 17-1, Pos. 4) with grease.
Because for the lubrication of open ring gear teeth a different type of grease is needed as for the other bearings,
SLS and CLS have two separate refilling lines with filters coming from the service arm.

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Basic function of the lubrication systems Lubrication system

17.2 BASIC FUNCTION OF THE LUBRICATION

SYSTEMS

Fig. 17-2 Basic function of the lubrication systems

17 - 4 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Basic function of the lubrication systems

Legend for Fig. 17-2:

(1) Lubrication pump drive (hydraulic)

(2) Pressure reducing valve (45 bar)

(3) Grease pump control solenoid (see Table 17-1)

(4) Hydraulic oil return line

(5) Hydraulic oil supply line (X4-pressure)

(6) Lubricant pressure gauge

(7) Lubricant in-line filter

(8) Lubricant pressure release solenoid valve(vent valve, see Table 17-1)

(9) Lubricant supply line from pump to injector

(10) Lubricant release line

(11) End-line switch (see Table 17-1)

(12) Lubricant injector

(13) Lubricant feed line from injector to the lubricating point (bearings or open gear of the slew circle
teeth)

(14) Bearing

(15) Dummy wheel

(16) Lubricant pump

(17) Lubricant

(18) Lubricant container

(19) Breather filter for lubricant container

(20) Binary sensors for lubricant level indication (see Table 17-1)

REMARKS: To identify the correct designation in the respective lubrication system, see following table:

System Solenoid valve Vent valve End-line switch Binary sensor

SLS 62Q509 62Q509a 62B046 62B109a/b/c

CLS 62Q507 62Q507a 80B043 62B108a/b/c

Table 17-1

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Lubrication systems (SLS & CLS) Lubrication system

17.3 LUBRICATION SYSTEMS (SLS & CLS)

17.3.1 LUBRICATION PUMP STATION

Fig. 17-3 Lubrication pump station SLS / CLS

17 - 6 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Lubrication systems (SLS & CLS)

Legend for Fig. 17-3:

(1) Lube station (CLS or SLS) (12) Hydraulic oil supply line (X4-pressure)

(2) Lube station top view (13) Breather filter for lubricant barrel

(3) Grease barrel (14) Lubricant pump

(4) Lubricant pump drive (hydraulic cylinder) (15) Cable connector for vent valve

(5) Flow control valve (16) Vent valve control & filter block
(vent valve de-energized open to barrel)

(6) Pressure reducing valve (17) Pressure relief valve

(7) Electric terminal box (18) Grease outlet filter

(8) Dip stick (19) Lubricant pressure gauge

(9) Lubricant level sensors (binary type) (20) End-line switch

(10) Grease pump control solenoid valve (21) Lubricant injector

(11) Hydraulic oil return line (22) Lubricant lines to lubricating points

(11a) Test port lubricant pump drive pressure (23) Lubrication pinion (dummy wheel) SLS only

Description

Both lubrication pump stations consists of a grease barrel (Fig. 17-3, Pos. 3) and a barrel cover with the pump
system (lube station, Fig. 17-3, Pos. 1).
The barrels are fix-mounted. With the refilling arm the barrels are rechargeable via a filter.

The main grease pump system is mounted onto the barrel cover. It includes the pump (Fig. 17-3, Pos. 4 & 14),
valves (Fig. 17-3, Pos. 5, 6, 10, 16), a grease filter (Fig. 17-3, Pos. 18), three grease level sensors (Fig. 17-3,
Pos. 9), and an end-line switch (Fig. 17-3, Pos. 20).

The pump stations of CLS and SLS basically have the same design. For further information about the lubrication
pump station refer to the PARTS & SERVICE NEWS AH15824 (latest edition).

General Function

– After the pilot pressure has been reduced it passes to the hydraulic cylinder (Fig. 17-3, Pos. 4) which operates
the grease pump (Fig. 17-3, Pos. 14).
– The hydraulic cylinder (Fig. 17-3, Pos. 4) operates the grease cylinder with 16 – 19 double strokes per minute.
In that way 480 - 570 cm3 (approx. 550 - 612 g) of lubricant are delivered per minute.
– With the vent valve (Fig. 17-3, Pos. 16) closed, the pump continues to cycle until the maximum pressure is
achieved and the injectors (Fig. 17-3, Pos. 21) have metered grease to the lubrication points. The pressure
in the lubrication system is 180 bar.
– When the maximum system pressure is reached, the end-line switch (Fig. 17-3, Pos. 20) switches and signals
the pump controller CR710 that the pressure in the lubrication system has reached 180 bar. Also the lubrica-
tion interval time relay is reset.
– The solenoid valve (Fig. 17-3, Pos. 10) is de-energized and the hydraulic oil stops flowing to the pump.
– The vent valve (Fig. 17-3, Pos. 16) is is de-energized, it opens and allows the grease pressure to drop to zero.
– All injectors move into their initial position by spring force and recharge themselves for the next lubricant cycle.
– The system is at rest now and ready for another lube cycle.

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 7

Lubrication systems (SLS & CLS) Lubrication system

17.3.2 GENERAL INFORMATION ON CLS

The hydraulic driven lubricant pump (Fig. 17-3, Pos. 4 & 14) pumps grease from a barrel (Fig. 17-3, Pos. 3)
through pipes or hoses to the injectors (Fig. 17-3, Pos. 21). These injectors pump a defined quantity of grease to
the lubrication points. After all injectors delivered their grease quantity to the lube points, the grease pump stops
and the next lubrication cycle will start after an adjusted time period (lubrication interval time relay 11K103).
The central lubrication system is only active if the engine is running at high idle.

17.3.3 GENERAL INFORMATION ON SLS

The slew ring gear lubrication system (SLS) uses a special dummy wheel (Fig. 17-3, Pos 23) to apply the
gear grease onto the slew ring gear. All other components between the grease barrel and the injectors are
comparable to the CLS lubrication systems.

With each lube cycle the dummy wheel (Fig. 17-3, Pos 23) receives grease from two or more parallel connected
injectors (Fig. 17-3, Pos 21). After the injectors delivered their gear grease quantity via the dummy wheel to the
slew ring gear, the grease pump stops and the next lubrication cycle will start after an adjusted time period (lubri-
cation interval time relay 11K007).

To prevent unnecessary lubrication with the slew ring in park position, the SLS pump only starts to operate after
"slew" was activated with the control lever.

The pinion center shaft acts as a rotary joint. From the center bore the lubricant is distributed through radial bores
only to those teeth that are in contact with the slew ring teeth.

Outlet bores at different pinion gear levels distribute the lubricant equally to the slew ring teeth.

17 - 8 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Lubrication systems (SLS & CLS)

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SHOP-10 06279-xD-GB-1 PC3000-6 17 - 9

Lubrication cycle Lubrication system

17.4 LUBRICATION CYCLE

Fig. 17-4 Action chart for lube cycles

PT Pause Time S- Switch point OFF - end-line switch

PI Pressure Increasing (grease supply line) PR Pressure Relieve

S+ Switch point ON - end-line switch

17 - 10 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Lubrication cycle

17.4.1 TIME SEGMENTS & SWITCH POINTS OF A LUBRICATION CYCLE

Terms Time segment Explanation
PI a ... b A lubrication cycle starts automatically after the pause time is expired or
manually if the switch for manual lubrication 20S124 (CLS) or
Pressure 20S126 (SLS) is actuated.
Increasing
REMARKS: For SLS there is also the pre-condition that the control
lever for "Slew" is moved out of its zero position.

The solenoid valve is energized and the pilot pressure (X4 pressure)
starts to move the oscillating cylinder. At the same time the vent valve is
energized (closed) and the lubrication pressure starts to increase.

This time segment for building-up the pressure in the lubricant line is not
adjustable.
S+ b After all lubricating points have been lubricated there is a pressure rise
which opens the end-line switch when the max. pressure is reached.
Switch point ON During normal application the end-line switch adjusted to 180+5 bar.
end-line switch The pressure increasing phase is now finished.

The switched end-line switch interrupts the power to the interval timiming
relay (pause time relay) which is thereby reset, thus interrupting the
power to the control solenoid valve and the vent valve.
PR b ... c With de-energized (open) vent valve the lubricant pressure drops com-
pletely to zero so the injectors can be recharged for the next lubrication
Pressure Relieve cycle.
S- While the lubricant pressure drops the end-line switch switches back
OFF.
Switch point OFF
end-line switch The end-line switch now supplies power to the interval timiming relay
(pause time relay) which starts to count down the adjusted pause time.
PT b (S-) ... a The counting of the pause time starts at "S-" when the end-line switch is
switched OFF.
Pause Time The next lubrication cycle starts after the pause time is expired.
Preconditions:
SLS & CLS: Motor is running in high idle
SLS only: Slew movement was activated
Via the interval timing relays the pause time is adjustable.

Table 17-2 Switching points

System Manual lube Solenoid valve Vent valve End-line switch Interval timing
switch relay

SLS 20S126 62Q509 62Q509a 62B046 11K007

CLS 20S124 62Q507 62Q507a 60B043 11K103

Table 17-3 Components

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Lubrication cycle Lubrication system

17.4.2 AUTOMATIC LUBRICATION MODE CLS

Fig. 17-5 Wiring Diagram 1 (relays) for CLS

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Lubrication system Lubrication cycle

17.4.2.1 FUNCTION
REMARKS: Refer to Fig. 17-5 and to Fig. 17-4 on page 17-10.

The CLS is entirely controlled by relays.

As soon as the battery master switch is activated the CLS is permanently supplied with power, independent of the
switching status of key switch 20S001.
The end-line switch [80B043] is in pressureless condition and the interval timing relay [11K103] is energized but
will not start counting until the engine runs in high idle.

Pause time (PT):

When engine runs in high idle the relay [11K045a] gets energized and activates the interval timing relay [11K103]
which starts to count down the adjusted pause time.

Pressure increasing starts (PI):

After the adjusted time interval has expired the interval timing relay energizes control solenoid valve [62Q507] and
the vent valve [62507a].

The lubrication pump begins to oscillate by means of X4 pressure.

With energized vent valve the lubricant release line is closed and the lubricant pressure increases.

Until all injectors have injected their adjusted amount of lubricant to the bearings the lubricant pressure in the sup-
ply line increases up to the setting of end-line switch [80B043].
During normal application the end-line switch adjusted to 180+5 bar.

Lubrication stops (S+, PR, S-):

After all lubricating points have been lubricated there is a pressure rise which switches the end-line switch when
the max. pressure is reached (S+). The pressure increasing phase is now finished.

The switched end-line switch interrupts the power to the interval timing relay [11K103] which is thereby reset, thus
interrupting the power to the control solenoid valve [62Q507] and the vent valve [62507a].
With de-energized vent valve the lubricant release line is opened and the lubricant pressure decreases to zero so
the injectors can be recharged for the next lubrication cycle.

While the lubricant pressure decreases the end-line switch [80B043] switches back to pressureless condition (S-).
Thus the end-line switch again supplies power to the interval timing relay [11K103] which starts to count down the
adjusted pause time.

17.4.2.2 SYSTEM MONITORING

– In case of an interrupted power supply the fail-safe relay1 [11K028] is not energized and KOMTRAX Plus gen-
erates the message G00185 Trouble central lubrication system.
– As soon as the interval timing relay [11K103] starts the lubrication cycle, the timing relay [11K104] gets ener-
gized and starts to count down the adjusted time (approx. double time of a lubrication cycle).
In case of a fault, e.g. leaking lubrication lines, the pump does not reach the end-line switch pressure setting
and the adjusted time interval of timing relay [11K104] expires.
Thus energizes relay [11K030], KOMTRAX Plus generates the message G00185 Trouble central lubrication
system and relay [11K030] starts the timing relay [11K139].
The activated timing relay [11K139] counts down the adjusted time interval as long as the machine is operated
in trouble condition (11K030 and 11K045a energized).
After the adjusted time interval (approx 4.2 h) has expired the bucket function is deactivated.

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 13

Lubrication cycle Lubrication system

17.4.3 AUTOMATIC LUBRICATION MODE SLS

Fig. 17-6 Wiring Diagram 1 (relays) for SLS

17 - 14 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Lubrication cycle

17.4.3.1 FUNCTION
REMARKS: Refer to Fig. 17-6 and to Fig. 17-4 on page 17-10.

The SLS is entirely controlled by relays.

As soon as the battery master switch is activated the SLS is permanently supplied with power, independent of the
switching status of key switch [20S001].
The end-line switch [62B046] is in pressureless condition and the interval timing relay [11K007] is energized but
will not start counting until the engine runs in high idle.

Pause time (PT):

When engine runs in high idle the relay [11K045a] gets energized and activates the interval timing relay [11K007]
which starts to count down the adjusted pause time.

Pressure increasing starts (PI):

After the adjusted time interval has expired the SLS is ready to start a lubrication cycle.
When slewing relay [11K073] gets energized. Thus energizing the control solenoid valve [62Q509] and the vent
valve [62509a].

The lubrication pump begins to oscillate by means of X4 pressure.

With energized vent valve the lubricant release line is closed and the lubricant pressure increases.

Until all injectors have injected their adjusted amount of lubricant to the bearings the lubricant pressure in the sup-
ply line increases up to the setting of end-line switch [62B046].
During normal application the end-line switch adjusted to 180+5 bar.

Lubrication stops (S+, PR, S-):

After all lubricating points have been lubricated there is a pressure rise which switches the end-line switch when
the max. pressure is reached (S+). The pressure increasing phase is now finished.

The switched end-line switch interrupts the power to the interval timing relay [11K007] which is thereby reset, thus
interrupting the power to the control solenoid valve [62Q509], the vent valve [62509a] and relay [11K073].
With de-energized vent valve the lubricant release line is opened and the lubricant pressure decreases to zero so
the injectors can be recharged for the next lubrication cycle.

While the lubricant pressure decreases the end-line switch [62B046] switches back to pressureless condition (S-).
Thus the end-line switch again supplies power to the interval timing relay [11K007] which starts to count down the
adjusted pause time.

17.4.3.2 SYSTEM MONITORING

– In case of an interrupted power supply the fail-safe relay1 [11K035] is not energized and KOMTRAX Plus gen-
erates the message G00188 Trouble slew ring lubrication system.
– As soon as the interval timing relay [11K007] starts the lubrication cycle, the timing relay [11K108] gets ener-
gized and starts to count down the adjusted time (approx. double time of a lubrication cycle).
In case of a fault, e.g. leaking lubrication lines, the pump does not reach the end-line switch pressure setting
and the adjusted time interval of timing relay [11K108] expires.
Thus energizes relay [11K038], KOMTRAX Plus generates the message G00188 Trouble slew ring lubrication
system and relay [11K038] starts the timing relay [11K140].
The activated timing relay [11K140] counts down the adjusted time interval as long as the machine is operated
in trouble condition (11K038 and 11K045a energized).
After the adjusted time interval (approx 4.2 h) has expired the bucket function is deactivated.

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 15

Lubrication cycle Lubrication system

17.4.4 AUTOMATIC LUBRICATION MODE ADJUSTMENTS

17.4.4.1 PAUSE TIME ADJUSTMENT & FAULT TIME MONITORING ADJUSTMENT

The main time adjustments of the two lubrication systems has to be done using the timing relays in the X2 switch
board inside of the cab base.

Adjust the timing relays according to the PM-Clinic.

(1) Setting of the 2nd c/o contact

(2) Adjustment of the time range by selecting the max. value

(3) Direct reading scale to set the time value

(4) Function selection

Adjustment procedure

1. Set Inst. Del. scale (Fig. 17-7, Pos. 1) to position D.

2. Choose time range according to Table 17-4 and set the

T-Range scale (Fig. 17-7, Pos. 2) accordingly.

3. Adjust the exact time on the Time scale (Fig. 17-7, Pos. 3).

– For 11K103 and 11K007 adjust the time according to the

Fig. 17-7
PM-Clinic.
– For 11K139 and 11K140 adjust the time according to
Table 17-5 on page 17-16.

4. Set the Function scale (Fig. 17-7, Pos. 4) to position

(ON-delay with Time adjusted time delay).

Examples:

Desired pause time: 20 min.

T-Range scale (Fig. 17-7, Pos. 2) set to 30 min. (yellow scale)
Time scale (Fig. 17-7, Pos. 3) set between 18 and 21, next to 21 (yellow scale)

Desired pause time: 1 h

T-Range scale (Fig. 17-7, Pos. 2) set to 100 s (white scale)
Time scale (Fig. 17-7, Pos. 3) set to 6 (white scale) => 60 s

Scale color Time range Max. value Scale color Time range Max. value

White 0.05 - 1 s 1s Yellow 0.15 - 3 s 3s

White 0.5 - 10 s 10 s Yellow 1.5 - 30 s 30 s

White 5.00 - 100 s 100 s Yellow 15.0 - 300 s 300 s

White 0.5 - 10 min 10 min Yellow 1.50 - 30 min. 30 min

Yellow 15.0 - 300 min. 300 min

Yellow 1.50 - 30 h 30 h

Yellow 15.0 - 300 h 300 h

Table 17-4 Time range for T-range setting

17 - 16 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Lubrication cycle

Relay Factory time setting Function

11K103 15 min CLS pause time between cycles (cycle interval timing)

11K139 4.2 h CLS fault time monitoring with bucket cut off

11K007 20 min SLS pause time between cycles (cycle interval timing)

11K140 4.2 h SLS fault time monitoring with bucket cut off

Table 17-5 Factory defaults

17.4.4.2 LUBE CYCLE MONITORING TIME ADJUSTMENT

REMARKS: The monitoring intervals of the timing relays 11K104 (CLS) and 11K108 (SLS) are bench adjusted
and must only be adjusted in case of replacement of the timing relay.

(1) Adjustment of the time range by selecting the max. value

(2) Direct reading scale to set the time value

Adjustment procedure

The time adjustment of 11K104 (CLS) and 11K108 (SLS) is

approx. double the time of a normal lubrication cycle (from pump
start to pump stop) to prevent a unnecessary system faults.

1. Set the time range on the scale (Fig. 17-7, Pos. 1) to 10 min.

2. Set the monitoring time on the scale (Fig. 17-7, Pos. 2) time
according to Table 17-5 on page 17-16.

Fig. 17-8

Time range Max. value Time range Max. value

0.05 - 1 s 1s 0.5 - 10 min 10 min

0.5 - 10 s 10 s 0.05 - 1 h 1h

0.05 - 1 min 1 min 0.5 - 10 h 10 h

Table 17-6 Time range setting

Relay Factory time setting Function

11K104 3 min CLS fault time monitoring with bucket cut off

11K08 2 min SLS fault time monitoring with bucket cut off

Table 17-7 Factory defaults

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 17

Lubrication cycle Lubrication system

17.4.5 MANUAL LUBRICATION MODE (CLS & SLS)

A manual lubrication cycle can be activated via the switches 20S124 (CLS) or 20S126 (SLS) at the dashboard.
The manual lubrication cycle runs as long as the concerned switch is actuated or until the pressure reaches the
switch point of the end-line switch and the lubrication pump stops.

REMARKS: The lubrication pump only stops for a short time periode because the time interval between the
switching points S+ and S- of the end-line switch is very short, refer to Fig. 17-4 on page 17-10.
The KOMTRAX Plus counts every completed lubrication cycle, so observe the cycle counter. on the
K+ monitor.

17.4.6 RESETTING A FAULTY LUBRICATION SYSTEM

To reset the lubrication system a complete manual lubrication cycle (refer to section 17.4.5 on page 17-18) must
be performed until the pressure reaches the switch point of the end-line switch and the lubrication pump stops.

REMARKS: Each time the pressure reaches the switch point of the end-line (end-line switch is switched) the
KOMTRAX Plus adds one lubrication cycle to the cycle counter.

The fault monitoring relay 11K038 (SLS) / 11K030 (CLS) gets de-energized and the timing relay 11K007 (SLS) /
11K103 (CLS) is reset.
The system is ready to start an automatic lubrication cycle.

REMARKS: Both lubrication systems are reset if the battery master switch is switched OFF.
The CLS can also be reset by opening circuit breaker 11F023.
The SLS can also be reset by opening circuit breaker 11F025.

17 - 18 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Lubrication cycle

Please continue reading on the next page.

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 19

Hydraulically driven lube pump Lubrication system

17.5 HYDRAULICALLY DRIVEN LUBE PUMP

Fig. 17-9 Hydraulically driven lubrication pump

17 - 20 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Hydraulically driven lube pump

Legend for Fig. 17-9:

(1) Pump drive hydraulic cylinder (11) Outlet check-valve (ball type)

(2) Flow control valve (12) Piston rod

(3) Pressure relief valve (13) Pump rod shaft seal

(4) Lubricant pump intake (14) Check-valve (ball type)

(5) Hydraulic oil supply port (15) Main piston and plunger

(6) Hydraulic oil return port (16) Piston rod set

(7) Pump drive control block (17) Inlet valve

(8) Breather port (18) Scoop piston

(9) Pump tube (19) Lubricant inlet

(10) Lubricant outlet port

Description

The lubrication pump is a hydraulically driven seal free differential piston pump. The pump pumps lubricant at the
up and down stroke but sucks lubricant only during the up stroke. The scoop piston at the pump bottom supports
the main pump especially with high viscosity lubricants. There are only one dynamic seal at the piston rod on top
of the pump pipe therefor less on wear and long service time.

The lubrication pump is divided in two main components, the pump drive hydraulic cylinder and the pump. The
pump drive and only the pump outlet are outside on top of the lubricant container, the pump itself is inside and
reaches into the lubricant.

The maximum possible lubricant pressure depend on the adjusted supply pressure.
The pressure multiplication factor between supply pressure and maximum lubricant pressure is 6.55.
The pressure reduction valve has to be adjusted to 45 bar.

Example:
45 bar supply pressure × 6.55 = 295 bar lubricant pressure.
During normal operation the end-line switch stops the pump before reaching this high pressure.
For a sufficient lube pump operation 16-19 double strokes/min for the pump drive cylinder are required. Therefore
the flow reducing valve has to be adjusted, refer to section 17.5.1 on page 17-22.

Technical pump data

Pump stroke Pump delivery per stroke Pump speed Total pump delivery

152 mm 30 cm3 / double stroke 16-19 double strokes / min 540-600 cm3 / min

Table 17-8

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Hydraulically driven lube pump Lubrication system

17.5.1 ADJUSTMENT OF LUBE PUMP SPEED

Fig. 17-10 Adjustment of lube pump speed

17 - 22 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Hydraulically driven lube pump

17.5.1.1 STROKE SPEED ADJUSTMENT

For a sufficient lubricating pump operation 16-19 double strokes/min. of the pump drive cylinder are required.
Therefore the flow control valve (Fig. 17-10, Pos. 2) has to be adjusted accordingly.

Adjustment procedure

1. Remove the connector (Fig. 17-10, Pos. 6) from the vent valve (Fig. 17-10, Pos. 7), in order to avoid any
pressure rise during the following test.

2. Run the engine at high idle.

3. Manually actuate the lube system using switch 20S26 (SLS)

or 20S124 (CLS) at the dashboard and count the double
strokes per minute.
Therefore remove the plug (Fig. 17-11, Pos. P) from the
pump cover and watch the piston going up and down.

If adjustment is required:

1. Loosen the lock nut (Fig. 17-10, Pos. 2b).

2. Turn the adjustment screw (Fig. 17-10, Pos. 2a) until the
correct number of double strokes/min. is achieved.

3. Tighten the lock nut (Fig. 17-10, Pos. 2b).

4. Stop the engine.

5. Connect the connector (Fig. 17-10, Pos. 6) to the vent valve

(Fig. 17-10, Pos. 7).

Fig. 17-11 Pump cover with plug

17.5.1.2 WORKING PRESSURE

The pressure reducing valve (Fig. 17-10, Pos. 3) is mounted on the oscillation control block. It reduces the supply
pressure.

This pressure reducing valve doesn’t need adjustment - it is bench tested at 50 bar.

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 23

Lubricant injectors Lubrication system

17.6 LUBRICANT INJECTORS

Fig. 17-12 Lubricant injectors type SL-1 and type SL-11

17 - 24 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Lubricant injectors

Legend for Fig. 17-12:

SL-1 Injector type SL-1 (7) Stud fitting (NPT)

SL-11 Injector type SL-11 (7a) Cap nut

(1) Adjustment screw (8) Discharge chamber

(2) Indicator stem (9) Passage

(3) Lock nut (10) Lubricant supply inlet

(4) Injector piston (11) Lubricant outlet

(5) Spring (12) Mounting manifold

(6) Slide valve

17.6.1 TIGHTENING TORQUES FOR FITTINGS AT GREASE INJECTORS

The exact tightening torque has to be observed when installing a fitting to a grease injector.

NOTICE
RISK OF DAMAGE ON GREASE INJECTORS
When installing a fitting to an injector, always observe the maximum tightening torque of
• 14 Nm for SL-1
• 17...20 Nm for SL-11
Otherwise the fitting will be screwed too far into the injector and the injector piston movement will be
blocked. As a result the grease supply will fail.

REMARKS: For the tightening procedure also refer to the PARTS & SERVICE NEWS AH10532 (latest edition).
In case of leakage use thread tape (Teflon®) or Loctite® when installing a fitting to any injector.

17.6.2 DESCRIPTION
Series SL-1 Injector

The lubricant output volume is adjustable from 0.13…1.3 cm³ per cycle.

An hydraulic type fitting with a screw type cover cap is provided for initial filling of the feeder line. It may also be
used for visual checks of the injector operation.

Series SL-11 Injector

The lubricant output volume is adjustable from 0.82…8.2 cm³ per cycle.

It is designed for systems where a large amount of lubricant is required. The operation principle is similar to the
series SL-1.

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 25

Lubricant injectors Lubrication system

17.6.3 ADJUSTMENT OF THE LUBRICANT OUTPUT

1. Loosen the lock nut (Fig. 17-12, Pos. 3).

2. Turn the adjustment screw (Fig. 17-12, Pos. 1) counterclockwise (OUT) for more lubrication outlet. Turn the
adjustment screw clockwise (IN) for less lubricant outlet.

3. Tighten the lock nut (Fig. 17-12, Pos. 3).

REMARKS: The max. lubricant outlet is adjusted if the indicator stem (Fig. 17-12, Pos. 2) can not be screwed fur-
ther out.

17 - 26 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Lubricant injectors

Please continue reading on the next page.

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 27

Lubricant injectors Lubrication system

17.6.4 OPERATION PRINCIPLE OF LUBRICANT INJECTORS

Fig. 17-13 Operation principle of lubricant injectors

17 - 28 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Lubricant injectors

Legend for Fig. 17-13:

(A) Normal position (rest position) pressure-free

(B) Inlet pressure increasing and lubricant application

(C) Maximum inlet pressure application completed

(D) Inlet pressure relieved and internally reloading

(1) Set screw (7) Service port

(2) Indicator stem (8) Discharge chamber

(3) Lock nut (9) Passage

(4) Injector piston (10) Lubricant supply inlet

(5) Spring (11) Lubricant outlet

(6) Slide valve (12) Measuring chamber

17.6.4.1 FUNCTION DESCRIPTION

Stage A Inlet pressure 0 bar

Outlet pressure 0 bar

The injector piston is in its normal, or rest position, visible by the extracted indicator stem (Fig. 17-13, Pos. 2)
which is blocked in final position by the set screw (Fig. 17-13, Pos. 1).
The discharge chamber (Fig. 17-13, Pos. 8) is filled with lubricant from the previous cycle.

Stage B Inlet pressure increasing from 0 to 180 bar

Outlet: lubricant injection 0 to 180 bar
Output volume: adjusted amount of lubricant

Under the pressure of incoming lubricant via port (Fig. 17-13, Pos. 10), slide valve (Fig. 17-13, Pos. 6) is about
to open the passage (Fig. 17-13, Pos. 9) leading to the piston (Fig. 17-13, Pos. 4). When the slide valve
(Fig. 17-13, Pos. 6) uncovers the passage (Fig. 17-13, Pos. 9), lubricant is admitted to the measuring chamber
(Fig. 17-13, Pos. 12) at the top of the piston (Fig. 17-13, Pos. 4), forcing the piston down. The piston
(Fig. 17-13, Pos. 4) forces lubricant from the discharge chamber (Fig. 17-13, Pos. 8) through the outlet port
(Fig. 17-13, Pos. 11) to the bearing. The indicator stem (Fig. 17-13, Pos. 2) retracts.

Stage C Inlet pressure at maximum 180 bar

Output injection is finished

As the piston (Fig. 17-13, Pos. 4) completes its stroke, it pushes the slide valve (Fig. 17-13, Pos. 6) past the
passage (Fig. 17-13, Pos. 9), cutting off further admission of lubricant to the passage (Fig. 17-13, Pos. 9). Pis-
ton (Fig. 17-13, Pos. 4) and slide valve (Fig. 17-13, Pos. 6) remain in this position until lubricant pressure in the
supply line (Fig. 17-13, Pos. 10) is vented (relieved) at the pump station. The indicator stem (Fig. 17-13, Pos. 2)
is fully retracted and the adjusted amount of lubricant is injected to the bearing.

Stage D Inlet pressure relieved

After lubricant supply pressure (Fig. 17-13, Pos. 10) is relieved, the compressed spring (Fig. 17-13, Pos. 5)
moves the slide valve (Fig. 17-13, Pos. 6) to the closed position. This opens the port from the measuring cham-
ber (Fig. 17-13, Pos. 12) and permits the lubricant to be transferred from the top of the piston to the discharge
chamber (Fig. 17-13, Pos. 8). The indicator stem (Fig. 17-13, Pos. 2) extract to its initial final stop of the adjust-
ment screw (Fig. 17-13, Pos. 1). Now the injector is prepared for the next lubricant application.

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 29

Lubricant injectors Lubrication system

17.6.5 CONNECTION OF ONE OR MORE INJECTORS

Fig. 17-14 Connection of lubricant injectors

17 - 30 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Lubricant injectors

Description

To increase the lubricant output volume, the injectors (Fig. 17-14, Pos. 1) are designed to be combined (2 or more
injectors).

A connector pipe (Fig. 17-14, Pos. 2) is used to connect two injectors (Fig. 17-14, Pos. 1). Lubricant from the first
injector, outlet (Fig. 17-14, Pos. b), is directed through the connector pipe to the inlet (Fig. 17-14, Pos. c) of the
second injector. Both injectors are now connected, in order to lubricate one lubricating point via pipe (Fig. 17-14,
Pos. 3).

This connection is possible for both injector types (SL-1 and SL-11).

NOTICE
RISK OF DAMAGE ON GREASE INJECTORS
When installing a fitting to an injector, always observe the maximum tightening torque of
• 14 Nm for SL-1
• 17...20 Nm for SL-11
Otherwise the fitting will be screwed too far into the injector and the injector piston movement will be
blocked. As a result the grease supply will fail.

For the tightening procedure also refer to the PARTS & SERVICE NEWS AH10532 (latest edition).

REMARKS: In case of leakage use thread tape (Teflon®) or Loctite® when installing a fitting to any injector.

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 31

Vent valve and grease outlet filter Lubrication system

17.7 VENT VALVE AND GREASE OUTLET FILTER

Fig. 17-15 Vent valve and grease outlet filter location

17 - 32 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Vent valve and grease outlet filter

Legend for Fig. 17-15:

(1) Plug screw

(2) O-ring

(3) Grease outlet filter (wire mesh type) - filtration grade 140 µm
Replacement interval: every 6000 operation hours or earlier if necessary

(4) Control & filter block

(5) Vent valve

(6) Pressure relief valve

(7) Grease return pipe - from vent valve into grease barrel

(8) Lubrication pump

(9) Pressure gauge

(10) Grease outlet port

(11) Mounting cover

(12) Lubricant level sensor "full"

(13) Lubricant level sensor "refill"

(14) Lubricant level sensor "empty"

(15) Dip stick

(16) Lubricant pump intake

17.7.1 VENT VALVE DESCRIPTION

Task

By the function of the vent valve the pressure in the lubricant supply line is relieved, after a lubrication cycle
is finished. The injector pistons move back into their initial positions. The vent valve is open if the solenoid
is de-energized.

Function

The solenoid is energized when a lubrication cycle starts and a pressure build-up in the grease supply line
is possible.

The solenoid gets de-energized, as soon as a lubrication cycle is finished. The supply line to the lubricant barrel
then gets open.

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 33

End-line switch Lubrication system

17.8 END-LINE SWITCH

Fig. 17-16 End-line switch

(1) Piston (5) Pressure switch

(2) Disk (6) Adjustment sleeve

(3) Switch contact (7) Connection to pressure circuit

(4) Spring (8) Electrical connection

17 - 34 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system End-line switch

17.8.1 DESCRIPTION
Task

The end-line switch is the main part to monitor and to control the lubrication system. It stops the lubrication pump
when the lubricant pressure reaches the max. adjusted pressure.

Function

One pressure control unit is installed in each lubrication system (CLS & SLS).

The grease pressure, produced by the hydraulic barrel pump, acts also at the piston (Fig. 17-16, Pos. 1).
If the force of the grease pressure exceeds the spring force (Fig. 17-16, Pos. 4), the piston is forced against the
disk (Fig. 17-16, Pos. 2). Thus the switch contacts (Fig. 17-16, Pos. 5) are operated and a signal is send to the
pump controller CR710 to indicate that the pressure in the lubrication system has reached 180 bar.
Also the lubrication interval time relay is reset.

Any adjustment has to be done with the sleeve (Fig. 17-16, Pos. 6):
Turning it clockwise → higher switch point
Turning it counterclockwise → lower switch point.

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 35

End-line switch Lubrication system

17.8.2 CLS & SLS END-LINE SWITCH ADJUSTMENT

Fig. 17-17 End-line switch adjustment (CLS & SLS)

17 - 36 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system End-line switch

Legend for Fig. 17-17:

[60B043] End-line switch CLS

[62B046] End-line switch SLS

(1) Pressure gauge

(2) Grease container

(3) Cable connector

(4) End-line switch

(5) Bolt

(6) Cover

(7) Allen key

(8) Allen screw

Procedure

For adjustment use the pressure gauge (Fig. 17-17, Pos. 1) mounted on top of the relevant grease container
(Fig. 17-17, Pos. 2).

REMARKS: For the following adjustment procedure two service technicians are required.

1. Run the engine at high idle.

2. Start a manual CLS or SLS lube cycle using dashboard switch 20S124 (CLS) or switch 20S126 (SLS).

3. Watch the pressure gauge (Fig. 17-17, Pos. 1).

At a pressure of 180±5 bar, the end-line switch of CLS or SLS must open and the lubrication pump must
be stopped.

REMARKS: 180±5 bar is the standard setting. Under particular circumstances it may be necessary to increase
the pressure slightly.

If re-setting is required

4. Screw out the bolts (Fig. 17-17, Pos. 5) and remove the cover (Fig. 17-17, Pos. 6).

5. Using an allen key (Fig. 17-17, Pos. 7) turn the allen screw (Fig. 17-17, Pos. 8) and alter the spring tension
until the switch operates at 180±5 bar.

6. After adjustment is finished, install the cover (Fig. 17-17, Pos. 6) and tighten the 4 bolts (Fig. 17-17, Pos. 5).

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 37

Lubricant level sensors Lubrication system

17.9 LUBRICANT LEVEL SENSORS

Fig. 17-18 Binary type lubricant level sensors

17 - 38 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Lubricant level sensors

17.9.1 DESCRIPTION
Task

The lubricant level sensor (Fig. 17-19) is a binary sensor type

consisting of three single sensors for full, pre-warning, and empty
level.

Lubricant maximum filling level monitoring is necessary to prevent

an overfilling of the grease barrel via the refilling arm.

The minimum grease level monitoring allows timely refilling of

grease and it prevents the grease pump from running dry.

Fig. 17-19

System Sensor Sensor Sensor

full pre-warning empty

SLS [62B109a] [62B109b] [62B109c]

CLS [62B108a] [62B108b] [62B108c]

Table 17-9

Function

When covered with grease (the grease level reaches the maximum) the full sensors [62B109a / 109a] activate the
"full" LEDs [55P076] or [55P078]. This indication LEDs are mounted at the refilling arm.
Additionally an acoustic signal via relay [11K056] is activated.

The pre-warning sensors [62B109b / 109b] are directly connected to the pump controller CR710.
If a grease level of 5% is reached, the KOMTRAX Plus generates the message G00012 Central lubrication system
grease level too low or G00013 Slew ring lubrication system grease level too low.
This allows grease charging in time, which prevents an unexpected breakdown.

The empty sensors [62B10ca / 109c] are connected to the KOMTRAX Plus controller via the relays [11K136] &
[11K138].
If the lubricant level reaches 0%, the KOMTRAX Plus generates the message G00184 Central lubrication system
empty or G00187 Slew ring lubrication system empty.
After approx. 4.2 h without refilling the bucket cut-off function is automatically activated. KOMTRAX Plus gener-
ates the message G00185 Trouble central lubrication system or G00188 Trouble slew ring lubrication system.

17.9.1.1 CHECKS
Check the lubricant levels of the CLS/SLS systems with the dip stick daily.

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 39

Commissioning Lubrication system

17.10 COMMISSIONING

17.10.1 COMMISSIONING OF THE CLS LUBRICATION SYSTEM

Commissioning procedures for the automatic Central Lubrication System CLS.
These procedures must be performed after the first assembly of the excavator, or after repair and exchange of
components.

WARNING
RISK OF INJURY
Some checks and adjustments can only be done with the engine running. For such jobs two persons
are necessary.
Thereby, the controls must not be left unattended while the other man carries out checks and
adjustments.
The service technician on the operator’s seat must be skilled in the operation of the excavator.
He must keep constant visual contact with the other service technician and both must agree on suitable
communication signals before they start their work.

1. Visually check of all hose and pipe connections from the lubrication pump station to the lubricating points
via the injectors.

2. Check the correct mounting of the lubrication system.

3. Check the correct connection of the hydraulic oil supply line and the tank line.

4. Check the correct electrical connection.

5. Check the correct kind and quality of the respective grease according to the OPERATION AND MAINTE-
NANCE MANUAL. In addition refer to the relevant PARTS & SERVICE NEWS.

6. Check the injector adjustment of each injector. Factory setting is approx. 75%.
Readjust if necessary, refer to section 17.6.3 on page 17-26.

7. Check if the grease supply line (from the pump station to the injectors) is pre-charged with grease.
If not, open (unplug) the supply line close to the end-line switch. Run the engine at high idle and activate the
lubrication station manually (switch 20S124) so long/often until grease comes out of the open end of the sup-
ply line. Stop the engine and close the open supply line.

8. Manually pre-lubricate all bearings with a grease gun of the lube track. To do this, unscrew the dust cap at the
second port of each injector and connect the grease gun to the grease nipple. Apply sufficient grease into the
bearing until a small amount of fresh grease appears at the bearing seals or open bearings.

9. Adjust the end-line switch if necessary, refer to section 17.8 on page 17-34.

10. Check the lubrication pump speed. If required adjust it, refer to section 17.5.1 on page 17-22.

11. Check the time settings of the pause time . Adjust the suggested settings given in the PM CLINIC forms, refer
to section 17.4.4 on page 17-16.
This is the basic setting and also a guaranty for sufficient lubrication.

REMARKS: A fine adjustment is possible to adapt the lubricant apply to the working and environmental
conditions by minimized lubricant consumption.

12. Run the engine at high idle and activate several cycles of the CLS lubrication manually.

13. Set the lubrication cycle counter to zero and note the actual working hours from the hour meter.

The excavator is now ready for operation.

17 - 40 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Commissioning

14. After ~20 working hours check the lubrication system. Check the lubricating points for sufficient grease.
Check the slew ring lubricating, a small amount of grease must appear at the inner slew ring seal.
Watch the cycle counter and compare it with the respective working hours.

Example:
Pause time setting = 30 minutes
Working hours since the last check = 10 hours
10 h / 0.5 h = 20 cycles
Compare with the indication of the cycle counter. There should be 20-1 cycles, provided no manual cycle
was activated.

– Check the lubrication system every day.

Compare all lubricating points. There should be a well balanced small amount of fresh grease at each
bearing seal or open bearing.
– Check the lubricant level of CLS with the dip stick.

17.10.2 FINE ADJUSTMENT

General

Under normal circumstances the lubrication system - with the basic adjustment - applies more lubricant as
required.

1. Find out the lubricating point with the lowest quantity of fresh grease. This point is the indicator for the
following Pause Time fine adjustment.

2. Reduce the applied quantity by extending the Pause Time as much until a small amount of wet grease
appears at the bearing seal or open bearing of the indicator point. Extend the Pause Time only in small steps
(~2-5 min). Between each step wait for 40 working hours or more and watch the lubricating points.

3. If there are one or more bearing points with too much grease, adjust the respective injector to a lower volume,
refer to section 17.6.3 on page 17-26. Change the setting only in small steps (max. 1-2 turns clockwise).
Between each step wait for 40 working hours or more and watch the lubricating points.
Be careful, don’t turn the set screw too much in, and block the injector against moving.

NOTE! Check the CLS every day (Daily Check)!

The lubricating points of a correct adjusted Central Lubrication System have a well balanced small
amount of wet grease.
Never let the excavator operate with a grease shortage. Find out the reason for this shortage and
eliminate this problem immediately.

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 41

Commissioning Lubrication system

17.10.3 COMMISSIONING OF THE SLS LUBRICATION SYSTEM

Commissioning procedures for the automatic Slew ring Lubricating System (SLS). These procedures must be
performed after the first assembly of the excavator, or after repair and exchange of components.

WARNING
RISK OF INJURY
Some checks and adjustments can only be done with the engine running. For such jobs two persons
are necessary.
Thereby, the controls must not be left unattended while the other man carries out checks and
adjustments.
The service technician on the operator’s seat must be skilled in the operation of the excavator.
He must keep constant visual contact with the other service technician and both must agree on suitable
communication signals before they start their work.

1. Visually check of all hose and pipe connections from the lubrication pump station to the dummy wheel via
the injectors.

2. Check the correct mounting of the lubrication system.

3. Check the correct connection of the hydraulic oil supply line and the tank line.

4. Check the correct electrical connection.

5. Check the correct kind and quality of the respective grease according to the OPERATION AND
MAINTENANCE MANUAL.

6. Check the injector adjustment of each injector. Factory setting is approx. 75%.
Readjust if necessary, refer to section 17.6.3 on page 17-26.

7. Check if the grease supply line (from the pump station to the injectors) is pre-charged with grease.
If not, open (unplug) the supply line close to the end-line switch. Run the engine at high idle and activate the
lubrication station so often until grease comes out of the open end of the supply line.
Stop the engine and close the open supply line.

8. Remove protection wax, dust ,or old grease with adequate solvent from the slew ring toothing.

NOTE! First apply open ring gear compound manually at the clean slew ring, before the assembly of
the slew ring protection. Use adhesive Voler® compound for the slew ring toothing.
It is delivered together with the new excavator. Otherwise refer to the Tools and Accessories
Catalogue (Part number 510 678 98 Adhesive Lubricant Voler Compound 2000 E).

9. Apply the slew parking brake. Run the engine at high idle and activate the SLS manually (switch 20S126) and
move the slew lever to one direction only for a short time. The SLS starts to work due to the slew movement.

10. Adjust the end-line switch if necessary, refer to section 17.8 on page 17-34.

11. Check the lubrication pump speed. If required adjust it, refer to section 17.5.1 on page 17-22.

12. Check the time settings of the pause time . Adjust the suggested settings given in the PM CLINIC forms, refer
to section 17.4.4 on page 17-16.
This is the basic setting and also a guaranty for sufficient lubrication.

13. Run the engine at high idle and activate two or three lubrication cycles manually.

14. Stop the engine and check the lubrication system. Check if a small amount of grease arrived at one or two
dummy wheel teeth.

17 - 42 PC3000-6 SHOP-10 06279-xD-GB-1

Lubrication system Commissioning

15. Set the lubrication cycle counter to zero and note the actual working hours from the hour meter.
The excavator is ready for digging.

16. After ~20 working hours check the SLS. Check the dummy wheel and the slew ring toothing. A small amount
of fresh grease must be at the slew ring toothing. Check the SLS lubricant cycle counter. Its indication must be
higher as the number of CLS cycles during the same time.

NOTE! Check the SLS every day (Daily Check)!

Never let the excavator work with a grease shortage. Check the lubricant level of the SLS with
the dip stick.
If the teeth get a clear metallic look it is immediately necessary to apply fresh open ring gear
lubricant. Find out the reason of this shortage and eliminate this problem immediately.
The slew ring toothing of a correct adjusted SLS have a thin layer of open ring gear lubricant.
There should be a small amount of fresh open ring gear lubricant around the tooth contact area.

SHOP-10 06279-xD-GB-1 PC3000-6 17 - 43

Commissioning Lubrication system

Please continue reading on the next page.

17 - 44 PC3000-6 SHOP-10 06279-xD-GB-1

Deep temperature equipment (option)

18 DEEP TEMPERATURE
EQUIPMENT (OPTION)

SHOP MANUAL General 18 - 1

General information Deep temperature equipment (option)

18.1 GENERAL INFORMATION

18.1.1 INTRODUCTION
For machine operation in arctic climates the excavators are equipped with adequate components.
These components are combined in the so called Deep Temperature Equipment.

This chapter overviews the Deep Temperature Equipment. It includes global information on Diesel machines and
electric machines as well, and it is not defined on any specific machine type.

Classification of temperature ranges

Temperature range down to -25°C down to -40°C down to -50°C

Classification Standard equipment TT equipment TTT equipment

Table 18-1

18.1.2 DEEP TEMPERATURE COMPONENTS OVERVIEW

In the following charts the additional or modified machine components for deep temperature operation are listed.

Mechanical Components X = Standard equipment (no modification)

Temperature down to
Component
-25°C -40°C -50°C

Manufacture's check, Manufacture's certificate,

High stress steel structure X ISO V-notch test 27 J ISO V-notch test 27 J
at -40°C at -50°C

Manufacture's check, Manufacture's certificate,

Castings and forgings X ISO V-notch test 27 J ISO V-notch test 27 J
at -40°C at -50°C

Screws and bolts X Modified material Modified material

Table 18-2

Batteries, Wiring, and Hoses X = Standard equipment (no modification)

Temperature down to
Component
-25°C -40°C -50°C

Batteries X Preheating Preheating

Wiring X X X

ICE-Champion flange
Hoses X X
sealings changed

Table 18-3

18 - 2 General SHOP MANUAL

Deep temperature equipment (option) General information

Diesel Engines X = Standard equipment (no modification)

Temperature down to
Component / Function
-25°C -40°C -50°C

Preheating + Ether start,

Engine start Ether start Preheating + Ether start Low idle adjusted to
1100 rpm

Engine coolant X Preheating Preheating

Engine oil X Preheating Preheating

Table 18-4

Cab, Cab base, and Machinery House X = Standard equipment (no modification)

Temperature down to
Component
-25°C -40°C -50°C

Cab X Preheating Preheating

Cab base (switch cabinet) X Preheating Preheating

Preheating.
Machinery house X X Below air inlet closed.
Air outlet reduced.

Table 18-5

Hydraulic System X = Standard equipment (no modification)

Temperature down to
Component
-25°C -40°C -50°C

Hydraulic oil X Preheating Preheating

PTO gear oil X Preheating Preheating

Modified material of
Cylinders X Modified material of bolts
sealings and scrapers

Sealings X Partly modified material Partly modified material

Preheating by
Travel motors X X
hydraulic circuit

18.1.3 POWER SUPPLY PRECONDITIONS FOR PREHEATING

Diesel machines: It is supposed that an external power supply or an external generator set is available.

Electric machines: It is supposed that the excavator power supply is ON.

SHOP MANUAL General 18 - 3

General information Deep temperature equipment (option)

18.1.4 POWER REQUIREMENTS FOR PREHEATING SYSTEMS

Power Number of heater elements per machine

Component Heater System
per unit PC3000-6 PC4000-6 PC5500-6 PC8000-6

Engine coolant Coolant heating system 1200 W 1 2

(KIM hot start) Coolant heating system 900 W 1 2

Oil heating system

Engine oil 500 W 1 1 2 2
ON: 15°C, OFF: 26°C

Centinel remote oil Oil heating system

500 W 1 1 2 2
tank ON: 15°C, OFF: 26°C

Oil heating system

Hydraulic oil tank 2000 W 5 6 6 7
ON: 5°C, OFF: 15°C

Hydraulic oil suction Oil heating system

500 W 2 2 3 3
tank ON: 15°C, OFF: 26°C

Oil heating system

PTO gear oil 300 W 2 2 4 4
ON: 15°C, OFF: 26°C

Cab base Fan heater 3000 W 1 1 1 1

Fan heater 3000 W 1 1 2 2

Machinery house Fan heater for engine
3000 W 1 — — —
drive belt

Modular battery pad

300 W 1 1 2 2
Batteries system

Battery charger 3680 W 1 1 1 1

Required electric power per machine type 34.6 kW 36.6 kW 48.0 kW 56.0 kW

Recommended power supply (80% efficiency) 44 kW 46 kW 60 kW 70 kW

Table 18-6 Overview of the power requirements

NOTE! The total power supply for the preheating systems may vary depending on the respective machine
equipment.

18 - 4 General SHOP MANUAL

Deep temperature equipment (option) Preheating procedure

18.2 PREHEATING PROCEDURE

18.2.1 GLOBAL FLOW CHART OF THE PREHEATING PROCEDURE

Fig. 18-1 Global flow chart of the preheating procedure

SHOP MANUAL General 18 - 5

Preheating procedure Deep temperature equipment (option)

18.2.2 STARTING THE PREHEATING PROCEDURE

Fig. 18-2 Defined parking position for preheating

[1] Defined parking position for machines with Front Shovel Attachment (FSA)

[2] Defined parking position for machines with Back Hoe Attachment (FSA)

Global steps for starting the preheating procedure

1. If the machine is to be stopped at temperatures below -25°C bring it in its defined parking position.
This is a precondition for an optimum preheating procedure.

2. Connect the external power supply for preheating.

3. Switch ON the preheating system.

NOTE! For detailed operation instructions of the preheating systems (Diesel-drive or E-drive) refer to
the OPERATION & MAINTENANCE MANUAL of your machine.

Information on the following functional illustrations for Diesel machines

The following functional illustrations of a preheating system for Diesel machines are exemplarily. Only the layout
for machines with 1 Diesel engine is shown here. If the machine is equipped with 2 Diesel engines, the preheating
system of engine #1 is comparable to the preheating system of engine #2.

18 - 6 General SHOP MANUAL

Deep temperature equipment (option) Preheating procedure

18.2.3 PREHEATING OF OPERATOR’S CAB AND DIESEL ENGINE

[COOLANT SYSTEM]

Fig. 18-3 Preheating of operator’s cab and Diesel engine (water system) - exemplary view

(1) Radiator in the cab (6) Leading to the cab

(2) Heater in the machinery house (7) Right side bank of Diesel engine
(below -40°C only)

(3) External generator set or external power (8) Left side bank of Diesel engine
supply

(4) Preheating of engine coolant and cab (9) Return from the cab

(5) Cab heater unit (fuel fired) [7.5 ~ 9 kW] (10) KIM Hot start unit (electric)

SHOP MANUAL General 18 - 7

Preheating procedure Deep temperature equipment (option)

18.2.4 PREHEATING OF LUBRICANTS AND SUPERSTRUCTURE

(DIESEL) [ELECTRIC SYSTEM]

Fig. 18-4 Preheating of lubricants and upper structure (electric system) - exemplary view

18 - 8 General SHOP MANUAL

Deep temperature equipment (option) Constant heating of travel motors (TTT equipment below-40°C only)

Legend for Fig. 18-4:

(1) Fan heater in the cab base (9) Diesel engine

(2) Fan heater in the machinery house* (10) Heater pad for battery

(3) Fan heater in the machinery house* (11) Battery charger

(4) External generator set or external power (12) Junction box for the preheating system
supply

(5) Hydraulic tank (13) Plug for external power supply or generator
set

(6) Suction manifold (14) Fan heater in the cab base

(7) PTO (15) Fan heater in the machinery house*

(8) Remote oil tank (16) Fan heater in the machinery house *

* TTT equipment below -40°C only

18.3 CONSTANT HEATING OF TRAVEL MOTORS

(TTT EQUIPMENT BELOW-40°C ONLY)

Fig. 18-5 Constant heating of travel motors (TTT equipment below -40°C only)

(1) Heating circuit

(2) Heated travel motor

SHOP MANUAL General 18 - 9

Component location Deep temperature equipment (option)

18.4 COMPONENT LOCATION

18.4.1 ELECTRIC HEATING ELEMENTS FOR HYDRAULIC & BATTERIES

[ELECTRIC MACHINE]

Fig. 18-6 Heating elements - hydraulic & batteries [Electric]

18 - 10 General SHOP MANUAL

Deep temperature equipment (option) Component location

Legend for Fig. 18-6:

(1) Hydraulic oil tank

(2) Switch box

(2a) Switch and control lights red & green

(3) Heating rods - for hydraulic oil tank

(4) Thermostat - for hydraulic oil tank

(5) Heating pads for batteries

(6) Heating rods - for PTOs

(7) Thermostats - for PTO and suction oil manifold

(8) Heating rods - for suction oil manifold

(9) Suction oil manifold

(10) PTO 1 & 2

Exemplary photograph of a heating rod for the hydraulic

oil tank.

Fig. 18-7 Heating rod - for hydraulic oil

tank

Exemplary view onto a switch box for the hydraulic heating

elements.

Fig. 18-8 Switch box for heating elements

SHOP MANUAL General 18 - 11

Component location Deep temperature equipment (option)

18.4.2 ELECTRIC HEATING ELEMENTS FOR HYDRAULICS

[DIESEL MACHINE]

Fig. 18-9 Electric heating elements for hydraulics [Diesel machine]

18 - 12 General SHOP MANUAL

Deep temperature equipment (option) Component location

Legend for Fig. 18-9:

(1) Hydraulic oil tank

(2) Switch box

(2a) Switch and control lights red & green

(3) Heating rods - for hydraulic oil tank

(4) Thermostat - for hydraulic oil tank

(5) Heating rods - for PTOs and suction oil manifold

(6) Thermostats - for PTO and suction oil manifold

(7) Suction oil manifold

(8) PTO 1 & 2

(9) KIM Hot start unit

SHOP MANUAL General 18 - 13

Component location Deep temperature equipment (option)

18.4.3 ELECTRIC HEATING ELEMENTS FOR ENGINES & BATTERIES

[DIESEL MACHINE]

Fig. 18-10 Electric heating elements for hydraulic & batteries [Diesel machine]

18 - 14 General SHOP MANUAL

Deep temperature equipment (option) Component location

Legend for Fig. 18-10:

(1) Platform (5) Engine coolant heater (engine 1)

(2) Thermostats - for engine remote oil tank (6) Heating pads for batteries

(3) Heating rods - for engine remote oil tank (7) Thermostats - for engines

(4) Engine coolant heater (engine 2) (8) Heating rods - for engines

Exemplary view onto an engine coolant heater unit.

Fig. 18-11 Engine coolant heater unit

Exemplary view onto the electric parts of the deep temperature

equipment in the cab base.

1 Space heater

2 Battery charger & temperature sensor

3 Location of the switch box for deep temperature control

Fig. 18-12 Electric parts in the cab base

SHOP MANUAL General 18 - 15

Components of TT equipment Deep temperature equipment (option)

18.5 COMPONENTS OF TT EQUIPMENT

18.5.1 PREHEATING COMPONENTS ON A DIESEL MACHINE

Exemplary components from PC8000-6

Heating elements

Component Equipment
Description Electric power
code range

40E260
40E261
40E262
40E263 Heating rods in the hydraulic oil tank 2 kW each TT
40E264
40E265
40E266

51E219-1 Engine 1 coolant heater

12 kW each TT
51E219-2 Engine 2 coolant heater

52E201-1 Engine 1 oil heater

500 W each TT
52E201-2 Engine 2 oil heater

63E213-1 Heating rod for engine 1 remote oil tank

500 W each TT
63E213-2 Heating rod for engine 1 remote oil tank

10T055 Battery charger 75 W each TT

10E231 Heater in the cab support 3 kW TT

Table 18-7

18 - 16 General SHOP MANUAL

Deep temperature equipment (option) Components of TT equipment

Switching elements

Component Equipment
Description Switch points
code range

ON = 15°C
40B267 Temperature switch for hydraulic oil tank TT
OFF = 26°C

40B260
40B261
40B262
Temperature switches for heating rods in the ON = 5°C
40B263 TT
hydraulic oil tank OFF = 15°C
40B264
40B265
40B266

65B210-1 Temperature switch for engine 1 coolant

— TT
65B210-2 Temperature switch for engine 2 coolant

52B201-1 Temperature switch for engine 1 oil ON = 15°C

TT
52B201-2 Temperature switch for engine 2 oil OFF = 26°C

63B204-1 Temperature switch for engine 1 remote oil tank ON = 15°C

TT
63B204-2 Temperature switch for engine 2 remote oil tank OFF = 26°C

16K201 KIM Hot Start switch box — TT

Table 18-8

SHOP MANUAL General 18 - 17

Components of TT equipment Deep temperature equipment (option)

18.5.2 PREHEATING COMPONENTS ON AN ELECTRIC MACHINE

Exemplary components from PC5500E-6, S/N 15092

Heating elements

Component Equipment
Description Electric power
code range

40E260
40E261
40E262
Heating rods in the hydraulic oil tank 2 kW each TT
40E263
40E264
40E265

59R012-1
59R012-2 Heating rods in the suction oil manifold 500 W each TT
59R012-3

56R023-1
56R023-2
Heating rods in the pump distributor gear 300 W each TT
56R024-1
56R024-1

71R004
71R005
Heating pads for batteries 75 W each TT
71R006
71R007

Table 18-9

Switching elements

Component Equipment
Description Switch points
code range

ON = 15°C
40B267 Temperature switch for hydraulic oil tank TT
OFF = 26°C

40B260
40B261
40B262 Temperature switches for heating rods in the ON = 5°C
TT
40B263 hydraulic oil tank OFF = 15°C
40B264
40B265

Temperature switch for heating rods in the suction oil ON = 15°C

59B014 TT
manifold OFF = 26°C

56B023-1 ON = 15°C
Temperature switches for heating rods in the PTOs TT
56B023-2 OFF = 26°C

Table 18-10

18 - 18 General SHOP MANUAL

Deep temperature equipment (option) Components of TT equipment

18.5.3 EXEMPLARY WIRING DIAGRAMS FOR PREHEATING SYSTEMS

Wiring diagrams from PC5500E-6, S/N 15092

18.5.3.1 WIRING DIAGRAM "HYDRAULIC OIL TANK PREHEATING" PART 1 OF 3

Fig. 18-13 Hydraulic oil tank preheating part 1 of 3

SHOP MANUAL General 18 - 19

Components of TT equipment Deep temperature equipment (option)

18.5.3.2 WIRING DIAGRAM "HYDRAULIC OIL TANK PREHEATING" PART 2 OF 3

Fig. 18-14 Hydraulic oil tank preheating part 2 of 3

18 - 20 General SHOP MANUAL

Deep temperature equipment (option) Components of TT equipment

18.5.3.3 WIRING DIAGRAM "HYDRAULIC OIL TANK PREHEATING" PART 3 OF 3

Fig. 18-15 Hydraulic oil tank preheating part 3 of 3

SHOP MANUAL General 18 - 21

Components of TT equipment Deep temperature equipment (option)

18.5.3.4 WIRING DIAGRAM "SUCTION OIL MANIFOLD PREHEATING"

Fig. 18-16 Suction oil manifold preheating

18 - 22 General SHOP MANUAL

Deep temperature equipment (option) Components of TT equipment

18.5.3.5 WIRING DIAGRAM "PTO PREHEATING"

Fig. 18-17 PTO preheating

SHOP MANUAL General 18 - 23

Components of TT equipment Deep temperature equipment (option)

18.5.3.6 WIRING DIAGRAM "BATTERY HEATER PADS"

Fig. 18-18 Battery preheating (example for E-machine)

18 - 24 General SHOP MANUAL

HYDRAULIC MINING EXCAVATOR

PC3000-6

Machine model Serial numbers

PC3000-6 06279, 06308, 06309, 06310, 06314 and up
with TIER2 & KOMTRAX Plus

40 Troubleshooting

Release 1 04/2017

® Copyright 2017 KOMATSU GERMANY GmbH

PC3000-6 1
2 PC3000-6
TABLE OF CONTENTS

1 INTRODUCTION........................................................................................ 1-1
1.1 OVERVIEW ........................................................................................................................................ 1-2
1.1.1 GENERAL ADVICE WHEN USING TROUBLESHOOTING CHARTS .................................. 1-2
1.2 GENERAL PRECAUTIONS ............................................................................................................... 1-3

2 GENERAL INFORMATION FOR TROUBLESHOOTING .......................... 2-1

2.1 PREPARATIONS FOR WORK .......................................................................................................... 2-2
2.2 PRECAUTIONS DURING WORK ...................................................................................................... 2-2
2.3 PRECAUTIONS WHEN CARRYING OUT ANY OPERATION .......................................................... 2-3
2.3.1 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK.............................................. 2-3
2.3.2 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK...................................... 2-3
2.3.3 PRECAUTIONS WHEN COMPLETING THE OPERATION .................................................. 2-4
2.4 FUNDAMENTAL REQUIREMENTS FOR TROUBLESHOOTING .................................................... 2-5
2.4.1 TECHNICAL DOCUMENTATION .......................................................................................... 2-5
2.4.2 TOOLS................................................................................................................................... 2-5
2.4.2.1 REFERENCE GUIDE FOR DEUTSCH REMOVAL TOOLS .................................. 2-8
2.4.3 PERSONNEL ......................................................................................................................... 2-9
2.5 POINTS TO REMEMBER WHEN TROUBLESHOOTING ................................................................. 2-9
2.6 SEQUENCE OF EVENTS IN TROUBLESHOOTING ...................................................................... 2-11
2.7 CHECKS BEFORE TROUBLESHOOTING ..................................................................................... 2-12
2.8 HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS.............................. 2-13
2.8.1 POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT ........................... 2-13
2.8.2 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT ........................ 2-15
2.9 GENERAL WORKING PROCEDURES ........................................................................................... 2-18
2.9.1 AIR BLEEDING OF VARIOUS HYDRAULIC PARTS .......................................................... 2-18
2.9.2 AIR BLEEDING FROM THE HYDRAULIC PUMPS ............................................................ 2-18
2.9.3 AIR BLEEDING FROM HYDRAULIC CYLINDERS ............................................................. 2-18
2.10 CYLINDER BYPASS TEST ............................................................................................................. 2-19
2.11 BASICS ABOUT "HOW TO CRIMP" (WITH STRAIN RELIEF)...................................................... 2-20
2.11.1 CRIMP TOOL & REPAIR KIT .............................................................................................. 2-20
2.11.2 GENERAL ............................................................................................................................ 2-21
2.11.3 SELECT THE REQUIRED CONNECTOR COMPONENTS ................................................ 2-21
2.11.4 STRIPPING A WIRE ............................................................................................................ 2-22
2.11.5 CRIMPING ........................................................................................................................... 2-23
2.11.6 CONNECTOR ASSEMBLY AFTER CRIMPING.................................................................. 2-24
2.12 CABLE SHIELDING......................................................................................................................... 2-25

3 MOUNTING LOCATIONS AND CONNECTOR TYPES ............................ 3-1

3.1 COMPONENT LOCATION................................................................................................................. 3-2
3.1.1 VIEW AT THE SUPERSTRUCTURE .................................................................................... 3-2
3.1.2 ENGINE - LOCATION OF ELECTRICAL COMPONENTS (1) .............................................. 3-4
3.1.3 ENGINE - LOCATION OF ELECTRICAL COMPONENTS (2) .............................................. 3-6
3.1.4 CONTROL AND FILTER PLATE - LOCATION OF COMPONENTS..................................... 3-8
3.1.5 PTO AND SUCTION OIL TANK - LOCATION OF ELECTRICAL COMPONENTS ............. 3-10

SHOP-40 06279-xD-GB-1 PC3000-6 TOC - 1

 3.1.6 PILOT CONTROL FRAME - LOCATION OF ELECTRICAL COMPONENTS ..................... 3-12
3.1.7 MAIN CONTROL BLOCKS - LOCATION OF COMPONENTS............................................ 3-14
3.1.8 LUBRICATION SYSTEM - LOCATION OF ELECTRICAL COMPONENTS........................ 3-16
3.1.9 CAB BASE - LOCATION OF ELECTRICAL COMPONENTS.............................................. 3-18
3.1.10 HYDRAULIC OIL TANK - LOCATION OF ELECTRICAL COMPONENTS ......................... 3-20
3.1.11 HYDRAULICALLY OPERATED ACCESS LADDER - LOCATION OF
ELECTRICAL COMPONENTS ............................................................................................ 3-22
3.1.12 REFILLING ARM - LOCATION OF ELECTRICAL COMPONENTS .................................... 3-23
3.1.13 AIR FILTER AND FUEL TANK - LOCATION OF ELECTRICAL COMPONENTS............... 3-24
3.2 CONNECTOR TYPES OVERVIEW.................................................................................................. 3-26

4 STANDARD VALUE TABLE FOR ELECTRICAL COMPONENTS............ 4-1

5 REFERENCES FOR TROUBLESHOOTING ............................................. 5-1
5.1 7-SEGMENT ERROR CODE INDICATION........................................................................................ 5-2
5.2 RELAY CHECKS................................................................................................................................ 5-4
5.2.1 SWITCH CONTACT TESTING USING THE TEST BUTTON ............................................... 5-4
5.2.2 MEASURING OF THE COIL RESISTANCE.......................................................................... 5-6

6 TABLES FOR TESTING AND TROUBLESHOOTING............................... 6-1

6.1 PT100 TEMPERATURE CHARTS (PT100)  CENTIGRADE - OHM .............................................. 6-2
6.2 TEST VALUE TABLE FOR PRESSURE SENSORS......................................................................... 6-3
6.2.1 TRANSDUCERS WITH OUTPUT VOLTAGE RANGE: 0.5....4.5 VOLT................................ 6-3
6.2.2 TRANSDUCERS WITH OUTPUT VOLTAGE RANGE: 0.5....9.5 VOLT................................ 6-3
6.3 TROUBLE CODE TABLES................................................................................................................ 6-4
6.3.1 TABLE OF CUMMINS TROUBLE CODES (TIER 2) ............................................................. 6-4
6.3.2 TABLE OF KOMTRAX PLUS TROUBLE CODES................................................................. 6-9
6.3.3 TABLE OF PUMP-CONTROLLER-CODES (MULTI MONITOR) ........................................ 6-13
6.4 TABLE OF INSTRUCTION MESSAGES ......................................................................................... 6-15
6.5 TABLES OF SYMPTOM CODES..................................................................................................... 6-18
6.5.1 SYMPTOMS OF THE ENGINES AND RELATED ELECTRICAL SYSTEMS...................... 6-18
6.5.2 SYMPTOMS OF THE HYDRAULIC SYSTEM..................................................................... 6-18
6.5.3 SYMPTOMS OF THE MECHANICAL SYSTEM .................................................................. 6-19
6.5.4 SYMPTOMS OF ADDITIONAL SYSTEMS.......................................................................... 6-19
6.6 CABLE COLOUR IDENTIFICATION ............................................................................................... 6-20

7 TROUBLESHOOTING BY KOMTRAX PLUS TROUBLE CODE............... 7-1

G00001 - Trouble Shut-Off (gate) valve................................................................................................ 7-2
View onto the gap of proximity switch 40B031 .............................................................................. 7-4
Input signal of the proximity switch 40B031 on the REAL TIME MONITOR.................................. 7-4
Wiring Diagram (40B031) for trouble code G00001 (Main gate valve open) ................................. 7-5

G00002 - Test speed 1800 1/min engine 1 ........................................................................................... 7-6

Input signal of the switch 11S041-1 on the REAL TIME MONITOR .............................................. 7-6
Wiring Diagram (11S041-1) for trouble code G00002 ................................................................... 7-7

G00007 - Trouble hydraulic oil level..................................................................................................... 7-8

Wiring Diagram (40B004) and the defined position of the attachment (G00007) ........................ 7-11

TOC - 2 PC3000-6 SHOP-40 06279-xD-GB-1

 G00012 - Central lubrication system grease level too low............................................................... 7-12

G00013 - Slew ring gear lubr. system grease level too low ............................................................. 7-12
Input signals of grease level sensors 62B108b & 62B109b on the REAL TIME MONITOR ....... 7-15
Wiring Diagram for trouble codes G00012 & G00013 ................................................................. 7-16
Wiring Diagram (junction box) for trouble codes G00012 & G00013........................................... 7-17

G00031 - Set engine to low idle .......................................................................................................... 7-18

Wiring Diagram (20S030) for trouble code G00031 .................................................................... 7-19
Input signal of the resistor 11T080 on the REAL TIME MONITOR ............................................. 7-19

G00060 - Fire in the power house....................................................................................................... 7-20

Wiring Diagram (fire alarm & safety circuit) for trouble code G00060 ......................................... 7-22

G00065 - Very low hydraulic oil level ................................................................................................. 7-23

View onto the hydraulic oil level label .......................................................................................... 7-23

G00066 - Trouble hydraulic oil temperature...................................................................................... 7-24

Hydraulic oil temperature table - 11K039 adjustment (T4 switch point) ...................................... 7-26
Wiring Diagram (59B015 and 11K039) for G00066..................................................................... 7-27

G00067 - Trouble battery voltage too high ........................................................................................ 7-28

Input signal of the resistor 11T080 on the REAL TIME MONITOR ............................................. 7-29
Wiring Diagram (11T080) for G00067 ......................................................................................... 7-29

G00070 - Trouble oil temperature gear (PTO 1) ................................................................................ 7-30

PTO gear oil temperature table - 11K143 adjustment ................................................................. 7-32
Input signal of 57B079 on the REAL TIME MONITOR ................................................................ 7-32
Wiring Diagram (59B049 / 11K143) for G00070.......................................................................... 7-33

G00071 - Trouble gear lubrication (PTO 1) ........................................................................................ 7-34

PTO gear oil temperature table - 11K182 adjustment ................................................................. 7-36
Wiring Diagram (57B017) for trouble code G00071 .................................................................... 7-36
Wiring Diagram (57B182 & 11K182) for G00071 ........................................................................ 7-37
Input signal of 57B017 on the REAL TIME MONITOR ................................................................ 7-37

G00091 - Pilot control cut out ............................................................................................................. 7-38

View onto the lock lever and the cover of 20S105 (G00091) ...................................................... 7-39
Wiring Diagram (20S105 and wiring) for G00091........................................................................ 7-39

G00092 - Emergency shut-down at access ladder ........................................................................... 7-40

G00093 - Emergency shut-down at valve block................................................................................ 7-40

G00095 - Emergency shut-down in cabin.......................................................................................... 7-40

Wiring Diagram 1 (emergency switches) for G00092~G00095 ................................................... 7-41
Wiring Diagram 2 (emergency switches signal lines) for G00092~G00095 ................................ 7-42

G00100 - Maintenance Safety Switch................................................................................................. 7-43

Wiring Diagram (50S058) for trouble code G00100 .................................................................... 7-44

SHOP-40 06279-xD-GB-1 PC3000-6 TOC - 3

 G00104 - Trouble battery current ....................................................................................................... 7-45
Input signal of the converter 11T117 on the REAL TIME MONITOR .......................................... 7-46
Wiring Diagram 1 (71T003 & 52G005) for trouble code G00104 ................................................ 7-47
Wiring Diagram 2 (52G005, 52M001-1 & 52M002-1) for trouble code G00104 .......................... 7-48

G00105 - Trouble battery charging current too low.......................................................................... 7-49

Input signals of 11T080 & 11T117on the REAL TIME MONITOR ............................................... 7-50
Wiring Diagram 1 (71T003 & 11T117) for trouble code G00105 ................................................. 7-51
Wiring Diagram 2 (11T080) for trouble code G00105.................................................................. 7-52

G00164 - Trouble air cleaner 1............................................................................................................ 7-53

View onto the engine air cleaner (G00164) ................................................................................. 7-54

G00165 - Trouble breather filter hydraulic oil tank ........................................................................... 7-55

View onto the pressure sensor 40B024 (G00165)....................................................................... 7-56
Input signal of 40B024 (filter clogged) on the REAL TIME MONITOR ........................................ 7-56

G00166 - Trouble oil filter gear (PTO 1) ............................................................................................. 7-57

Hydraulic oil temperature table - 11K026 adjustment (T3 switch point) ...................................... 7-57
View onto the PTO 1 gear oil filter with pressure sensor 57B027 (G00166) ............................... 7-58
Input signal of 57B027 (filter clogged) on the REAL TIME MONITOR ........................................ 7-58

G00169 - Trouble return oil filter hydraulic oil tank .......................................................................... 7-59
Hydraulic oil temperature table - 11K026 adjustment (T3 switch point) ...................................... 7-59
View onto the pressure sensor 40B026 (G00169)....................................................................... 7-60
Input signal of 40B026 (filter clogged) on the REAL TIME MONITOR ........................................ 7-60

G00170 - Trouble leak oil filter hydraulic oil tank ............................................................................. 7-61
Hydraulic oil temperature table - 11K026 adjustment (T3 switch point) ...................................... 7-61
View onto the pressure sensor 40B025 (G00170)....................................................................... 7-62
Input signal of 40B025 (filter clogged) on the REAL TIME MONITOR ........................................ 7-62

G00176 - Trouble battery voltage too low.......................................................................................... 7-63

Wiring Diagram (71T003) for trouble code G00176..................................................................... 7-65

G00177 - Trouble battery charging circuit ......................................................................................... 7-66

Wiring Diagram (measuring points 1-3) for trouble code G00177 ............................................... 7-67

G00178 - Trouble battery charging current too high ........................................................................ 7-68

Wiring Diagram (71T003 & 11T117) for trouble code G00178 .................................................... 7-69

G00184 - Central lubrication system empty ...................................................................................... 7-70

Wiring Diagram 1 (62B108c & 62B109c) for trouble codes G00184 & G00187 .......................... 7-73
Wiring Diagram 2 (wiring to 14K300) for trouble codes G00184 & G00187 ................................ 7-74
Wiring Diagram 3 (junction box) for trouble codes G00184 & G00187........................................ 7-75
Input signals of grease level sensors 62B108c & 62B109c on the REAL TIME MONITOR ........ 7-76

TOC - 4 PC3000-6 SHOP-40 06279-xD-GB-1

 G00185 - Trouble central lubrication system .................................................................................... 7-77
Wiring Diagram 1 (relays) for trouble code G00185 .................................................................... 7-82
Wiring Diagram 2 (11K50 & trouble signal circuit CLS/SLS) for trouble code G00185 ............... 7-83
Wiring Diagram 3 (10K511a) for trouble code G00185 ............................................................... 7-84
View onto the vent valve 62Q507a .............................................................................................. 7-85
Action chart for lube cycles.......................................................................................................... 7-86

G00187 - Slew ring gear lubrication system empty .......................................................................... 7-87

G00188 - Trouble slew ring gear lubrication system........................................................................ 7-87

Wiring Diagram 1 (relays) for trouble code G00188 .................................................................... 7-93
Wiring Diagram 2 (11K50 & trouble signal circuit CLS/SLS) for trouble code G00188 ............... 7-94
Wiring Diagram 3 (10K511a) for trouble code G00188 ............................................................... 7-95
View onto the pressure switch 10B047 and wiring Diagram 3 for trouble code G00188............. 7-96
View onto the vent valve 62Q509a .............................................................................................. 7-97
Action chart for lube cycles.......................................................................................................... 7-98

G00207 - Engine remote oil tank 1 empty.......................................................................................... 7-99

G00222 - Load limiting clam defective............................................................................................. 7-100

Wiring Diagram (10B155 & 10B156) for trouble code G00222.................................................. 7-102

G00243 - Fill up fuel tank................................................................................................................... 7-103

G00245 - Engine shutdown from ground......................................................................................... 7-104

G00256 - Operator warning system.................................................................................................. 7-105

G00262 - Trouble screen at hydr. cooler entry clogged................................................................. 7-106

Location of 40B165 and the strainer at the intermediate pipe (G00262) ................................... 7-107

G00422 - Can-net sys (J1939) ........................................................................................................... 7-108

Wiring Diagram (CAN-BUS) for trouble code G00422............................................................... 7-109

G00491 - Communication failure MH800 <=> K+ Controller .......................................................... 7-110

Wiring Diagram (K+ monitor (MH801) → K+ controller) for trouble code G00491 .................... 7-111

DBBQKR - Communication failure CR710 <=> KOMTRAX Plus Controller ................................. 7-112
Wiring Diagram (CR710 <=> KOMTRAX Plus) for trouble code DBBQKR ............................... 7-113

DBB3KK - Abnormality in VBAT voltage (KOMTRAX Plus VBAT<10V)........................................ 7-114

DBB0KK - KOMTRAX Plus source voltage Error............................................................................ 7-115

Wiring Diagram - K+ controller 24V supply and GND connections ........................................... 7-116

DBB0KQ - KOMTRAX Plus Connector Mismatch ........................................................................... 7-117

DGH2KA - Hyd. Oil Temp. Sensor Failure ....................................................................................... 7-118

Wiring Diagram (59B032-1) for trouble code DGH2KA ............................................................. 7-119

DGH2KB - Hyd. Oil Temp. Sensor Failure ....................................................................................... 7-120

Wiring Diagram (59B032-1) for trouble code DGH2KB ............................................................. 7-121

SHOP-40 06279-xD-GB-1 PC3000-6 TOC - 5

 J100KA - Pilot Press. Sensor Failure ............................................................................................... 7-122
Wiring Diagram (57B086) for trouble code J100KA................................................................... 7-124

J100KB - Pilot Press. Sensor Failure ............................................................................................... 7-125

Wiring Diagram (57B086) for trouble code J100KB................................................................... 7-126

J100L6 - Abnomal Pilot Pump press................................................................................................ 7-127

Wiring Diagram (57B086) for trouble code J100L6 ................................................................... 7-128

DGE5KA - Ambient air temp Sensor Failure ................................................................................... 7-129

Wiring Diagram (13B090) for trouble code DGE5KA................................................................. 7-130

DGE5KB - Ambient air temp Sensor Failure ................................................................................... 7-131

Wiring Diagram (13B090) for trouble code DGE5KB................................................................. 7-132

F@DANS - Trouble High Exhaust Temperature Cylinder RB1 ...................................................... 7-133

F@DBNS - Trouble High Exhaust Temperature Cylinder RB2 ...................................................... 7-133

F@DCNS - Trouble High Exhaust Temperature Cylinder RB3 ...................................................... 7-133

F@DDNS - Trouble High Exhaust Temperature Cylinder RB4 ...................................................... 7-133

F@DENS - Trouble High Exhaust Temperature Cylinder RB5....................................................... 7-133

F@DFNS - Trouble High Exhaust Temperature Cylinder RB6....................................................... 7-133

F@DGNS - Trouble High Exhaust Temperature Cylinder LB1....................................................... 7-133

F@DHNS - Trouble High Exhaust Temperature Cylinder LB2....................................................... 7-133

F@DJNS - Trouble High Exhaust Temperature Cylinder LB3 ....................................................... 7-133

F@DKNS - Trouble High Exhaust Temperature Cylinder LB4....................................................... 7-133

F@DLNS - Trouble High Exhaust Temperature Cylinder LB5 ....................................................... 7-133

F@DMNS - Trouble High Exhaust Temperature Cylinder LB6 ...................................................... 7-133

Input signals of the engine cylinder temperature sensors on the REAL TIME MONITOR ........ 7-134
Wiring Diagram for trouble codes F@D(A...M)NS ..................................................................... 7-135

DGTAKX - Trouble monitoring Exhaust Temp Cylinder RB1......................................................... 7-136

DGTBKX - Trouble monitoring Exhaust Temp Cylinder RB2......................................................... 7-136

DGTCKX - Trouble monitoring Exhaust Temp Cylinder RB3......................................................... 7-136

DGTDKX - Trouble monitoring Exhaust Temp Cylinder RB4......................................................... 7-136

DGTEKX - Trouble monitoring Exhaust Temp Cylinder RB5......................................................... 7-136

DGTFKX - Trouble monitoring Exhaust Temp Cylinder RB6 ......................................................... 7-136

DGTGKX - Trouble monitoring Exhaust Temp Cylinder LB1......................................................... 7-136

DGTHKX - Trouble monitoring Exhaust Temp Cylinder LB2 ......................................................... 7-136

TOC - 6 PC3000-6 SHOP-40 06279-xD-GB-1

 DGTJKX - Trouble monitoring Exhaust Temp Cylinder LB3 ......................................................... 7-136

DGTKKX - Trouble monitoring Exhaust Temp Cylinder LB4......................................................... 7-136

DGTLKX - Trouble monitoring Exhaust Temp Cylinder LB5 ......................................................... 7-136

DGTMKX - Trouble monitoring Exhaust Temp Cylinder LB6 ........................................................ 7-136

Input signals of the engine cylinder temperature sensors on the REAL TIME MONITOR ........ 7-137
Wiring Diagram for trouble codes DGT(A...M)KX ...................................................................... 7-138

DJF1KX - Trouble monitoring fuel level........................................................................................... 7-139

Wiring Diagram (31B063) for trouble code DJF1KX.................................................................. 7-141

8 TROUBLESHOOTING BY SYMPTOMS.................................................... 8-1

8.1 SYMPTOMS OF THE ENGINE AND RELATED ELECTRICAL SYSTEM ........................................ 8-2

SEL001 - Engine does not start (engine does not rotate) .................................................................. 8-2
Wiring Diagram 1 (engine start) for trouble code SEL001 & SEL001a.......................................... 8-4

SEL001a - Engine does not start (Pre-lube does not stop)................................................................ 8-5

SEL002 - Engine stops while in operation........................................................................................... 8-6

View onto the fuel system water separator (SEL002).................................................................... 8-7

SEL003 - Engine speed is hunting during boom-up movement........................................................ 8-8

SEL004 - Engine does not stop .......................................................................................................... 8-10

SEL005 - Engine lacks output (no power) ......................................................................................... 8-11

Judgment Table for SEL005 ..................................................................................................... 8-12

SEL006 - Exhaust smoke is black ...................................................................................................... 8-13

Judgment Table for SEL006 ........................................................................................................ 8-14

SEL007 - Oil consumption is excessive ............................................................................................ 8-15

Judgment Table for SEL007 ....................................................................................................... 8-16

SEL008 - Oil becomes contaminated quickly.................................................................................... 8-17

Judgment Table for SEL008 ....................................................................................................... 8-18

SEL009 - Fuel consumption is excessive.......................................................................................... 8-19

Judgment Table for SEL009 ....................................................................................................... 8-20

SEL010 - Oil is in engine coolant ....................................................................................................... 8-21

Judgment Table for SEL010 ....................................................................................................... 8-22

SEL011 - Oil level rises........................................................................................................................ 8-23

Judgment Table for SEL011 ........................................................................................................ 8-24

SEL012 - Coolant temperature becomes too high (overheating) .................................................... 8-25

Judgment Table for SEL012 ........................................................................................................ 8-26

SHOP-40 06279-xD-GB-1 PC3000-6 TOC - 7

 8.2 SYMPTOMS OF THE HYDRAULIC SYSTEM ................................................................................. 8-27

SHY001 - All the work equipment shows lack of power or slow movement
(especially the "boom up" function) .................................................................................. 8-27

SHY002 - Engine speed sharply drops or engine stalls too much.................................................. 8-29

SHY003 - No work equipment, travel or slew movement ................................................................. 8-31

SHY004 - Work equipment has too much hydraulic drift ................................................................. 8-32

SHY005 - Work equipment has big time lag ...................................................................................... 8-33

Hydraulic oil temperature table - 11K026 and 11K171 adjustment ............................................. 8-33

SHY006 - Machine deviates during travel movement ....................................................................... 8-34

SHY007 - Hydraulic system has lack of power ................................................................................. 8-35

SHY008 - Machine does not slew (or slew speed is very low)......................................................... 8-36
Slew brake valve block (SHY008) ............................................................................................... 8-37

SHY009 - Slew acceleration is poor (or slew speed is very low)..................................................... 8-38

SHY010 - Excessive overrun when stopping slew movement ........................................................ 8-40

SHY011 - Floating system without function (FSA only) ................................................................... 8-42

Floating system - overview (SHY011) ......................................................................................... 8-43

SHY012 - Abnormal noise coming from SRV or MRV ...................................................................... 8-44

SHY013 - Track tensioning system without function (or with poor function) ................................ 8-45
View onto the elements of the hydraulic track tensioning system (SHY013)............................... 8-47

SHY014 - Ladder does not move, or slow movement ...................................................................... 8-48

SHY015 - Refilling arm does not move, or slow movement............................................................. 8-50

SHY016 - Refilling arm is sagging when engine is not running ...................................................... 8-52

SHY017 - The hydr. driven grease pump does not move................................................................. 8-53

SHY018 - Abnormal track chain movement during digging ............................................................ 8-55

SHY019 - Slew parking brake without function................................................................................. 8-56

SHY020 - Travel parking brake without function .............................................................................. 8-57

8.3 SYMPTOMS OF THE MECHANICAL SYSTEM .............................................................................. 8-58

SME001 - Abnormal noise is made .................................................................................................... 8-58

Judgment Table for SME001 ....................................................................................................... 8-59

SME002 - Abnormal noise around the PTO / hydraulic pumps ....................................................... 8-60

SME003 - Vibration is excessive (engine mountings) ...................................................................... 8-62

Judgment Table for SME003 ....................................................................................................... 8-63

SME004 - Vibration is excessive (engine torsion) ............................................................................ 8-64

TOC - 8 PC3000-6 SHOP-40 06279-xD-GB-1

 SME005 - There is a big shock when stopping slew movement ..................................................... 8-65

SME006 - There is a big abnormal noise when moving/stopping slew movement ....................... 8-66

SME007 - Fan blades make abnormal noise ..................................................................................... 8-68

SME008 - Abnormal noise coming from a travel gearbox ............................................................... 8-69

SME009 - Abnormal noise coming from the work equipment (lack of grease).............................. 8-71

SME010 - Abnormal idler movement.................................................................................................. 8-73

SME011 - Leak at the PTO shaft seal ................................................................................................. 8-74

8.4 SYMPTOMS OF ADDITIONAL SYSTEMS...................................................................................... 8-76

SAD001 - Air conditioner for the cabin does not work..................................................................... 8-76
View onto the A/C unit (SAD001) ................................................................................................ 8-77

SAD002 - Air conditioner compressor clutch is burnt ..................................................................... 8-78

View onto the A/C compressor and its mounting (SAD002) ........................................................ 8-79

SAD003 - Air conditioning system defective (pipes and hoses full of moisture) .......................... 8-80
View onto an A/C filling and service station................................................................................. 8-81

9 TROUBLESHOOTING BY PUMP CONTROLLER TROUBLE

CODES (MULTI MONITOR) ...................................................................... 9-1
DXAAKA - Solenoid-1(Pump-1) open circuit ....................................................................................... 9-2

DXABKA - Solenoid-2(Pump-2) open circuit ....................................................................................... 9-2

DXACKA - Solenoid-3(Pump-3) open circuit ....................................................................................... 9-2

DXADKA - Solenoid-4(Pump-4) open circuit ....................................................................................... 9-2

DXAEKA - Solenoid-5(Pump-5) open circuit ....................................................................................... 9-2

DXAFKA - Solenoid-6(Pump-6) open circuit ....................................................................................... 9-2

Wiring Diagram - EPC valve control (pump controller) .................................................................. 9-3

DXAAKB - Solenoid-1(Pump-1) short circuit....................................................................................... 9-4

DXABKB - Solenoid-2(Pump-2) short circuit....................................................................................... 9-4

DXACKB - Solenoid-3(Pump-3) short circuit....................................................................................... 9-4

DXADKB - Solenoid-4(Pump-4) short circuit....................................................................................... 9-4

DXAEKB - Solenoid-5(Pump-5) short circuit....................................................................................... 9-4

DXAFKB - Solenoid-6(Pump-6) short circuit ....................................................................................... 9-4

Wiring Diagram - EPC valve control (pump controller) .................................................................. 9-5

DHPEMA - Pump-1/2 pressure sensor abnormality............................................................................ 9-6

DHPGMA - Pump-3/4 pressure sensor abnormality ........................................................................... 9-6

SHOP-40 06279-xD-GB-1 PC3000-6 TOC - 9

 DHPJMA - Pump-5/6 pressure sensor abnormality ............................................................................ 9-6
Wiring Diagram - PWR & GND supply for pressure sensors (pumps 1...3)................................... 9-7

DLE2MA - Engine speed sensor abnormality ..................................................................................... 9-8

Wiring Diagram - engine RPM signal (52B064) to pump controller ............................................... 9-9

DA25KP - 5V sensor1 power abnormality ......................................................................................... 9-10

Wiring Diagram - 5V sensor power supply for trouble code DA25KP.......................................... 9-12

DA22KK - Pump Solenoid Power Low Error ..................................................................................... 9-13

DA29KQ - Model Selection Abnormality ............................................................................................ 9-14

10 APPENDIX ............................................................................................... 10-1

10.1 COMPARISON OF TROUBLE CODES: VHMS (INCL. RETROFIT KIT) VS. KOMTRAX PLUS ... 10-2
10.1.1 VHMS TROUBLE CODES VS. KOMTRAX PLUS TROUBLE CODES ............................... 10-2
10.1.2 PUMP CONTROLLER CR700 VS. PUMP CONTROLLER CR710 TROUBLE CODES ..... 10-6

TOC - 10 PC3000-6 SHOP-40 06279-xD-GB-1

Introduction

1 INTRODUCTION

SHOP-40 06279-xD-GB-1 PC3000-6 1 -1

Overview Introduction

1.1 OVERVIEW
In chapter 40 TROUBLESHOOTING you find troubleshooting information which should assist you when trouble-
shooting on the machine.

– Section 1: Safety
Contains the global Safety Notes which always have to be followed!
– Section 2: Introduction and General Information for Troubleshooting
Contains precautions and considerations which are given in addition for troubleshooting.
Furthermore you find fundamental requirements and points to remember when troubleshooting.
Also you find recommendations concerning the sequence of work steps and checks which should be done
before troubleshooting, how to handle electric and hydraulic equipment, and how to perform basic working
procedures.
– Section 3: Mounting Locations and Connector Types
Provides you with information about mounting locations of components and illustrations of different connector
types as they are used on your machine.
– Section 4: Standard Value Table for Electrical Component
Provides you with charts of standard values for electrical components as a quick reference guide.
– Section 5: References for Troubleshooting
Provides you with troubleshooting features at the KOMTRAX Plus controller and with general troubleshooting
procedures for system’s relays.
– Section 6: Tables for Testing and Troubleshooting
Contains various assistant Tables for Testing and Troubleshooting.
– Section 7: Troubleshooting by KOMTRAX Plus Trouble Code
In this section troubleshooting charts for the KOMTRAX Plus trouble codes odes are listed in the sequence of
the trouble codes as they are stored in the KOMTRAX Plus system.
– Section 8: Troubleshooting by Symptoms
Troubleshooting charts for various engine electrical, mechanical, and hydraulic problems according to symp-
toms of malfunctions which the monitoring & control system can not detect under the particular conditions.
Therefore these malfunctions are not indicated by defined and stored trouble codes or messages via
KOMTRAX Plus.
– Section 9: Troubleshooting by pump controller trouble codes (Multi Monitor)
In this section troubleshooting charts for the pump controller trouble codes odes are listed in the sequence of
the trouble codes as they are stored in the KOMTRAX Plus system and in the Multi Monitor.

1.1.1 GENERAL ADVICE WHEN USING TROUBLESHOOTING CHARTS

Even as many system messages and troubleshooting procedures as possible are detailed in this manual, the
troubleshooting charts in chapter 7~9 can not cover all eventual malfunctions which may possibly occur.
In particular situations a general inspection of the suspected system may be necessary.

Furthermore, it is not necessary that you strictly follow the sequence of the given troubleshooting charts in every
case. The troubleshooting charts try to present all necessary steps for the identification and repair of any trouble,
independent of your knowledge, experience, and your location on the machine during troubleshooting.

REMARKS: It is important and essential to find the cause for any trouble in the easiest way and in the shortest
time.
Due to the complex control system on the machine, the intensive use of the available IT tools is
recommended for troubleshooting.

1 -2 PC3000-6 SHOP-40 06279-xD-GB-1

Introduction General Precautions

1.2 GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before
operating the machine.

1. Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations
of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual.

2. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in
their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on
the floor. Smoke only in the areas provided for smoking. Never smoke while working.

3. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes,
or clothes with buttons missing.

– Always wear safety glasses when hitting parts with a hammer.

– Always wear safety glasses when grinding parts with a grinder, etc.
4. When carrying out any operation with 2 or more workers, always agree on the operating procedure before
starting. Always inform your fellow workers before starting any step of the operation. Before starting work,
hang UNDER REPAIR warning signs in the operator's compartment.

5. Only qualified workers must carry out work and operation which require license or qualification.

6. Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them.
Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

7. If welding repairs are needed, always have a trained and experienced welder carry out the work. When carry-
ing out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for
welding work.

8. Before starting work, warm up your body thoroughly to start work under good condition.

Safety points

1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5 Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work
7 Wearing protective goggles (for cleaning or grinding work)
8 Wearing shielding goggles and protectors (for welding work)
9 Good physical condition and preparation
10 Precautions against work which you are not used to or you are used to too much

SHOP-40 06279-xD-GB-1 PC3000-6 1 -3

General Precautions Introduction

Please continue reading on the next page.

1 -4 PC3000-6 SHOP-40 06279-xD-GB-1

General Information for Troubleshooting

2 GENERAL INFORMATION
FOR TROUBLESHOOTING

SHOP-40 06279-xD-GB-1 PC3000-6 2 -1

Preparations For Work General Information for Troubleshooting

2.1 PREPARATIONS FOR WORK

1. Before adding oil or making any repairs, park the machine on hard and level ground. Isolate the machine
according to local regulations.

2. Before starting work, make sure that the work equipment is lowered to the ground. Also make sure that the
maintenance safety switch (S58) is switched OFF and locked with a padlock. In addition hang up warning
signs.

3. When disassembling or assembling, support the respective unit with blocks, jacks, or stands as necessary
before starting work.

4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the
handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is
impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

2.2 PRECAUTIONS DURING WORK

1. Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure
completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from spurting out.

2. The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded.
Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits.

3. Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine.
When checking the machine without stopping the engine (measuring oil pressure, revolving speed, tempera-
ture, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts.

4. Before starting work, remove the leads from the negative (–) terminal first.

5. When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that
the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capac-
ity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting
any other part. Do not work with any part still raised by the hoist or crane.

6. When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts
in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove
the cover.

7. When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may
cause electrical fires.

8. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up
immediately. Fuel or oil on the floor can cause you to slip and can even start fires.

9. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular.

10. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must
not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by
contact with other parts when the machine is operated.

11. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so
be extremely careful when installing tubes for high pressure circuits. In addition, check that connecting parts
are correctly installed.

12. When assembling or installing parts, always tighten them to the specified torques. When installing protective
parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check
that they are installed correctly.

2 -2 PC3000-6 SHOP-40 06279-xD-GB-1

General Information for Troubleshooting Precautions When Carrying Out Any Operation

13. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

14. When measuring hydraulic pressure, check that the measuring tools are correctly assembled.

15. Take care when removing or installing the tracks of track-type machines. When removing the track, the track
separates suddenly, so never let anyone stand at either end of the track.

16. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poison-
ing. Accordingly, open the windows and doors to ventilate well.

2.3 PRECAUTIONS WHEN CARRYING OUT ANY

OPERATION
When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below.

2.3.1 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK

1. If the coolant contains antifreeze, dispose of it correctly.

2. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.

3. When draining oil, prepare a container of adequate size to catch the oil.

4. Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.

5. To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.

6. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.

7. Check the number and thickness of the shims, and keep in a safe place.

8. When raising components, be sure to use lifting equipment of ample strength.

9. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.

10. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering
after removal.

11. After disconnecting any piping during disassembly operations make sure to use the correct plugs and seals
when connecting the piping again.

2.3.2 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK

1. Tighten all bolts and nuts (sleeve nuts) to the specified torque.

2. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.

3. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.

4. Bend the cotter pins and lock plates securely.

5. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 - 3 drops of adhesive.

SHOP-40 06279-xD-GB-1 PC3000-6 2 -3

Precautions When Carrying Out Any Operation General Information for Troubleshooting

6. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt
or damage, then coat uniformly with gasket sealant.

7. Clean all parts, and correct any damage, dents, burrs, or rust.

8. Coat rotating parts and sliding parts with engine oil.

9. When press fitting parts, coat the surface with anti-friction compound (LM-P).

10. After fitting snap rings, check that the snap ring is fitted securely in the ring groove.

11. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.

12. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.

13. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

14. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:

– Start the engine and run at low idle.

– Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the cylinder
100 mm from the end of its stroke.
– Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
– After doing this, run the engine at normal speed.
NOTE! When using the machine for the first time after repair or long storage, follow the same procedure.

2.3.3 PRECAUTIONS WHEN COMPLETING THE OPERATION

Refilling with coolant, oil and grease

– If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine
to circulate the coolant through the system. Then check the coolant level again.
– If any engine component has been removed and installed again, add engine oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
– If the piping or hydraulic equipment has been removed, always bleed the air from the system after
reassembling the parts.
NOTE! For details, refer to section 2.9 on page 2-18 (General Working Procedures/Air bleeding).

– Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

2 -4 PC3000-6 SHOP-40 06279-xD-GB-1

General Information for Troubleshooting Fundamental Requirements for Troubleshooting

2.4 FUNDAMENTAL REQUIREMENTS FOR TROUBLE-

SHOOTING

2.4.1 TECHNICAL DOCUMENTATION

The personnel in charge of troubleshooting must have permanent and easy access to the following appropriate
and up-to-date documents of the relevant hydraulic excavator:

– Electric Wiring Diagram

– Hydraulic Circuit Diagram
– Operation & Maintenance Manual
– SHOP MANUAL part "10 Structure & function"
– Cross-Reference Chart
– Cummins Troubleshooting and Repair Manual for the QSK60 Engine (SDA 12V 160 Komatsu Engine)
– Inspection and Maintenance Manual of the equipped Fire Suppression System (optional equipment)
– Inspection and Maintenance Manual of the equipped Air Conditioning System
Without the above documents troubleshooting is ineffective and unreliable!

2.4.2 TOOLS
For proper troubleshooting and subsequent repairs it is essential to have access to complete facilities which
include appropriate measuring instruments as well as necessary tools for the repair of a hydraulic excavator.

For troubleshooting, testing, and repair the following tools are obligatory:

Multi Tester Electrical Cable Set for Multi Tester

The cable set includes:

732 702 40 Measuring cable

732 703 40 Measuring cable
732 704 40 Probe tip
732 705 40 Probe tip
732 706 40 Crocodile clip
732 707 40 Crocodile clip

P/N 232 756 40 P/N 232 496 40

SHOP-40 06279-xD-GB-1 PC3000-6 2 -5

Fundamental Requirements for Troubleshooting General Information for Troubleshooting

Deutsch T-Box Deutsch Test-Cable Clamp-On Ammeter

P/N 232 762 40 A: P/N 232 808 40 P/N 232 756 40

B: P/N 232 809 40

Magnetic Stick Insulation Pliers Deutsch Crimp Pliers

P/N 232 712 40 P/N 232 663 40 P/N 793 729 73

Standard Deutsch Removal Tools

P/N Size P/N Size

932 634 40 1.00 mm2 932 633 40 1.00 - 2.00 mm2

932 632 40 1.50 mm2 932 631 40 3 - 8 - 16 mm2

Also refer to section 2.4.2.1 on page 2-8: Reference Guide for Deutsch Removal Tools

2 -6 PC3000-6 SHOP-40 06279-xD-GB-1

General Information for Troubleshooting Fundamental Requirements for Troubleshooting

Cable Stripping Knife Digital Dial Gauge Infrared Thermometer

(4-16 mm)

P/N 232 699 40 P/N 794 537 73 P/N 232 665 40

RPM Tester Digital hydr. test gauge VHMS technical analysis

tool box

P/N 232 551 40 P/N 232 720 40 P/N 792 504 73

VHMS Download Cable

VHMS Download Cable

(serial connection)

P/N 894 580 40

SHOP-40 06279-xD-GB-1 PC3000-6 2 -7

Fundamental Requirements for Troubleshooting General Information for Troubleshooting

2.4.2.1 REFERENCE GUIDE FOR DEUTSCH REMOVAL TOOLS

Fig. 2-1 Reference Guide for Deutsch Removal Tools

2 -8 PC3000-6 SHOP-40 06279-xD-GB-1

General Information for Troubleshooting Points To Remember When Troubleshooting

2.4.3 PERSONNEL
Only authorized and trained personnel should perform troubleshooting and the resulting repairs.

Work on the electrical system and equipment of the machine must be carried out only by a skilled electrician or
by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical
engineering rules and regulations.

Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of
the hydraulic equipment.

Work on the Fire Suppression System must be carried out only by certified persons.

2.5 POINTS TO REMEMBER WHEN TROUBLESHOOTING

- Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.

- When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and do not allow
any unauthorized person to come near.

- If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.

- Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

- When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.

- When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the
internal pressure first. When installing measuring equipment, be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the
structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions
to form some idea of possible causes of the failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately any failure occurs:

– Parts that have no connection with the failure or other unnecessary parts will be disassembled.
– It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil or grease, and at the same time, will also lose the confidence
of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough
prior investigation and to carry out troubleshooting in accordance with the fixed procedure.

2. Points to ask user or operator:

– Have any other problems occurred apart from the problem that has been reported?
– Was there anything strange about the machine before the failure occurred?
– Did the failure occur suddenly, or were there problems with the machine condition before this?
– Under what conditions did the failure occur?
– Had any repairs been carried out before the failure?
– When were these repairs carried out?
– Has the same kind of failure occurred before?

SHOP-40 06279-xD-GB-1 PC3000-6 2 -9

Points To Remember When Troubleshooting General Information for Troubleshooting

3. Checks before troubleshooting

– Check the oil level.

– Check for any external leakage of oil from the piping or hydraulic equipment.
– Other maintenance items can be checked externally, so check any item that is considered to be necessary.
4. Confirming failure

– Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem
with the method of operation etc.
– When operating the machine to re-enact the troubleshooting symptoms, do not carry out any investigation
or measurement that may make the problem worse.
5. Troubleshooting

– Use the results of the investigation and inspection in items 2-4 to narrow down the causes of failure, then
use the troubleshooting flowchart to locate the position of the failure exactly.
The basic procedure for troubleshooting is as follows:

– Start from the simple points.

– Start from the most likely points.
– Investigate other related parts or information.

6. Measures to remove the root cause of any failure

– Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur
again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

2 - 10 PC3000-6 SHOP-40 06279-xD-GB-1

General Information for Troubleshooting Sequence Of Events In Troubleshooting

2.6 SEQUENCE OF EVENTS IN TROUBLESHOOTING

Fig. 2-2 Sequence Of Events In Troubleshooting

SHOP-40 06279-xD-GB-1 PC3000-6 2 - 11

Checks Before Troubleshooting General Information for Troubleshooting

2.7 CHECKS BEFORE TROUBLESHOOTING

Item Inspection Criterion Remedy

1. Check of level and type of fuel - Add fuel

2. Check of fuel for foreign matter - Clean and drain

3. Check of fuel filter - Replace

4. Check of hydraulic oil level - Add oil

Lubricating oil, 5. Check of hydraulic oil strainer - Clean and drain

coolant 6. Check of slew machinery oil level - Add oil

7. Check of level and type of engine oil (in oil pan) - Add oil

8. Check of coolant level - Add coolant

9. Check of dust indicator for clogging - Clean or replace

10. Check of hydraulic oil filter - Replace

1. Check of battery terminals and wiring for looseness and Retighten or

-
corrosion replace

Electrical 2. Check of alternator terminals and wiring for looseness and Retighten or
-
equipment corrosion replace

3. Check of starting motor terminals and wiring for looseness Retighten or

-
and corrosion replace

1. Check for abnormal noise and smell - Repair

Hydraulic,
mechanical 2. Check for oil leakage - Repair
equipment
3. Bleeding air - Bleed air

1. Check of battery voltage (with engine stopped) 22 - 24V Replace

2. Check level of battery electrolyte - Add or replace

3. Check of wires for discoloration, burn, and removal of the

- Replace
isolation cover

4. Check for released wire clamp and dropping wire - Repair

5. Check of wires for wetness (in particular check connectors Disconnect the
Electrical -
and terminals for wetness) connectors and dry
components
6. Check for broken or corroded fuses - Repair

After operating
for several
7. Check alternator voltage (engine running at over half throttle) Replace
minutes:
27.5 - 29.5V

8. Check battery relay for operating sound

- Replace
(when starting switch is turned ON or OFF)

2 - 12 PC3000-6 SHOP-40 06279-xD-GB-1

General Information for Troubleshooting Handling Of Electric Equipment And Hydraulic Components

2.8 HANDLING OF ELECTRIC EQUIPMENT AND

HYDRAULIC COMPONENTS

2.8.1 POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT

1. Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting one component to

another component, connectors used for connecting and discon-
necting one wire from another wire, and protectors or tubes used
for protecting the wiring.
Compared with other electrical components fitted in boxes or
cases, wiring harnesses are more likely to be affected by the
direct effects of rain, water, heat, or vibration.
Furthermore, during inspection and repair operations, they are
frequently removed and installed again, so they are likely to suffer
deformation or damage. For this reason, it is necessary to be
extremely careful when handling wiring harnesses. Fig. 2-3 Handling wiring and connectors

2. Main failures occurring in wiring harness

– Defective contact of connectors (defective contact between

male and female)
Problems with defective contacts are likely to occur because the
male connector is not properly inserted into the female connector,
or because one or both of the connectors is deformed or the posi-
tion is not correctly aligned, or because there is corrosion or oxi-
dization of the contact surfaces.

Fig. 2-4 Defective contact of connectors

– Defective crimping or soldering of connectors

The pins of the male and female connectors are in contact at the
crimped terminal or soldered portion, but if there is excessive
force brought to bear on the wiring, the plating at the joint will peel
and cause improper connection or breakage.

Fig. 2-5 Defective crimping or soldering

– Disconnections in wiring
If the wiring is held and the connectors are pulled apart, or com-
ponents are lifted with a crane with the wiring still connected, or
a heavy object hits the wiring, the crimping of the connector may
separate, or the soldering may be damaged, or the wiring may be
broken.

Fig. 2-6 Disconnections in wiring

SHOP-40 06279-xD-GB-1 PC3000-6 2 - 13

Handling Of Electric Equipment And Hydraulic Components General Information for Troubleshooting

– High-pressure water entering connector

The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter the connector, depend-
ing on the direction of the water jet. Accordingly, take care not to
splash water over the connector.
The connector is designed to prevent water from entering, but at
the same time, if water does enter, it is difficult for it to be drained.
Therefore, if water should get into the connector, the pins will be
short-circuited by the water, so if any water gets in, immediately
dry the connector or take other appropriate action before passing
electricity through it. Fig. 2-7 High-pressure water entering

– Oil or dirt stuck to connector

If oil or grease are stuck to the connector and an oil film is formed
on the mating surface between the male and female pins, the oil
will not let the electricity pass, so there will be defective contact.
If there is oil or grease stuck to the connector, wipe it off with a dry
cloth or blow it dry with compressed air and spray it with a contact
restorer.

NOTE! When wiping the mating portion of the connector, be

careful not to use excessive force or deform the
pins.
If there is oil or water in the compressed air, the con-
Fig. 2-8 Oil or dirt stuck to connector
tacts will become even dirtier, so remove the oil and
water from the compressed air completely before
cleaning with compressed air.

3. Disconnecting connectors

When disconnecting the connectors, hold the connectors.

For connectors held by a screw, loosen the screw fully, then
hold the male and female connectors in each hand and pull
apart. For connectors which have a lock stopper, press down
the stopper with your thumb and pull the connectors apart.

NOTE! Never pull with one hand.

Fig. 2-9 Disconnecting connectors

– When removing from clips

Both of the connector and clip have stoppers, which are engaged
with each other when the connector is installed.

Fig. 2-10 When removing from clips (1)

2 - 14 PC3000-6 SHOP-40 06279-xD-GB-1

General Information for Troubleshooting Handling Of Electric Equipment And Hydraulic Components

When removing a connector from a clip, pull the connector in

a parallel direction to the clip for removing stoppers.

If the connector is twisted up and down or to the left or right,

the housing may break.

Fig. 2-11 When removing from clips (2)

– Action to take after removing connectors

After removing any connector, cover it with a vinyl bag to prevent
any dust, dirt, oil, or water from getting in the connector portion.

NOTE! If the machine is left disassembled for a long time, it

is particularly easy for improper contact to occur, so
always cover the connector.

Fig. 2-12 Protect connectors after removing

2.8.2 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC

EQUIPMENT
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.

– Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or repairing the
machine in rain or high winds, or places where there is a lot
of dust.

Fig. 2-13 Handling hydraulic equipment

SHOP-40 06279-xD-GB-1 PC3000-6 2 - 15

Handling Of Electric Equipment And Hydraulic Components General Information for Troubleshooting

– Disassembly and maintenance work in the field

If disassembly or maintenance work is carried out on hydraulic
equipment in the field, there is danger of dust entering the equip-
ment. It is also difficult to check the performance after repairs, so
it is desirable to use unit exchange.

Disassembly and maintenance of hydraulic equipment should be

carried out in a specially prepared dustproof workshop, and the
performance should be checked with special test equipment.

Fig. 2-14 Work in the field

– Sealing openings
After any piping or equipment is removed, the openings should be
sealed with caps, tapes, or vinyl bags to prevent any dirt or dust
from entering.

If the opening is left open or is blocked with a rag, there is danger

of dirt entering or of the surrounding area being made dirty by
leaking oil so never do this.

Do not simply drain oil out onto the ground, but collect it and ask
the customer to dispose of it, or take it back with you for disposal.

Fig. 2-15 Sealing openings

– Do not let any dirt or dust get in during refilling operations

Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area
around it clean, and also use clean pumps and oil containers.
If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an
even more effective method.

– Change hydraulic oil when the temperature is high

When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from
the circuit together with the oil, so it is best to change the oil when it is still warm.
When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the
hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.)
If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the
hydraulic oil.

– Flushing operations
After disassembling and assembling the equipment, or changing
the oil, use flushing oil to remove the contaminants, sludge, and
old oil from the hydraulic circuit.

Normally, flushing is carried out twice: primary flushing is carried

out with flushing oil, and secondary flushing is carried out with the
specified hydraulic oil.

Fig. 2-16 Flushing operations

2 - 16 PC3000-6 SHOP-40 06279-xD-GB-1

General Information for Troubleshooting Handling Of Electric Equipment And Hydraulic Components

– Cleaning operations
After repairing the hydraulic equipment (pump, control valve etc.)
or when running the machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit.

The oil cleaning equipment is used to remove the ultra fine (about
3 µ) particles that the filter built in the hydraulic equipment cannot
remove, so it is an extremely effective device.

Fig. 2-17 Cleaning operations

SHOP-40 06279-xD-GB-1 PC3000-6 2 - 17

General working procedures General Information for Troubleshooting

2.9 GENERAL WORKING PROCEDURES

2.9.1 AIR BLEEDING OF VARIOUS HYDRAULIC PARTS

Fig. 2-18 Air Bleeding of Various Hydraulic Parts

2.9.2 AIR BLEEDING FROM THE HYDRAULIC PUMPS

The air bleeding procedures for the hydraulic pumps are described in the following manuals.
Refer to these manuals as necessary.

– Operation & Maintenance Manual, section HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION
STRAINERS AND PULSATION DAMPER
– PARTS & SERVICE NEWS AH01513 (latest version)
NOTE! Before starting the air bleeding work explained above, run the engine at low idle for 10 minutes.

2.9.3 AIR BLEEDING FROM HYDRAULIC CYLINDERS

1. Start the engine and keep it running at low idle for 5 minutes.

2. Running the engine at high idle raise and lower the respective cylinders 12 to 15 times.

NOTE! Be careful not to apply the relief pressure, stopping the piston rod approx. 100 mm before its stroke
end.

3. Apply the relief pressure smoothly by extending the piston rod to its stroke end and with the engine running at
high idle.

4. For bleeding air from the arm cylinder and bucket cylinder, follow the same steps explained in items 2) and 3)
above.

2 - 18 PC3000-6 SHOP-40 06279-xD-GB-1

General Information for Troubleshooting Cylinder bypass test

2.10 CYLINDER BYPASS TEST

The cylinder bypass test can be performed in order to check if a hydraulic cylinder has an internal leakage.
A cylinder with an internal leakage generates a higher temperature (at operating temperature of the machine)
than a hydraulic cylinder which has no internal leakage.

For a bypass test at mining machines always use an infrared thermometer, refer to section "Tools" on page 2-5 in
this manual.

NOTE! Refer to chapter SAFETY and observe all safety notes for the following procedure.

Procedure

1. Before starting the bypass test, always make sure that the hydraulic circuit which is to be tested, has reached
the operating temperature (T3).

2. Bring the concerning cylinders in their end position  rod end completely moved in or out.

3. Keep up the system pressure in the concerning hydraulic circuit for approx. 10 minutes.

4. During these 10 minutes, measure and monitor the cylinder temperature in the piston area of both cylinders,
using an infrared thermometer.

If any cylinder seal package is leaking, hydraulic oil is now pressed through this leakage, which causes the
temperature to increase (90°C and higher) within a few minutes.

Case 1 Case 2

Seal package is leaking in 1 cylinder only Seal package is leaking in both cylinders

Defective cylinder: Both defective cylinders:

Temperature increase during the test, Temperature increase during the test,
increased temperature approx. 90°C increased temperature approx. 90°C

Proper cylinder:
No temperature increase during the test, -
normal temperature approx. 70°C

Remark: Remark:
The hydraulic oil will heat up at the MRV, A strong drift occurs.
not in the proper cylinder.

SHOP-40 06279-xD-GB-1 PC3000-6 2 - 19

Basics about "How to crimp" (with strain relief) General Information for Troubleshooting

2.11 BASICS ABOUT "HOW TO CRIMP"

(WITH STRAIN RELIEF)

2.11.1 CRIMP TOOL & REPAIR KIT

Fig. 2-19 Crimp Tool P/N 950 750 40 & Repair Kit P/N 232 986 40

2 - 20 PC3000-6 SHOP-40 06279-xD-GB-1

General Information for Troubleshooting Basics about "How to crimp" (with strain relief)

2.11.2 GENERAL
NOTE! Use the shown tool and repair boxes.
Study the instruction manual of the tool kit and observe the given specifications.

In the following example a CAN BUS connector is replaced for demonstration.

2.11.3 SELECT THE REQUIRED CONNECTOR COMPONENTS

Before starting to work, select the required components

for the particular connector repair from the tool boxes.

For this example:

(1) Connector insert

(2) Pins for CAN H & L

(3) Pin for CAN shield

(4) Shrink hose for the cable

(5) Connector housing

(6) Shrink hose for the connector housing

Fig. 2-20 Selected connector components

Use a standard hot-air gun (approx. 1400W) for heating

the shrink hoses.

Fig. 2-21 Heat gun (example)

SHOP-40 06279-xD-GB-1 PC3000-6 2 - 21

Basics about "How to crimp" (with strain relief) General Information for Troubleshooting

2.11.4 STRIPPING A WIRE

Step 1 Determine the required cable length inside the

new connector.

Step 2 Remove the outer cable isolation as far as necessary

without damaging the cable shield (1).

Step 3 Finish the single wires, the inner insulating foil,

and the shield (2).

Step 4 Push the following components onto the cable (3):

- Shrink hose for the connector housing
- Connector housing
- Shrink hose for the cable

Step 5 Shorten the shield cable (4) according to the

longer terminal (5).

(A) Max. length of cable strand

(B) Length for cable stripping

(C) Crimp range for strain relief

Step 6 Strip the red and blue cable as described.

Fig. 2-22 Length of cable strand

2 - 22 PC3000-6 SHOP-40 06279-xD-GB-1

General Information for Troubleshooting Basics about "How to crimp" (with strain relief)

2.11.5 CRIMPING

Step 1 With the help of the User Instructions in the crimp tool
box, determine AWG size and P/N of the crimp pliers
to be used for the CAN High/Low connector terminals.

Pliers: 950 758 40

AWG: 16-18

Step 2 Crimp CAN H & L terminals and check for

a proper crimp result as shown (1).

Step 3 Crimping the shield terminal.

- The longer shield terminal is without strain relief.
- Verify that the cable strand is pushed against the
stop inside the terminal (2).
- Check the cable strand through the inspection hole (3).
- Use the Deutsch crimp tool HDT 48 for crimping.
- Adjust the terminal protrusion up to 1 mm (4).
- Crimp the shield terminal (5).

Fig. 2-23 Crimping

SHOP-40 06279-xD-GB-1 PC3000-6 2 - 23

Basics about "How to crimp" (with strain relief) General Information for Troubleshooting

2.11.6 CONNECTOR ASSEMBLY AFTER CRIMPING

Step 1 Push the terminals into the connector backside (1)

until they click into place.
- Start with the long shield terminal (C).
- Then insert the High & Low terminals (A & B).
- Check for proper terminal seat at the connector
front side (2).

Step 2 Move the shrink hose (3) onto the cables and shrink it.

Step 3 Fully slide the connector housing (4) onto the connector
insert, and fold down the connector halves (5).

Step 4 Visually inspect the completed connector (6)

which is still without shrink hose.

Step 5 Move the shrink hose (7) onto the connector housing
and shrink it.

Fig. 2-24 Connector assembly

2 - 24 PC3000-6 SHOP-40 06279-xD-GB-1

General Information for Troubleshooting Cable Shielding

2.12 CABLE SHIELDING

If the shielding of any sensor wiring is defective, that does not mean that the sensor itself must be faulty in every
case.

However, as long as the shielding is damaged, it is possible that a weak signal of any sensor may be influenced by
electromagnetic fields of other electrical components or conductors.

Also the signals in data transfer cables may be influenced by interference if the shielding is faulty.

Therefore it is necessary to repair a damaged cable shielding immediately. If an effective repair is not guaranteed
(e.g. due to a back mounted cable shielding) replace the affected component and/or cable.

SHOP-40 06279-xD-GB-1 PC3000-6 2 - 25

Cable Shielding General Information for Troubleshooting

Please continue reading on the next page.

2 - 26 PC3000-6 SHOP-40 06279-xD-GB-1

Mounting Locations and Connector Types

3 MOUNTING LOCATIONS
AND CONNECTOR TYPES

SHOP-40 06279-xD-GB-1 PC3000-6 3 -1

Component location Mounting Locations and Connector Types

3.1 COMPONENT LOCATION

3.1.1 VIEW AT THE SUPERSTRUCTURE

Fig. 3-1 View at the superstructure

3 -2 PC3000-6 SHOP-40 06279-xD-GB-1

Mounting Locations and Connector Types Component location

Legend for Fig. 3-1:

(1) Operator’s cab (10) Main hydraulic oil reservoir

(2) Cab base incl. X2-board and pilot control (11) Control and filter plate

(3) Fuel tank (12) Hydraulic pump assemblies

(4) Hydraulically operated access ladder (13) PTO (Pump Distributor Gear)

(5) Engine air cleaner (14) Engine oil reserve tank

(6) Batteries (15) Diesel engine

(7) Distributor manifold (16) Central lubrication system (CLS)

(8) Main control valves (17) Slew ring gear lubrication system (SLS)

(9) Hydraulic oil cooler assembly

SHOP-40 06279-xD-GB-1 PC3000-6 3 -3

Component location Mounting Locations and Connector Types

3.1.2 ENGINE - LOCATION OF ELECTRICAL COMPONENTS (1)

Fig. 3-2 Location of engine electrical parts (1)

3 -4 PC3000-6 SHOP-40 06279-xD-GB-1

Mounting Locations and Connector Types Component location

Legend for Fig. 3-2:

[52B064] Engine speed sensor

[52B093] Pressure switch, engine oil pressure

[52B201] Temperature switch, engine oil temperature (not shown, TT & TTT only)

[52G005] Alternator

[52G006] Prelube pump

[52K014] Quantum engine control (not shown)

[52K030] Prelube timer relay

[52M001-1] Starter motor 1

[52M002-1] Starter motor 2

[52Q002a] Starter relay

[52Q004] Magnetic clutch, air conditioning compressor

[52Q030a] Prelube relay

SHOP-40 06279-xD-GB-1 PC3000-6 3 -5

Component location Mounting Locations and Connector Types

3.1.3 ENGINE - LOCATION OF ELECTRICAL COMPONENTS (2)

Fig. 3-3 Location of engine electrical parts (2)

3 -6 PC3000-6 SHOP-40 06279-xD-GB-1

Mounting Locations and Connector Types Component location

Legend for Fig. 3-3:

Engine temperature monitoring left cylinder bank, cylinders 1...6:

52B243-1 Engine temperature sensor cylinder 1 52T243-1 Amplifier cylinder 1

52B243-2 Engine temperature sensor cylinder 2 52T243-2 Amplifier cylinder 2

52B243-3 Engine temperature sensor cylinder 3 52T243-3 Amplifier cylinder 3

52B243-4 Engine temperature sensor cylinder 4 52T243-4 Amplifier cylinder 4

52B243-5 Engine temperature sensor cylinder 5 52T243-5 Amplifier cylinder 5

52B243-6 Engine temperature sensor cylinder 6 52T243-6 Amplifier cylinder 6

Engine temperature monitoring right cylinder bank cylinders 1...6:

52B244-1 Engine temperature sensor cylinder 1 52T244-1 Amplifier cylinder 1

52B244-2 Engine temperature sensor cylinder 2 52T244-2 Amplifier cylinder 2

52B244-3 Engine temperature sensor cylinder 3 52T244-3 Amplifier cylinder 3

52B244-4 Engine temperature sensor cylinder 4 52T244-4 Amplifier cylinder 4

52B244-5 Engine temperature sensor cylinder 5 52T244-5 Amplifier cylinder 5

52B244-6 Engine temperature sensor cylinder 6 52T244-6 Amplifier cylinder 6

SHOP-40 06279-xD-GB-1 PC3000-6 3 -7

Component location Mounting Locations and Connector Types

3.1.4 CONTROL AND FILTER PLATE - LOCATION OF COMPONENTS

Fig. 3-4 Control and filter plate - location of components

3 -8 PC3000-6 SHOP-40 06279-xD-GB-1

Mounting Locations and Connector Types Component location

Legend for Fig. 3-4:

Hydraulic components:

(20) Pressure filter, PTO gear oil (252.1) X2-pressure reducing valve (35±3 bar)

(21) Pressure relief valve, PTO gear lubrication (252.2) X4-pressure relief valve (60±1 bar)

(26.1) Pressure filter, pilot oil (256) Control block - slew brake

(28) Pressure filter, hydraulic fan drive pump (257) Control block - travel parking brake

(29) Pressure reducing valve (257.1) SRV - travel parking brake (50 bar)

(34) Pressure relief valve (258) Control block - access ladder

(120) Bladder accumulator (258.3) SRV - access ladder (70 bar)

(252) Control block - pilot pressure (259) Control block - refilling arm

Electric components:

[57B017] Pressure switch, PTO gear oil pressure

[57B027] Pressure switch, PTO gear oil pressure filter clogged

[57B086] Pressure transducer, X2 pilot pressure

[57K506a/b] Solenoid valve, hydraulic oil cooler fan drive (minimum/medium speed)

[57K553] Solenoid valve, PTO preload pressure

[57Q505] Solenoid valve, slew parking brake control pressure

[57Q516] Solenoid valve, travel parking brake control pressure

[57Q620] Solenoid valve, slew shut-off (emergency)

[57Q623a/b] Solenoid valve, hydraulic access ladder - a) up, b) down

[57Q624a/b] Solenoid valve, refilling arm - a) up, b) down

[57Q624c] Solenoid valve, refilling arm park valve

[57Q625] Solenoid valve, hydraulic access ladder - speed control

REMARKS: For switching points and switching conditions of the sensors and switches refer to chapter 4, "Stan-
dard Value Table for Electrical Components".

SHOP-40 06279-xD-GB-1 PC3000-6 3 -9

Component location Mounting Locations and Connector Types

3.1.5 PTO AND SUCTION OIL TANK - LOCATION OF ELECTRICAL

COMPONENTS

Fig. 3-5 PTO and suction oil tank - location of electrical components

3 - 10 PC3000-6 SHOP-40 06279-xD-GB-1

Mounting Locations and Connector Types Component location

Legend for Fig. 3-5:

PTO and Suction oil tank

[59B015] Hydraulic oil temperature sensor, suction oil tank - bucket motion cut-off

[59B032-1] Hydraulic oil temperature sensor, suction oil tank

[57B049] Temperature sensor, PTO gear oil temperature

[57B182] Temperature sensor, PTO gear oil temperature - pressure relief of oil cooler

HPV 375+375 main pump assemblies (tandem pumps)

(1) Servo valve for swash plate regulation with integrated EPC-valve

(I) Main pump assembly I

(II) Main pump assembly II

(III) Main pump assembly III

[57K658f/r] EPC valve, main pump assembly I (front/rear)

[57K659f/r] EPC valve, main pump assembly II (front/rear)

[57K660f/r] EPC valve, main pump assembly III (front/rear)

REMARKS: For switching points and switching conditions of the sensors and switches refer to chapter 4, "Stan-
dard Value Table for Electrical Components".

Both single pumps in each main pump assembly are individually equipped with a servo valve (Fig. 3-5, Pos. 1)
with an integrated EPC valve. The servo valve controls the swash plate angle.

SHOP-40 06279-xD-GB-1 PC3000-6 3 - 11

Component location Mounting Locations and Connector Types

3.1.6 PILOT CONTROL FRAME - LOCATION OF ELECTRICAL

COMPONENTS

Fig. 3-6 Pilot control frame - location of components

3 - 12 PC3000-6 SHOP-40 06279-xD-GB-1

Mounting Locations and Connector Types Component location

Legend for Fig. 3-6:

[10B037] Pressure switch, motion detection traveling

[10B047] Pressure switch, motion detection slewing

[10B155] FSA only - pressure switch, pressure cut-off, clam closing

[10B156] FSA only (optional) - pressure switch, monitoring pressure cut-off, clam closing (10B155)

[10K040] FSA only - solenoid valve, bucket shut-off

[10K511] FSA only - solenoid valve, pilot control cut-off, clam

[10K511a] Solenoid valve, pilot control cut-off, bucket

[10K511b] Solenoid valve, pilot control cut-off, stick

[10K511c] Solenoid valve, pilot control cut-off, boom

[10K611d] BHA only - solenoid valve, pilot control release

[10K611e] FSA only - solenoid valve, pilot control release

[10Q515] Solenoid valve, pilot control locking slew service brake

REMARKS: For switching points and switching conditions of the sensors and switches refer to chapter 4, "Stan-
dard Value Table for Electrical Components".

SHOP-40 06279-xD-GB-1 PC3000-6 3 - 13

Component location Mounting Locations and Connector Types

3.1.7 MAIN CONTROL BLOCKS - LOCATION OF COMPONENTS

Fig. 3-7 Main control blocks - location of components

3 - 14 PC3000-6 SHOP-40 06279-xD-GB-1

Mounting Locations and Connector Types Component location

Legend for Fig. 3-7:

Electric components:

[61B158a] Pressure transducer, pump pressure main pump I

[61B158b] Pressure transducer, pump pressure main pump II

[61B158c] Pressure transducer, pump pressure main pump III

[61K632] Solenoid valve - stick floating function (FSA only)

[61K635] Solenoid valve - boom floating function (FSA only)

Hydraulic components:

(9) Main control block I

(10) Main control block II

(11) Main control block III

(37.1) High pressure filter, main pump I

(37.2) High pressure filter, main pump II

(37.3) High pressure filter, main pump III

(132.1) Pilot controlled floating spool valve - stick (FSA only)

(132.2) Pilot controlled floating spool valve - stick (FSA only)

(132.3) Pilot controlled floating spool valve - boom (FSA only)

REMARKS: For switching points and switching conditions of the sensors and switches refer to chapter 4, "Stan-
dard Value Table for Electrical Components".

SHOP-40 06279-xD-GB-1 PC3000-6 3 - 15

Component location Mounting Locations and Connector Types

3.1.8 LUBRICATION SYSTEM - LOCATION OF ELECTRICAL

COMPONENTS

Fig. 3-8 Lubrication system - location of electrical components

3 - 16 PC3000-6 SHOP-40 06279-xD-GB-1

Mounting Locations and Connector Types Component location

Legend for Fig. 3-8:

[62Q507] Solenoid valve, grease pump - Central Lubrication System (CLS)

[62Q507a] Solenoid valve, lubrication pressure release (vent valve) - CLS

[62Q509] Solenoid valve, grease pump - Slew ring Lubrication System (SLS)

[62Q509a] Solenoid valve, lubrication pressure release (vent valve) - SLS

[62B046] End line pressure switch (SLS)

[62B108a] Grease barrel level sensor - full (CLS)

[62B108b] Grease barrel level sensor - pre-warning (CLS)

[62B108c] Grease barrel level sensor - empty (CLS)

[62B109a] Grease barrel level sensor - full (SLS)

[62B109b] Grease barrel level sensor - pre-warning (SLS)

[62B109c] Grease barrel level sensor - empty (SLS)

[80B043] End line pressure switch (CLS)

SHOP-40 06279-xD-GB-1 PC3000-6 3 - 17

Component location Mounting Locations and Connector Types

3.1.9 CAB BASE - LOCATION OF ELECTRICAL COMPONENTS

Fig. 3-9 Cab base - location of electrical components

3 - 18 PC3000-6 SHOP-40 06279-xD-GB-1

Mounting Locations and Connector Types Component location

Legend for Fig. 3-9:

(1) X2 switch board

(2) KOMTRAX switch box

[10K032] Electronic pump controller CR710

[11P046] KONTRAX Plus display MH801 in cab base (Multimonitor)

[14T058] ORBCOMM controller

[14K300] KOMTRAX Plus controller

SHOP-40 06279-xD-GB-1 PC3000-6 3 - 19

Component location Mounting Locations and Connector Types

3.1.10 HYDRAULIC OIL TANK - LOCATION OF ELECTRICAL

COMPONENTS

Fig. 3-10 Hydraulic Oil Tank - Location of electrical components

3 - 20 PC3000-6 SHOP-40 06279-xD-GB-1

Mounting Locations and Connector Types Component location

Legend for Fig. 3-10:

[40B004] Hydraulic oil level sensor (low level indication)

[40B024] Oil reservoir breather filter clogging switch

[40B025] Pressure switch, leak oil filter monitoring

[40B026] Pressure switch, return oil filter monitoring

[40B031] Proximity switch for shutoff gate valve

[40B040] Temperature sensor, hydraulic oil cooler fan low speed

[40B042] Oil level switch, refilling system maximum filling

[40B050] Hydraulic oil level sensor (refill level indication)

[40B075] Temperature sensor, low hydraulic oil temperature (½ Qmax and back pressure reduction)

[40B165] Pressure switch oil cooler strainer clogged

[40B171] Temperature sensor, hydraulic oil cooler fan medium speed

[40K601] Solenoid valve, Oil cooler preload pressure (controlled by converter relay 11K100)

REMARKS: For switching points and switching conditions of the sensors and switches refer to chapter 4, "Stan-
dard Value Table for Electrical Components".

SHOP-40 06279-xD-GB-1 PC3000-6 3 - 21

Component location Mounting Locations and Connector Types

3.1.11 HYDRAULICALLY OPERATED ACCESS LADDER - LOCATION OF

ELECTRICAL COMPONENTS

Fig. 3-11 Hydraulically operated access ladder

[70B091] Ladder limit switch - DOWN-position

[70B122] Ladder limit switch - UP-position

[20S084] Ladder switch (up/down), operator’s cab

[70S018] Light switch, ladder

[70S073] Ladder switch, up/down

[70S073b] Ladder switch, up/down - 2nd hand

[70S084a] Ladder pull switch

REMARKS: For switching points and switching conditions of the sensors and switches refer to chapter 4, "Stan-
dard Value Table for Electrical Components".

3 - 22 PC3000-6 SHOP-40 06279-xD-GB-1

Mounting Locations and Connector Types Component location

3.1.12 REFILLING ARM - LOCATION OF ELECTRICAL COMPONENTS

Fig. 3-12 Refilling arm - location of electrical components

[55B023] Refilling arm limit switch - up

[55S087] Refilling arm pull switch

REMARKS: For switching points and switching conditions of the sensors and switches refer to chapter 4, "Stan-
dard Value Table for Electrical Components".

SHOP-40 06279-xD-GB-1 PC3000-6 3 - 23

Component location Mounting Locations and Connector Types

3.1.13 AIR FILTER AND FUEL TANK - LOCATION OF ELECTRICAL

COMPONENTS

Fig. 3-13 Air filter and fuel tank - location of electrical components

3 - 24 PC3000-6 SHOP-40 06279-xD-GB-1

Mounting Locations and Connector Types Component location

Legend for Fig. 3-13:

(1) Air filter assembly

(2) Fuel tank

(3) Fuel shut-off cock

[31B063] Pressure transducer for fuel level indication

[31Q599] Fuel shut off solenoid valve

[52B018] Pressure switch, engine air filter pressure bank 1

[52B019] Pressure switch, engine air filter pressure bank 2

REMARKS: For switching points and switching conditions of the sensors and switches refer to chapter 4, "Stan-
dard Value Table for Electrical Components".

SHOP-40 06279-xD-GB-1 PC3000-6 3 - 25

Connector Types Overview Mounting Locations and Connector Types

3.2 CONNECTOR TYPES OVERVIEW

Terminology declaration

The terms male & female refer to the connector pins & sockets, while the terms male housing & female housing
refer to the mating portion of the connector housing parts.

Male (female housing) Female (male housing)

2 pins DT04-2P (Deutsch) 2 sockets DT06-2S (Deutsch)

3 pins DT04-3P (Deutsch) 3 sockets DT06-3S (Deutsch)

4 pins DT04-6P (Deutsch) 4 sockets DT06-6S (Deutsch)

3 - 26 PC3000-6 SHOP-40 06279-xD-GB-1

Mounting Locations and Connector Types Connector Types Overview

31-pole connector with aluminium housing 21-pole connector with plastic housing

Grease barrel connector CAN bus connector

Deutsch connectors HD 34/36-18-8-S… Deutsch connectors HD 34/36-18-14-S…

Picture shows socket rear insert.

Picture shows socket rear insert.

SHOP-40 06279-xD-GB-1 PC3000-6 3 - 27

Connector Types Overview Mounting Locations and Connector Types

Deutsch connectors HD 34/36-24-14-S… Deutsch connectors HD 34/36-24-9-S…

Picture shows socket rear insert. Picture shows socket rear insert.

Deutsch connectors HD 34/36-24-21-S… Deutsch connectors HD 34/36-24-16-S…

Picture shows socket rear insert. Picture shows socket rear insert.

Deutsch connectors HD 34/36-24-31-S… Deutsch connectors HD 34/36-24-23-S…

Picture shows socket rear insert. Picture shows socket rear insert.

Deutsch connectors HD 34/36-24-91-S…

Picture shows socket rear insert.

3 - 28 PC3000-6 SHOP-40 06279-xD-GB-1

Standard Value Table for Electrical Components

4 STANDARD VALUE TABLE

FOR ELECTRICAL
COMPONENTS

SHOP-40 06279-xD-GB-1 PC3000-6 4 -1

 Standard Value Table for Electrical Components

Used abbreviations

Eng Engine

N.C. Normally Closed

N.O. Normally Open

20S001 Main key switch 20S001

Part 10 SHOP MANUAL part "10 Structure & function"

Deutsch T-box Electrical test box for Deutsch connectors

CAN T-box Electrical test box for the CAN bus

TIER 2 Engine Emission Standard

Component

Component

Inspection
method
System

name

Measurement
code

Judgement table
conditions

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Measure

All relays with 7 A max table below, it is normal.

switching current
Between (A1) - (A2) 557 ± 1.0Ω
Relais

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Measure

All relays with 10 A max. table below, it is normal.

switching current
Between (A1) - (A2) 443 ± 1.0Ω

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Measure

Fuel tank shut table below, it is normal 2. Disconnect con-

off solenoid 31Q599
nector
valve Between (1) - (2) 8.0 ± 2.0Ω
3. Insert T-box
1. 20S001 OFF
If the condition is within the range shown in the 2. Disconnect con-
resistance
Measure

Engine speed table below, it is normal. nector

52B064
sensor 3. Insert T-box
Between (1) - (2) 850 ± 50Ω
Engine related parts

4. Pick up adjust-
ment: Refer to SM

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Measure

Engine cold table below, it is normal.

50Q502a 2. Disconnect con-
start aid sole-
50Q502b nector
noid valve Between (1) - (2) 38 ± 3Ω
3. Insert T-box
1. 20S001 OFF
If the condition is within the range shown in the
2. Disconnect con-
table below, it is normal.
Measure voltage

nector
Engine air Switch point: Over 50 mbar suction pressure
cleaner clog- 52B018 3. Insert T-box
ging switch 52B019 Between (1) - (2) 0V 4. 20S001 ON
[N.O. type]
5. Engine high idle

Between (1) - (2) 22 - 24V 6. Filters: clogged

4 -2 PC3000-6 SHOP-40 06279-xD-GB-1

Standard Value Table for Electrical Components

Component

Component

Inspection
method
System

name
Measurement

code
Judgement table
conditions

1. 20S001 OFF
If the condition is within the range shown in the
2. Disconnect con-
table below, it is normal.

Measure voltage
nector
Engine oil pres- Switch point: 0,17 bar
sure switch low 3. Insert T-box
52B093
idle Between (1) - (2) 22 - 24V 4. 20S001 ON
[N.O. type]
5. Engine low idle

Between (1) - (2) 0V 6. Shutdown

52B243-1 If the condition is within the range shown in the 1. 20S001 OFF
52B243-2 table below, it is normal.
2. Disconnect con-
Engine related parts

52B243-3
Between (A) - (B) Refer to PT100 nector
52B243-4
Engine cylin- 52B243-5 temperature charts 3. Insert T-box
resistance
Measure

der tempera- 52B243-6

ture sensor 52B244-1
(PT100 type) 52B244-2
52B244-3
52B244-4
52B244-5
52B244-6
If the condition is within the range shown in the 1. Start engine
table below, it is normal.
2. Engine high idle
Alternator
When the engine is running (high idle)
Measure

→ between
voltage

52G005 27.5 - 29.5 V

alternator ter-
minal D+ and
Remark:
chassis
If the battery is cold, or after starting in cold
areas, the voltage may not increase for a time.

56K658f 1. 20S001 OFF

Pump regulation

56K658r If the condition is within the range shown in the 2. Disconnect con-
resistance

EPC valve
Measure

56K659f table below, it is normal. nector

(pump angle 56K659r
solenoid valve) Between (1) - (2) 9.7 ± 0.5Ω 3. Insert T-box
56K660f
56K660r

SHOP-40 06279-xD-GB-1 PC3000-6 4 -3

 Standard Value Table for Electrical Components

Component

Component

Inspection
method
System

name
Measurement

code
Judgement table
conditions

1. 20S001 OFF
If the condition is within the range shown in the 2. Disconnect con-
table below, it is normal.
nector
Switch point: 0.5 bar
3. Insert T-box
PTO gear oil Measure
voltage
Between (1) - (2) 0V 4. 20S001 ON
pressure switch 57B017
[N.C. type] 5. Engine OFF
6. Engine high idle
7. When filter clogged
Between (1) - (2) 22 - 24V
differential pres-
sure >0.5 bar
1. 20S001 OFF
If the condition is within the range shown in the 2. Disconnect con-
table below, it is normal. nector
Measure
voltage

Switch point: 5 bar 3. Insert T-box

PTO gear oil fil-
PTO & related parts

4. Engine high idle

ter clogging Between (1) - (2) 0V
57B027 5. From switch point
switch
[N.O. type] 5 bar
1. 20S001 OFF
resistance
Measure

2. Disconnect con-
Between (1) - (2) min. 1MΩ
nector
3. Insert T-box
If the condition is within the range shown in the 1. 20S001 OFF
resistance

table below, it is normal.

Measure

PTO gear oil 2. Disconnect con-

temperature 57B049 nector
sensor Between (1) - (2) Refer to PT100
temperature charts 3. Insert T-box

PTO gear oil If the condition is within the range shown in the 1. 20S001 OFF
resistance

table below, it is normal.

Measure

temperature 2. Disconnect con-

sensor - pres- 57B182 nector
sure relief of oil Between (1) - (2) Refer to PT100
cooler temperature charts 3. Insert T-box

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Measure

PTO preload table below, it is normal. 2. Disconnect con-

pressure sole- 57K553
nector
noid valve Between (1) - (2) 23 ± 1.0Ω
3. Insert T-box

4 -4 PC3000-6 SHOP-40 06279-xD-GB-1

Standard Value Table for Electrical Components

Component

Component

Inspection
method
System

name
Measurement

code
Judgement table
conditions

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Refilling arm

Measure
table below, it is normal. 2. Disconnect con-
solenoid valve 57Q624a
nector
→ up Between (1) - (2) 20 ± 1.0Ω
3. Insert T-box

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Refilling arm
Measure
table below, it is normal. 2. Disconnect con-
solenoid valve 57Q624b
nector
→ down Between (1) - (2) 20 ± 1.0Ω
3. Insert T-box
1. 20S001 OFF
Refilling arm

If the condition is within the range shown in the

resistance

Refilling arm
Measure

table below, it is normal. 2. Disconnect con-

solenoid valve, 57Q624c
nector
speed control Between (1) - (2) 35 ± 1.0Ω
3. Insert T-box
1. 120S001 OFF
Refilling arm If the condition is within the range shown in the 2. Disconnect con-
table below, it is normal.
Measure voltage

limit switch nector

[N.O. type]
Between (A) - (B) 22 - 24V 3. Insert T-box
→ arm in down
55B023 Between (A) - (C) 0V
position 4. 20S001 ON
5. Engine OFF

→ arm in up 1. Start engine

Between (A) - (C) 22 - 24V
position 2. Engine high idle
1. 20S001 OFF
If the condition is within the range shown in the 2. Disconnect con-
table below, it is normal. nector
Up:
Measure

Ladder limit 3. Insert T-box

voltage

70B122 Between (A) - (B) 22 - 24V

switch Between (A) - (C) 0V
Down: 4. 20S001 ON
[N.O. type]
70B091 5. Engine OFF
1. Start engine
Between (A) - (C) 22 - 24V
2. Engine high idle

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Measure

Ladder
Ladder

table below, it is normal. 2. Disconnect con-

solenoid valve 57Q623b
nector
→ down Between (1) - (2) 20 ± 1.0Ω
3. Insert T-box

If the condition is within the range shown in the 1. 20S001 OFF

Ladder
resistance
Measure

solenoid valve, table below, it is normal. 2. Disconnect con-

57Q625
speed control nector
→ fast Between (1) - (2) 35 ± 1.0Ω
3. Insert T-box

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Measure

Ladder table below, it is normal. 2. Disconnect con-

solenoid valve 57Q623a
nector
→ up Between (1) - (2) 20 ± 1.0Ω
3. Insert T-box

SHOP-40 06279-xD-GB-1 PC3000-6 4 -5

 Standard Value Table for Electrical Components

Component

Component

Inspection
method
System

name
Measurement

code
Judgement table
conditions

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Measure
Slew parking table below, it is normal. 2. Disconnect con-
brake solenoid 57Q505
nector
valve Between (1) - (2) 20 ± 1.0Ω
3. Insert T-box

If the condition is within the range shown in the 1. 20S001 OFF

Slew shut-off resistance
Measure
table below, it is normal. 2. Disconnect con-
solenoid valve 57Q620
nector
Slew system

(emergency) Between (1) - (2) 35 ± 1.0Ω

3. Insert T-box

If the condition is within the range shown in the 1. 20S001 OFF

table below, it is normal. 2. Disconnect con-
Measure voltage

Pressure Switch point: 7 bar nector

switch motion
3. Insert T-box
detection slew- 10B047 Between (1) - (2) 0V
ing 4. 20S001 ON
[N.O. type] 5. Engine high idle
Between (1) - (2) 22 - 24V 6. When slewing
pressure >7 bar

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Measure

Travel parking table below, it is normal. 2. Disconnect con-

brake solenoid 57Q516
nector
valve Between (1) - (2) 20 ± 1.0Ω
3. Insert T-box
Travel System

If the condition is within the range shown in the 1. 20S001 OFF

table below, it is normal. 2. Disconnect con-
Measure voltage

Pressure Switch point: 7 bar nector

switch motion
3. Insert T-box
detection trav- 10B037 Between (1) - (2) 0V
elling 4. 20S001 ON
[N.O. type] 5. Engine high idle
Between (1) - (2) 22 - 24V 6. When travelling
pressure >7 bar

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Measure

Oil cooler pre- table below, it is normal. 2. Disconnect con-

load pressure 40K601
nector
solenoid valve Between (1) - (2) 20 ± 1.0Ω
3. Insert T-box

Hydraulic brake If the condition is within the range shown in the 1. 20S001 OFF
resistance
Measure

(shut-off) table below, it is normal. 2. Disconnect con-

Hydraulic system

solenoid valve 10Q515

nector
Between (1) - (2) 20 ± 1.0Ω
(emergency) 3. Insert T-box

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Measure

Oil cooler fan 57K605a table below, it is normal. 2. Disconnect con-

drive solenoid
57K605b nector
valve Between (1) - (2) 22 ± 1.0Ω
3. Insert T-box
1. 20S001 OFF
If the condition is within the range shown in the
resistance
Measure

FS Bucket
table below, it is normal. 2. Disconnect con-
shut-off 10K040
nector
solenoid valve Between (1) - (2) 20 ± 1.0Ω
3. Insert T-box

4 -6 PC3000-6 SHOP-40 06279-xD-GB-1

Standard Value Table for Electrical Components

Component

Component

Inspection
method
System

name
Measurement

code
Judgement table
conditions

10K511 If the condition is within the range shown in the 1. 20S001 OFF

resistance
Measure
Pilot control table below, it is normal.
10K511a 2. Disconnect con-
cut-off solenoid
10K511b nector
valve Between (1) - (2) 20 ± 1.0Ω
10K511c 3. Insert T-box

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Measure
Pilot control 10K611d table below, it is normal. 2. Disconnect con-
release sole-
10K611e nector
noid valve Between (1) - (2) 20 ± 1.0Ω
3. Insert T-box

Hydraulic oil 1. 20S001 OFF

If the condition is within the range shown in the
level sensor table below, it is normal. 2. Disconnect con-
(level: low) nector
Between (A) - (B) 22 - 24V
Measure voltage

[N.O. type] 3. Insert T-box

Between (A) - (C) 22 - 24V
→ with oil 4. 20S001 ON
40B004
1. 20S001 OFF
2. Disconnect con-
→ without oil Between (A) - (B) 22 - 24V nector
Between (A) - (C) 0V
3. Insert T-box
4. 20S001 ON
Hydraulic system

Hydraulic oil 1. 20S001 OFF

If the condition is within the range shown in the
level sensor table below, it is normal. 2. Disconnect con-
(level: refill) nector
Between (A) - (B) 22 - 24V
Measure voltage

[N.O. type] 3. Insert T-box

Between (A) - (C) 22 - 24V
→ with oil 4. 20S001 ON
40B050
1. 20S001 OFF
2. Disconnect con-
Between (A) - (B) 22 - 24V nector
→ without oil
Between (A) - (C) 0V
3. Insert T-box
4. 20S001 ON
1. 20S001 OFF
If the condition is within the range shown in the 2. Disconnect con-
table below, it is normal.
Measure voltage

nector
Oil reservoir
Switch point: 80 mbar
breather filter 3. Insert T-box
clogging switch 40B024
Between (1) - (2) 0V 4. 20S001 ON
[N.O. type]
5. Engine high idle

Between (1) - (2) 22 - 24V 6. Filters: clogged

If the condition is within the range shown in the 1. 20S001 OFF

resistance

Hydr. oil tem- table below, it is normal.

Measure

2. Disconnect con-
perature sensor 59B015
Between (1) - (2) Refer to PT100 nector
(PT100 type)
temperature charts 3. Insert T-box

SHOP-40 06279-xD-GB-1 PC3000-6 4 -7

 Standard Value Table for Electrical Components

Component

Component

Inspection
method
System

name
Measurement

code
Judgement table
conditions

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Hydr. oil tem- table below, it is normal.

Measure
2. Disconnect con-
perature sensor 59B032-1
Between (1) - (2) Refer to PT100 nector
(PT100 type)
temperature charts 3. Insert T-box

1. 20S001 OFF
If the condition is within the range shown in the 2. Disconnect con-
table below, it is normal.
Measure voltage

nector
Pressure
Switch point: 0.5 bar
switch, leak oil 3. Insert T-box
filter monitoring 40B025
Between (1) - (2) 0V 4. 20S001 ON
[N.O. type]
5. Engine high idle
6. Filters: clogged
Between (1) - (2) 22 - 24V

1. 20S001 OFF
If the condition is within the range shown in the 2. Disconnect con-
table below, it is normal. nector
Measure voltage

Hydr. oil tank

shut off gate Between (A) - (B) 22 - 24V 3. Insert T-box
valve 40B031 Between (A) - (C) 0V 4. 20S001 ON
(proximity
5. Main gate closed
switch)
Hydraulic system

Between (A) - (B) 22 - 24V 6. Main gate open

Between (A) - (C) 22 - 24V

61K632 If the condition is within the range shown in the 1. 20S001 OFF
resistance
Measure

Floating sole- Stick table below, it is normal. 2. Disconnect con-

noid valve 61K632 nector
Between (1) - (2) 20 ± 1.0Ω
Boom 3. Insert T-box

If the condition is within the range shown in the 1. 20S001 OFF

table below, it is normal. 2. Disconnect con-
Measure voltage

Range: 0 - 50 bar nector

X2 pressure
3. Insert T-box
transducer 57B086 Between (A) - (C) 22 - 24V
4. 20S001 ON
(analog)
5. Engine high idle
Between (B) - (C) 0.5 - 9.5V 6. Max. pressure
50 bar

If the condition is within the range shown in the 1. 20S001 OFF

table below, it is normal. 2. Disconnect con-
Switch point: 2 bar nector
Measure voltage

Pressure
switch, return 3. Insert T-box
Between (1) - (2) 0V
oil filter moni- 40B026 4. 20S001 ON
toring
5. Engine high idle
[N.O. type]
Between (1) - (2) 22 - 24V 6. When filter clogged
differential pres-
sure >2 bar

4 -8 PC3000-6 SHOP-40 06279-xD-GB-1

Standard Value Table for Electrical Components

Component

Component

Inspection
method
System

name
Measurement

code
Judgement table
conditions

Temperature If the condition is within the range shown in the 1. 20S001 OFF

resistance
sensor, hydrau- table below, it is normal.

Measure
2. Disconnect con-
lic oil cooler fan 40B040
Between (1) - (2) Refer to PT100 nector
low speed
temperature charts 3. Insert T-box
(PT100 type)
Temperature If the condition is within the range shown in the 1. 20S001 OFF

resistance
sensor low Measure table below, it is normal.
2. Disconnect con-
hydraulic oil 40B075
Between (1) - (2) Refer to PT100 nector
temperature
temperature charts 3. Insert T-box
(PT100 type)

If the condition is within the range shown in the 1. 20S001 OFF

table below, it is normal. 2. Disconnect con-
Measure voltage

Pressure Switch point: 8.5 bar nector

switch pres-
3. Insert T-box
sure cut-off, 10B155 Between (1) - (2) 0V
clam closing 4. 20S001 ON
[N.O. type] 5. Engine high idle
Between (1) - (2) 22 - 24V 6. pressure cut off
pressure >8.5 bar

If the condition is within the range shown in the 1. 20S001 OFF

Hydraulic system

table below, it is normal. 2. Disconnect con-

Pressure
Measure voltage

Switch point: 22 bar nector

switch monitor-
ing pressure 3. Insert T-box
cut-off, clam 10BB156 Between (1) - (2) 0V
4. 20S001 ON
closing
5. Engine high idle
[N.O. type]
Between (1) - (2) 22 - 24V 6. Fault message
pressure >22 bar
1. 20S001 OFF
If the condition is within the range shown in the
table below, it is normal. 2. Disconnect con-
Measure voltage

Pressure trans-
ducer, pump nector
61B158a Between (A) - (B) 5V
pressure main 61B158b 3. Insert T-box
Between (A) - (C) 0.4 - 0.5V
pump 61B158c 4. 20S001 ON
(analog)
Between (A) - (C) 0.5 - 4.5V 5. Engine high idle

If the condition is within the range shown in the 1. 20S001 OFF

table below, it is normal. 2. Disconnect con-
Switch point: 2 bar nector
Measure voltage

Pressure
switch oil 3. Insert T-box
Between (1) - (2) 0V
cooler strainer 40B165 4. 20S001 ON
clogged
5. Engine high idle
[N.O. type]
Between (1) - (2) 22 - 24V 6. When filter clogged
differential pres-
sure >2 bar

SHOP-40 06279-xD-GB-1 PC3000-6 4 -9

 Standard Value Table for Electrical Components

Component

Component

Inspection
method
System

name
Measurement

code
Judgement table
conditions

If the condition is within the range shown in the 1. 20S001 OFF

table below, it is normal. 2. Disconnect con-
Switch point: 180 bar nector

Measure voltage
End line switch 3. Insert T-box
Between (1) - (2) 22 - 24V
grease pres- 80B043 4. 20S001 ON
sure 62B046 5. Engine high idle
[N.C. type]
6. Grease pump
Between (1) - (2) 0V running
7. Grease pressure
180 bar available
If the condition is within the range shown in the 1. 20S001 OFF
resistance
Measure

Grease pump 62Q507 table below, it is normal. 2. Disconnect con-

solenoid valve 62Q509 nector
Between (1) - (2) 22 ± 1.0Ω
3. Insert T-box
Lubrication systems

If the condition is within the range shown in the 1. 20S001 OFF

Lubrication line
resistance
Measure

release sole- 62Q507a table below, it is normal. 2. Disconnect con-

noid valve 62Q509a nector
Between (1) - (2) 22 ± 1.0Ω
(Vent valve)
3. Insert T-box
1. 20S001 OFF
If the condition is within the range shown in the
table below, it is normal. 2. Disconnect con-
CLS nector
62B108a At connector 62X_120
3. Insert T-box
62B108b 62B108a pin B & GND 22 - 24V→ with grease
62B108c 4. 20S001 ON
62B108b pin E & GND 0V → no grease
Measure voltage

62B108c pin J & GND 5. Measure sensor

Grease barrel
output
level sensor
1. 20S001 OFF
(Binary type) If the condition is within the range shown in the
table below, it is normal. 2. Disconnect con-
SLS nector
62B109a At connector 62X_130
3. Insert T-box
62B109b 62B109a pin B & GND 22 - 24V→ with grease
62B109c 4. 20S001 ON
62B109b pin E & GND 0V → no grease
62B109c pin J & GND 5. Measure sensor
output
1. 20S001 OFF
Measure voltage

If the condition is within the range shown in the 2. Disconnect con-

Magnetic clutch table below, it is normal. nector
52Q004
compressor 3. Insert T-box
Between (1) - (2) 22 - 24V
Air conditioning

4. 20S001 ON
5. Switch ON A/C
1. 20S001 OFF
Measure voltage

If the condition is within the range shown in the 2. Disconnect con-

Heater mixing table below, it is normal. nector
20Q097
valve 3. Insert T-box
Between (1) - (2) 22 - 24V
4. 20S001 ON
5. Switch ON heater

4 - 10 PC3000-6 SHOP-40 06279-xD-GB-1

Standard Value Table for Electrical Components

Component

Component

Inspection
method
System

name
Measurement

code
Judgement table
conditions

If the condition is within the range shown in the 1. 20S001 OFF

table below, it is normal. 2. Disconnect con-

Measure voltage
Range: 0 - 0.4 bar nector
Pressure trans-
Fuel tank

ducer for fuel 3. Insert T-box

level indication 57B086 Between (A) - (C) 22 - 24V
4. 20S001 ON
(analog)
5. Engine high idle
Between (B) - (C) 0.5 - 9.5V 6. Max. pressure
0.4 bar

If the condition is within the range shown in the 1. 20S001 OFF

resistance
Measure

CAN bus 14R101 table below, it is normal. 2. Disconnect CAN-

CAN

resistor 20R100 connector

Between (A) - (B) 120Ω
3. Insert T-box

SHOP-40 06279-xD-GB-1 PC3000-6 4 - 11

 Standard Value Table for Electrical Components

Please continue reading on the next page.

4 - 12 PC3000-6 SHOP-40 06279-xD-GB-1

References for Troubleshooting

5 REFERENCES FOR
TROUBLESHOOTING

SHOP-40 06279-xD-GB-1 PC3000-6 5 -1

7-segment error code indication References for Troubleshooting

5.1 7-SEGMENT ERROR CODE INDICATION

(1) KOMTRAX Plus controller

(2) 7-segment LED display

(3) 7-segment digit

If certain errors occur on the machine, the trouble messages are

not only displayed on the K+ monitor - special fault codes are also
displayed via 7-segment LED at the K+ controller.

The 7-segment fault code exists of the letter M and 3 figures.

Example:

M901 for message KOMTRAX Plus source voltage Error

Fig. 5-1 7-segment display

As the 7-segment system can not display letter "M" it displays

letter "n" instead.

The 7-segment system can display 2 figures only.

Therefore the 4-digit fault code is split.
For example M901 is displayed as "n9" and "01" alternately.

The alternating indication of the split fault code is repeated,

as long as the error exists.

Fig. 5-1 7-segment fault code M901

5 -2 PC3000-6 SHOP-40 06279-xD-GB-1

References for Troubleshooting 7-segment error code indication

Please continue reading on the next page.

SHOP-40 06279-xD-GB-1 PC3000-6 5 -3

Relay checks References for Troubleshooting

5.2 RELAY CHECKS

For the entire controlling of electrical functions, basically two types of relays are used: 7A and 10A switching cur-
rent types.

Fig. 5-2 Relay types and terminal layouts

(1) Test button (3) Power LED

(2) Test indicator (optional) (4) Contact switch indicators (optional)

5.2.1 SWITCH CONTACT TESTING USING THE TEST BUTTON

With main key switch 20S001 OFF the test button (Fig. 5-3, Pos. 1) can be used in two ways:

– The plastic pip (located directly above the test button) remains intact.
In this case, when the test button is pushed, the contacts operate.
When the test button is released the contacts return to their former state.
– The plastic pip is broken-off (using an appropriate cutting tool).
In this case, (in addition to the above function), when the test button is pushed and rotated, the contacts are
latched in the operating state, and remain so until the test button is rotated back to its former position.
In both cases ensure that the test button actuation is swift and decisive.

5 -4 PC3000-6 SHOP-40 06279-xD-GB-1

References for Troubleshooting Relay checks

Testing procedure (example 7A relay)

1. Switch main key switch 20S001 OFF.

2. Check the continuity between terminals of the switching contacts using a multimeter.

– Between terminals 9 and 1 => continuity if relay is OK.

– Between terminals 9 and 5 => no continuity if relay is OK.
3. Actuate the test button (Fig. 5-3, Pos. 1) and measure again.

– Between terminals 9 and 1 => no continuity if relay is OK.

– Between terminals 9 and 5 => continuity if relay is OK.

The relay is OK if all measurements meet the specifications:

7A relays
Test button Measure between Value when OK Test button Measure between Value when OK
1 (12) Continuity 1 (12) No continuity
9 (11) 9 (11)
5 (14) No continuity 5 (14) Continuity
2 (22) Continuity 2 (22) No continuity
10 (21) 10 (21)
6 (24 No continuity 6 (24 Continuity
Not actuated Actuated
3 (32) Continuity 3 (32) No continuity
11 (31) 11 (31)
7 (34) No continuity 7 (34) Continuity
4 (42) Continuity 4 (42) No continuity
12 (41) 12 (41)
8 (44) No continuity 8 (44) Continuity

10A relays
Test button Measure between Value when OK Test button Measure between Value when OK
12 (4) Continuity 12 (4) No continuity
11 (1) 11 (1)
14 (3) No continuity 14 (3) Continuity
22 (5) Continuity 22 (5) No continuity
Not actuated 21 (6) Actuated 21 (6)
24 (7) No continuity 24 (7) Continuity
32 (8) Continuity 32 (8) No continuity
31 (11) 31 (11)
34 (9) No continuity 34 (9) Continuity

SHOP-40 06279-xD-GB-1 PC3000-6 5 -5

Relay checks References for Troubleshooting

5.2.2 MEASURING OF THE COIL RESISTANCE

A free-wheeling diode is installed for protection against overvoltage when switching off the relay.
The free-wheeling diode has the task of preventing the voltage build-up when switching off the coil.

Measuring procedure

1. Switch main key switch 20S001 OFF.

2. Measure the coil resistance between terminals A1 and A2. using a
multimeter.
If the relay is OK the following resistances should be measured:

– 557 ± 1.0Ω for relays with 7A max. switching current

– 443 ± 1.0Ω for relays with 10A max. switching current
REMARKS: When measuring the wrong direction (between A2
and A1) the measured resistance will be approx. 0Ω
due to the free-wheeling diode (Fig. 5-3, Pos. 1).

Fig. 5-3
NOTICE
Relays with defective free-wheeling diodes are not limited in
their function as switches and are still working without prob-
lems as long as the diode does not have an internal short cir-
cuit, but due to the absence of the "surge protector"
electronic components (pump controller, K+ controller) in the
circuit may take damage.

3. Check the proper function of the free-wheeling diode using the multimeter in diode testing mode:
– Between terminals A1 and A2 => no continuity if diode is OK.
– Between terminals A2 and A1 => continuity if diode is OK.

The relay is OK if all measurements meet the specifications:

Test Point Measuring type Measure between Value when OK

– 557 ± 1.0Ω (7A relay)
A1 A2
Relay coil Resistance – 443 ± 1.0Ω (10A relay)
A2 A1 approx. 0Ω

Free-wheeling A1 A2 No continuity
Diode testing
diode A2 A1 Continuity

Table 5-1 Relay testing/specifications

5 -6 PC3000-6 SHOP-40 06279-xD-GB-1

References for Troubleshooting Relay checks

7A relays:

11K003a 11K005 11K011 11K011a 11K030 11K037 11K038 11K045

11K050 11K051 11K057 11K064 11K064a 11K073 11K079 11K100a

11K134 11K136 11K138 11K144 11K145 11K146 11K191 11K276a

11Q132 11Q147 11Q148 11Q192 11Q048 11Q167 11Q193 11Q194

11Q194a 11Q197 11Q197a 11Q198 11Q198a

10A relays:

11K003b 11K026a 11K111 11K276 11Q166

SHOP-40 06279-xD-GB-1 PC3000-6 5 -7

Relay checks References for Troubleshooting

Please continue reading on the next page.

5 -8 PC3000-6 SHOP-40 06279-xD-GB-1

Tables for Testing and Troubleshooting

6 TABLES FOR TESTING

AND TROUBLESHOOTING

SHOP-40 06279-xD-GB-1 PC3000-6 6 -1

PT100 TEMPERATURE CHARTS (PT100)  Centigrade - Ohm Tables for Testing and Troubleshooting

6.1 PT100 TEMPERATURE CHARTS

(PT100)  CENTIGRADE - OHM
Basic resistance values (Ohm) for measuring the resistance of PT100 sensors in relation to temperature
(degree centigrade)

Resistance values according to ISO 4376

Fig. 6-4 PT100 Temperature Charts (degree centigrade - resistance)

6 -2 PC3000-6 SHOP-40 06279-xD-GB-1

Tables for Testing and Troubleshooting Test Value Table for pressure Sensors

6.2 TEST VALUE TABLE FOR PRESSURE SENSORS

6.2.1 TRANSDUCERS WITH OUTPUT VOLTAGE RANGE: 0.5....4.5 VOLT

Pressure range: 0bar...500bar

bar Volt bar Volt bar Volt bar Volt

0 0.5 150 1.70 300 2.90 450 4.1

10 0.58 160 1.78 310 2.98 460 4.18

20 0.66 170 1.86 320 3.06 470 4.26

30 0.74 180 1.94 330 3.14 480 4.34

40 0.82 190 2.02 340 3.22 490 4.42

50 0.90 200 2.10 350 3.30 500 4.50

60 0.98 210 2.18 360 3.38

70 1.06 220 2.26 370 3.46

80 1.14 230 2.34 380 3.54

90 1.22 240 2.42 390 3.62

100 1.30 250 2.50 400 3.70

110 1.38 260 2.58 410 3.78

120 1.46 270 2.66 420 3.86

130 1.54 280 2.74 430 3.94

140 1.62 290 2.82 440 4.02

6.2.2 TRANSDUCERS WITH OUTPUT VOLTAGE RANGE: 0.5....9.5 VOLT

Pressure range: 0bar...50bar

bar 0 1 2 3 4 5 6 7 8 9

0 0.50 0.19 0.38 0.57 0.76 0.95 1.14 1.33 1.52 1.71

10 1.90 2.09 2.28 2.47 2.66 2.85 3.04 3.23 3.42 3.61

20 3.80 3.99 4.18 4.37 4.56 4.75 4.94 5.13 5.32 5.51

30 5.70 5.89 6.08 6.27 6.46 6.65 6.84 7.03 7.22 7.41

40 7.60 7.79 7.98 8.17 8.36 8.55 8.74 8.93 9.12 9.31

50 9.5 - - - - - - - - -

Pressure range: 0bar...0.4bar

bar 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4

Volt 0.5 1.1875 2.375 3.5925 4.75 5.9375 7.125 8.3125 9.5

SHOP-40 06279-xD-GB-1 PC3000-6 6 -3

Trouble Code Tables Tables for Testing and Troubleshooting

6.3 TROUBLE CODE TABLES

6.3.1 TABLE OF CUMMINS TROUBLE CODES (TIER 2)

Explanation of the columns in the following Trouble Code chart

Column 1 Trouble Code C-Code number

1 = displayed once
Column 2 Display
2 = displayed at each occurrence

Column 3 Acoustic Signal 1 = an acoustic signal sounds if the relating trouble occurs

Colour Code of 0 = Red

Column 4
Top Message 1 = Yellow

Instruction Number of the Instruction Message, which is displayed together with

Column 5
Message No. the Trouble Code (numbers 1 - 58)

Column 6 Message Displayed text of the Trouble Code

Table of C-Codes:
Acoustic Signal

Message No.
Instruction
Display

Trouble
Color

Message
Code

CA115 1 1 0 34 Engine Speed Signal Lost

CB115 1 1 0 34 Engine Speed Signal Lost
CA135 Oil Press Ckt Failed High
CA141 Oil Press Ckt Failed Low
CA144 2 1 1 20 Coolant Temp Ckt Failed High
CA145 2 1 1 20 Coolant Temp Ckt Failed Low
CA146 1 1 1 40 Coolant Temp Above Normal
CA151 2 1 0 33 High Coolant Temp
CA153 Int Man Temp 1 Ckt Failed High
CA154 Int Man Temp 1 Ckt Failed Low
CA155 2 1 0 32 High Int Man Temp 1
CA156 Int Man Temp 2 Ckt Failed High
CA157 Int Man Temp 2 Ckt Failed Low
CA158 2 1 0 32 High Int Man Temp 2
CA159 Int Man Temp 3 Ckt Failed High
CA161 Int Man Temp 3 Ckt Failed Low
CA162 2 1 0 32 High Int Man Temp 3
CA163 Int Man Temp 4 Ckt Failed High
CA164 Int Man Temp 4 Ckt Failed Low

6 -4 PC3000-6 SHOP-40 06279-xD-GB-1

Tables for Testing and Troubleshooting Trouble Code Tables

Acoustic Signal

Message No.
Instruction
Display
Trouble

Color
Message
Code

CA165 2 1 0 32 High Int Man Temp 4

CA187 Sensor Supply 2 Ckt Failed Low
CB187 Sensor Supply 2 Ckt Failed Low
CA195 Coolant Level Ckt Failed High
CA196 Coolant Level Ckt Failed Low
CA197 Coolant Level Below Normal
CA212 Oil Temp Ckt Failed High
CA213 Oil Temp Ckt Failed Low
CA214 2 1 0 32 Engine Oil Temp too High
CA221 Ambient Air Press Failed High
CA222 Ambient Air Press Failed Low
CA223 Centinel Burn Valve Below Normal
CA224 Centinel Burn Valve Above Normal
CA227 Sensor Supply 2 Ckt Failed High
CB227 Sensor Supply 2 Ckt Failed High
CA228 2 1 0 32 Very Low Coolant Pressure
CA231 Coolant Press Ckt Failed High
CA232 Coolant Press Ckt Failed Low
CA234 2 1 0 32 Engine overspeed
CA235 2 1 0 31 Low Coolant Level
CA238 Sensor Supply 3 Ckt Failed Low
CB238 Sensor Supply 3 Ckt Failed Low
CA245 Fan Control Circuit Failed Low
CA263 Fuel Temp Ckt Failed High
CA265 Fuel Temp Ckt Failed Low
CA266 2 1 0 33 Very High Fuel Temp
CA271 1 1 40 Fuel Pump Press 1 Ckt Failed Low
CA272 1 1 40 Fuel Pump Press 1 Ckt Failed High
CA322 1 1 40 Injector Sol Driver Cyl 1 Below Normal
CA323 1 1 40 Injector Sol Driver Cyl 5 Below Normal
CA324 1 1 40 Injector Sol Driver Cyl 3 Below Normal
CB325 1 1 40 Injector Sol Driver Cyl 6 Below Normal
CA331 1 1 40 Injector Sol Driver Cyl 2 Below Normal
CB332 1 1 40 Injector Sol Driver Cyl 4 Below Normal

SHOP-40 06279-xD-GB-1 PC3000-6 6 -5

Trouble Code Tables Tables for Testing and Troubleshooting

Acoustic Signal

Message No.
Instruction
Trouble Display

Color
Message
Code

ECM Hardware Issue Non Mission

CA343
Disabling
ECM Hardware Issue Non Mission
CB343
Disabling
CA351 1 0 34 Injector Power Supply Failed
CB351 1 0 34 Injector Power Supply Failed
CA352 Sensor Supply 1 Ckt Failed Low
CB352 Sensor Supply 1 Ckt Failed Low
CA386 Sensor Supply 1 Ckt Failed High
CB386 Sensor Supply 1 Ckt Failed High
CA415 2 1 0 32 Very Low Oil Pressure
CA418 1 1 31 WIF Indicator Warning
CA421 1 1 1 40 Engine Oil Temp Above Normal
CA441 1 1 1 31 Low Battery Voltage
CB441 1 1 1 31 Low Battery Voltage
CA442 1 1 1 31 High Battery Voltage
CB442 1 1 1 31 High Battery Voltage
CA449 2 1 0 31 High Rail Pressure
CA451 Rail Press Ckt Failed High
CA452 Rail Press Ckt Failed Low
CA488 1 1 31 High Intake Manifold Temp
CA527 Dual Output A Failed High
CA529 Dual Output B Failed High
CA546 Fuel Del Pressure Ckt Failed High
CA547 Fuel Del Pressure Ckt Failed Low
CA556 2 1 0 32 High Crankcase Pressure
CA559 1 1 40 Rail Pressure 1 Below Normal
CA689 1 1 40 Engine Crankshaft Speed Erratic
CB689 1 1 40 Engine Crankshaft Speed Erratic
CA731 Engine Speed Cam/Crank Misalignment
CB731 Engine Speed Cam/Crank Misalignment
CA783 2 1 0 32 Rapid rise int man temp 1
CA1117 Power Lost with Ignition On
CB1117 Power Lost with Ignition On
CA1357 1 1 31 Remote Oil Level Below Normal

6 -6 PC3000-6 SHOP-40 06279-xD-GB-1

Tables for Testing and Troubleshooting Trouble Code Tables

Acoustic Signal

Message No.
Instruction
Display
Trouble

Color
Message
Code

CB1362 1 1 31 High Lube Oil Filter Restriction

CA1363 1 1 40 Int Man Press 1 Below Normal
CB1367 Pre Filter Oil Press Ckt Failed High
CB1368 Pre Filter Oil Press Ckt Failed Low
CA1373 Ether Injection Ckt Failed
CA1383 Int Man Press 1 Failed High
CA1384 Int Man Press 1 Failed Low
CB1385 Int Man Press 2 Failed High
CB1386 Int Man Press 2 Failed Low
CA1387 2 1 0 34 J1939 Engine Commanded Shutdown
CA1517 1 0 31 ECM Detects Most Severe Fault
CA1542 Engine oil level sensor Ckt Failed High
CA1543 Engine oil level sensor Ckt Failed Low
CB1548 40 Injector Sol Driver 7 Below Normal
CA1549 40 Injector Sol Driver 8 Below Normal
CA1551 40 Injector Sol Driver 10 Below Normal
CA1552 40 Injector Sol Driver 11 Below Normal
CB1553 40 Injector Sol Driver 12 Below Normal
CB1622 Injector Sol Driver 9 Below Normal
CA1638 1 1 40 Int Man Press 2 Below Normal
CA1843 Crankcase Press Ckt Failed High
CA1844 Crankcase Press Ckt Failed Low
CA1845 WIF Indicator Ckt Failed High
CA1846 WIF Indicator Ckt Failed Low
CA1852 1 1 31 WIF Indicator Above Normal
CA1891 Engine Oil Change Interval Exceeded
CA1984 1 1 31 Int Man Temp 2 Above Normal
CA1985 1 1 31 Int Man Temp 3 Above Normal
CA1986 1 1 31 Int Man Temp 4 Above Normal
CA2157 2 1 0 32 Rapid Rise Int Man Temp 2
CA2158 2 1 0 32 Rapid Rise Int Man Temp 3
CA2159 2 1 0 32 Rapid Rise Int Man Temp 4
CA2185 Sensor Supply 4 Ckt Above Normal
CB2185 Sensor Supply 4 Ckt Above Normal
CA2186 Sensor Supply 4 Ckt Below Normal

SHOP-40 06279-xD-GB-1 PC3000-6 6 -7

Trouble Code Tables Tables for Testing and Troubleshooting

Acoustic Signal

Message No.
Instruction
Trouble Display

Color
Message
Code

CB2186 Sensor Supply 4 Ckt Below Normal

CA2215 1 1 40 Fuel Pump Pressure Below Normal
CA2261 1 1 31 Fuel Pump Del Pressure Above Normal
CA2262 1 1 40 Fuel Pump Del Pressure Below Normal
CA2265 Lift Pump Supply Ckt Failed High
CA2266 Lift Pump Supply Ckt Failed Low
CA2311 Fuel Injection Valve Ckt Error
CA2377 Fan Control Ckt Failed High
CA2474 Turbocharger 1 Speed - Data Erratic
Accelerator pedal Idle validation Ckt
CA2697
failed
CA2727 J1939 between Parent and Child Error
CA2734 1 1 31 Ether Bottle Empty
CA2963 1 1 33 Engine Coolant Temp Above Normal
CA2964 1 1 33 Int Man Temp 1 Above Normal

6 -8 PC3000-6 SHOP-40 06279-xD-GB-1

Tables for Testing and Troubleshooting Trouble Code Tables

6.3.2 TABLE OF KOMTRAX PLUS TROUBLE CODES

Explanation of the columns in the following Trouble Code chart

Column 1 Trouble Code Code number

1 = displayed once
Column 2 Display 2 = displayed at each occurrence
0 = NOT displayed

Column 3 Acoustic Signal 1 = an acoustic signal sounds if the relating trouble occurs

Column 4 7 segments LED Short-code of the displayed Trouble Code at the K+ controller

0 = Red
Colour Code of 1 = Yellow
Column 5
Top Message 2 = Green
3 = Blue

Instruction Number of the Instruction Message, which is displayed together with

Column 6
Message No. the Trouble Code (numbers 1 - 58)

The error/message is saved in a History Memory:

1 = Service & Operator History
Column 7 Memory 2 = Service History
3 = Operator History
4 = KOMTRAX Plu History

Column 8 Message Displayed text of the Trouble Code

Table of KOMTRAX Plus Trouble Codes:

7 segments LED
Acoustic Signal

Message No.
Instruction

Memory
Display

Trouble
Color

Message
Code

G00001 2 M481 0 1 1 Trouble Shut-Off (gate) valve

Test speed 1800 1/min
G00002 2 M231 3 37 3
engine 1
G00007 2 M581 0 2 1 Trouble hydraulic oil level
Central lubrication system
G00012 1 M541 1 17 3
grease level too low
Slew ring gear lubr. system
G00013 1 M542 1 17 3
grease level too low
G00031 2 1 M232 3 0 3 Set engine to low idle
G00060 2 M492 0 6 1 Fire in the power house
G00065 1 M582 1 2 1 Very low hydraulic oil level
Trouble
G00066 2 M590 1 2 1
hydraulic oil temperature
Trouble battery voltage
G00067 1 M991 1 2 1
too high

SHOP-40 06279-xD-GB-1 PC3000-6 6 -9

Trouble Code Tables Tables for Testing and Troubleshooting

7 segments LED
Acoustic Signal

Message No.
Instruction

Memory
Trouble Display

Color
Message
Code

Trouble oil temperature

G00070 2 1 M591 1 2 1
gear (PTO 1)
Trouble gear lubrication
G00071 2 1 M592 1 2 1
(PTO 1)
G00091 2 M593 3 9 3 Pilot control cut out
Emergency shut-down
G00092 2 M482 0 10 3
at access ladder
Emergency shut-down
G00093 2 M594 0 10 1
at valve block
Emergency shut-down
G00095 2 M483 0 10 3
in cabin
Emergency shut-down
G00097 2 M484 0 10 3
at counterweight
G00100 2 MA01 3 11 3 Maintenance Safety Switch
G00104 2 1 M995 1 15 1 Trouble battery current
Trouble battery charging
G00105 2 1 M996 1 16 1
current too low
G00164 1 M485 1 17 1 Trouble air cleaner 1
Trouble breather filter
G00165 1 M595 1 17 1
hydraulic oil tank
G00166 1 M596 1 17 1 Trouble oil filter gear (PTO 1)
Trouble return oil filter
G00169 1 M597 1 17 1
hydraulic oil tank
Trouble leak oil filter
G00170 1 M598 1 17 1
hydraulic oil tank
Trouble battery voltage
G00176 1 M992 1 17 1
too low
Trouble battery charging
G00177 1 M997 1 17 1
circuit
Trouble battery charging
G00178 1 M998 1 17 1
current too high
Central lubrication
G00184 1 1 M538 1 20 1
system empty
Trouble central lubrication
G00185 1 1 M536 1 20 1
system
Slew ring gear lubrication
G00187 1 1 M539 1 20 1
system empty
Trouble slew ring gear
G00188 1 1 M537 1 20 1
lubrication system
Engine remote oil-tank 1
G00207 1 1 M233 1 2 1
empty

6 - 10 PC3000-6 SHOP-40 06279-xD-GB-1

Tables for Testing and Troubleshooting Trouble Code Tables

7 segments LED
Acoustic Signal

Message No.
Instruction

Memory
Display
Trouble

Color
Message
Code

Load limiting
G00222 2 1 M486 1 2 1
clam defective
G00243 1 1 M487 3 23 3 Fill up fuel tank
Engine shutdown from
G00245 2 M234 0 24 1
ground
G00256 2 MA02 3 45 3 Operator warning system
Trouble screen at hydr.
G00262 1 1 M599 1 20 1
cooler entry clogged
G00422 2 1 M801 1 2 1 Can-net sys (J1939)
Communication failure
G00491 2 1 1 2 1
MH800 <=> KOMTRAX Plus Controller
Communication failure
DBBQKR 2 1 M802 1 2 2
CR710 <=> KOMTRAX Plus Controller
Abnormality in VBAT voltage
DBB3KK 2 1 M905 1 2 2
(KOMTRAX Plus VBAT<10V)

DBB0KK 2 1 M901 1 2 2 KOMTRAX Plus source voltage Error

DBB0KQ 2 1 MF11 1 2 2 KOMTRAX Plus Connector Mismatch

DGH2KA 1 M521 1 2 2 Hyd. Oil Temp. Sensor Failure

DGH2KB 1 M522 1 2 2 Hyd. Oil Temp. Sensor Failure
J100KA 1 M511 1 17 2 Pilot Press. Sensor Failure
J100KB 1 M512 1 17 2 Pilot Press. Sensor Failure
J100L6 1 M571 1 17 2 Abnomal Pilot Pump press

DGE5KA M401 2 Ambient air temp Sensor Failure

DGE5KB M402 1 2 Ambient air temp Sensor Failure

Trouble High Exhaust Temperature

F@DANS 2 1 M651 0 32 2
Cylinder RB1
Trouble High Exhaust Temperature
F@DBNS 2 1 M652 0 32 2
Cylinder RB2
Trouble High Exhaust Temperature
F@DCNS 2 1 M653 0 32 2
Cylinder RB3
Trouble High Exhaust Temperature
F@DDNS 2 1 M654 0 32 2
Cylinder RB4
Trouble High Exhaust Temperature
F@DENS 2 1 M655 0 32 2
Cylinder RB5
Trouble High Exhaust Temperature
F@DFNS 2 1 M656 0 32 2
Cylinder RB6
Trouble High Exhaust Temperature
F@DGNS 2 1 M641 0 32 2
Cylinder LB1

SHOP-40 06279-xD-GB-1 PC3000-6 6 - 11

Trouble Code Tables Tables for Testing and Troubleshooting

7 segments LED
Acoustic Signal

Message No.
Instruction

Memory
Trouble Display

Color
Message
Code

Trouble High Exhaust Temperature

F@DHNS 2 1 M642 0 32 2
Cylinder LB2
Trouble High Exhaust Temperature
F@DJNS 2 1 M643 0 32 2
Cylinder LB3
Trouble High Exhaust Temperature
F@DKNS 2 1 M644 0 32 2
Cylinder LB4
Trouble High Exhaust Temperature
F@DLNS 2 1 M645 0 32 2
Cylinder LB5
Trouble High Exhaust Temperature
F@DMNS 2 1 M646 0 32 2
Cylinder LB6
Trouble monitoring Exhaust Temp
DGTAKX 1 M721 1 31 2
Cylinder RB1
Trouble monitoring Exhaust Temp
DGTBKX 1 M722 1 31 2
Cylinder RB2
Trouble monitoring Exhaust Temp
DGTCKX 1 M723 1 31 2
Cylinder RB3
Trouble monitoring Exhaust Temp
DGTDKX 1 M724 1 31 2
Cylinder RB4
Trouble monitoring Exhaust Temp
DGTEKX 1 M725 1 31 2
Cylinder RB5
Trouble monitoring Exhaust Temp
DGTFKX 1 M726 1 31 2
Cylinder RB6
Trouble monitoring Exhaust Temp
DGTGKX 1 M671 1 31 2
Cylinder LB1
Trouble monitoring Exhaust Temp
DGTHKX 1 M672 1 31 2
Cylinder LB2
Trouble monitoring Exhaust Temp
DGTJKX 1 M673 1 31 2
Cylinder LB3
Trouble monitoring Exhaust Temp
DGTKKX 1 M674 1 31 2
Cylinder LB4
Trouble monitoring Exhaust Temp
DGTLKX 1 M675 1 31 2
Cylinder LB5
Trouble monitoring Exhaust Temp
DGTMKX 1 M676 1 31 2
Cylinder LB6
DJF1KX 1 M580 1 17 2 Trouble monitoring fuel level

6 - 12 PC3000-6 SHOP-40 06279-xD-GB-1

Tables for Testing and Troubleshooting Trouble Code Tables

6.3.3 TABLE OF PUMP-CONTROLLER-CODES (MULTI MONITOR)

Trouble messages of the pump controller are displayed on the KOMTRAX Plus display and on the Multimonitor in
the cab base.

Explanation of the columns in the following Trouble Code chart

Column 1 Trouble Code Code number

1 = displayed once
Column 2 Display 2 = displayed at each occurrence
0 = NOT displayed

Column 3 Acoustic Signal 1 = an acoustic signal sounds if the relating trouble occurs

Column 4 7 segments LED Short-code of the displayed Trouble Code at the K+ controller

0 = Red
Colour Code of
1 = Yellow
Column 5 Top Message
2 = Green
(K+ display only)
3 = Blue

Instruction Number of the Instruction Message, which is displayed together with

Column 6
Message No. the Trouble Code (numbers 1 - 58)

The error/message is saved in a History Memory:

1 = Service & Operator History
Column 7 Memory 2 = Service History
3 = Operator History
4 = KOMTRAX Plus History

Column 8 Message Displayed text of the Trouble Code

Table of Pump-Controller-Codes:
7 segments LED
Acoustic Signal

Color (K+ only)

Message No.
Instruction

Memory
Display

Trouble-
Message
Code

DXAAKA 1 1 1 40 2 Solenoid-1(Pump-1) open circuit

DXAAKB 1 1 1 40 2 Solenoid-1(Pump-1) short circuit
DXABKA 1 1 1 40 2 Solenoid-2(Pump-2) open circuit
DXABKB 1 1 1 40 2 Solenoid-2(Pump-2) short circuit
DXACKA 1 1 1 40 2 Solenoid-3(Pump-3) open circuit
DXACKB 1 1 1 40 2 Solenoid-3(Pump-3) short circuit
DXADKA 1 1 1 40 2 Solenoid-4(Pump-4) open circuit
DXADKB 1 1 1 40 2 Solenoid-4(Pump-4) short circuit
DXAEKA 1 1 1 40 2 Solenoid-5(Pump-5) open circuit
DXAEKB 1 1 1 40 2 Solenoid-5(Pump-5) short circuit
DXAFKA 1 1 1 40 2 Solenoid-6(Pump-6) open circuit
DXAFKB 1 1 1 40 2 Solenoid-6(Pump-6) short circuit

SHOP-40 06279-xD-GB-1 PC3000-6 6 - 13

Trouble Code Tables Tables for Testing and Troubleshooting

7 segments LED
Acoustic Signal

Color (K+ only)

Message No.
Instruction

Memory
Trouble- Display
Message
Code

DHPEMA 1 1 1 40 2 Pump-1/2 pressure sensor abnormality

DHPGMA 1 1 1 40 2 Pump-3/4 pressure sensor abnormality
DHPJMA 1 1 1 40 2 Pump-5/6 pressure sensor abnormality
DLE2MA 1 1 1 40 2 Engine speed sensor abnormality
DA25KP 1 1 1 40 2 5V sensor1 power abnormality
DA22KK 1 1 1 40 2 Pump Solenoid Power Low Error
DA29KQ 1 1 1 40 2 Model Selection Abnormality

6 - 14 PC3000-6 SHOP-40 06279-xD-GB-1

Tables for Testing and Troubleshooting Table of Instruction Messages

6.4 TABLE OF INSTRUCTION MESSAGES

Message
Instruction Message
No.

Engine stopped because of main Shut-Off

(gate) valve.
1
- Open the Shut-Off (gate) valve.
- If failure exist further, inform service.

2 Inform service.

Stop the engine.

3
- Inform service.

Start blocked because of main Shut-Off

(gate) valve.
4
- Open the Shut-Off (gate) valve.
- If failure exist further, inform service.

Start blocked
5
- Inform service.

The fire suppression system has been actuated.

- Inform the fire brigade.
6 - Evacuate endangered persons.
- Fight the fire.
- Inform service.

Bucket motion switched off.

7
- Inform service.

No 24V at circuit breaker 11F013

8
- If failure exist further, inform service.

Ladder end switch or lock lever contact open

9 or service arm down or unlock.
- If failure exist further, inform service.

Emergency shut-down switch was

actuated.
10
- Unlock before restarting.
- If failure exist further, inform service.

Engine switched off by

11 Maintenance Safety Switch
in the engine room.

12 Operate the machine into the parking position.

13 Please wait! No high idle !

Enable switch for refilling arm active

14
- If failure exist further, inform service.

Load of the batteries too high.

15
- Inform service.

Batteries are not being charged.

16
- Inform service.

17 Inform service till end of shift and then press cancel button.

SHOP-40 06279-xD-GB-1 PC3000-6 6 - 15

Table of Instruction Messages Tables for Testing and Troubleshooting

Message
Instruction Message
No.

Slew ring gear house brake OFF

18 - Inform service till end of shift and then
press cancel button.

Travel gear house brake OFF

19 - Inform service till end of shift and then
press cancel button.

20 Inform service and then press cancel button.

Hydraulic oil far below operating

temperature !
21
- Pre-heat hydraulic oil or warm up at
low idle speed and reduced power.

22 Engine runs (starter motor inactive).

A fuel reserve only is still in the tank

23
- Order tanker.

Engine shutdown has been actuated from

24
ground man.

Hydraulic oil below operating

25 temperature.
- Operate with reduced power !

26 Slew ring gear house brake ON

27 Hydraulic oil overheat - engine power derated

The VHMS is by-passed.

28
- Reset by-pass switch.

Engine shutdown by keyswitch before proper

engine cool down.
29
- Before you switch off the engine, cool down
the engine in the low idle for 2-3 minutes.

Hydraulic oil far below operating

temperature !
30
- Pre-heat hydraulic oil or warm up at
low idle speed and reduced power.

31 Continue shift but advise service.

32 Stop engine call service.

Derate active, continue to work.

33 Later shutdown possible.
Inform service.

34 Call service because of shutdown.

Interrupt work and inform service about

35
Speed Derate .

Continue work until next PM

36
(Schedule work for next PM)

Switch Testspeed in cab base forces the

37
engine to run constantly 1800 1/min.

6 - 16 PC3000-6 SHOP-40 06279-xD-GB-1

Tables for Testing and Troubleshooting Table of Instruction Messages

Message
Instruction Message
No.

38 If failure exist further, inform service.

Inform service
39
if attachment in defined position.

Continue to work and inform service about

40
Power Derate.

Cable Drum at limit.

41
- Move the shovel in an other direction.

Motor overheated. Wait until cooldown.

42
- If failure exists further, inform service.

Switch off and restart motor

43
- If failure exists further, inform service.

Switch off and restart motor

44 (It may be necessary to wait for cool down)
- If failure exists further, inform service.

Switch off windscreen wiper

46
and call service.

Only upper windscreen wiper!

47
Inform service.

No 24V at circuit breaker 11F013a

48
- If failure exist further, inform service.

Only lower windscreen wiper!

49
Inform service.

Reverse travel cut out by

50
cable drum.

Cable drum-motor temperature

51 too high.
Allow motor to cool down.

Permanently switch off by

52 device overheating.
Inform service.

53 Temporary switch off by

heating-air overheating.
Inform service.

54 Wait during one minute after

last start of motor.

55 Risk of collision with the cable drum!

56 Key switch off and back on !

57 Cool down period !

58 Travel gear house brake ON

SHOP-40 06279-xD-GB-1 PC3000-6 6 - 17

TABLES OF SYMPTOM CODES Tables for Testing and Troubleshooting

6.5 TABLES OF SYMPTOM CODES

For the troubleshooting procedures of the Symptom Codes refer to section 8 Troubleshooting by symptoms.

6.5.1 SYMPTOMS OF THE ENGINES AND RELATED ELECTRICAL

SYSTEMS
S-Code Trouble Description

SEL001 Engine does not start (engine does not rotate)

SEL001a Engine does not start (Pre-lube does not stop)

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 Exhaust smoke is black

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)

6.5.2 SYMPTOMS OF THE HYDRAULIC SYSTEM

S-Code Trouble Description

All the work equipment shows lack of power or slow movement

SHY001
(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 Machine deviates during travel movement

SHY007 Hydraulic system has lack of power

SHY008 Machine does not slew (or slew speed is very low)

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)

SHY012 Abnormal noise coming from SRV or MRV

6 - 18 PC3000-6 SHOP-40 06279-xD-GB-1

Tables for Testing and Troubleshooting TABLES OF SYMPTOM CODES

S-Code Trouble Description

SHY013 Track tensioning system without function (or with poor function)

SHY014 Ladder 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

SHY009 Slew parking brake without function

SHY020 Travel parking brake without function

6.5.3 SYMPTOMS OF THE MECHANICAL SYSTEM

S-Code Trouble Description

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

6.5.4 SYMPTOMS OF ADDITIONAL SYSTEMS

S-Code Trouble Description

SAD001 Air conditioner for the cabin does not work

SAD002 Air conditioner compressor clutch is burnt

SAD003 Air conditioning system defective (pipes and hoses full of moisture

SHOP-40 06279-xD-GB-1 PC3000-6 6 - 19

Cable colour identification Tables for Testing and Troubleshooting

6.6 CABLE COLOUR IDENTIFICATION

Short Marks
Colour Colour
(English) (German) German German
Standard IEC 60757*
(current) (previous)
Black Schwarz BK SW sw
Brown Braun BN BR br
Red Rot RD RT rt
Orange Orange OG OR or
Yellow Gelb YE GE ge
Green Grün GN GN gn
Blue Blau BU BL bl
Violet Violett VT VI vi
Grey Grau GY GR gr
White Weiß WH WS ws
Pink Rosa PK RS rs
Turquoise Türkis TQ TK tk

6 - 20 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

7 TROUBLESHOOTING BY
KOMTRAX PLUS TROUBLE
CODE

SHOP-40 06279-xD-GB-1 PC3000-6 7 -1

 Troubleshooting by KOMTRAX Plus trouble code

G00001 - Trouble Shut-Off (gate) valve

[1/4]
Trouble code
Message Trouble Shut-Off (gate) valve
G00001

Contents of trouble The system assumes that the main gate valve is not completely open while the engine is running.

– If the voltage at the proximity switch 40B031 is 0 V, the main gate valve should be closed.
Related information
– Use the REAL TIME MONITOR for verification (03 Hydraulic, screen 3/3)
– Background colour of the trouble code information: red
Action of controller
– 7 segment LED-Code at K+ controller: M481
Problem that appears
Engine shutdown & start is blocked.
on the machine
Engine stopped because of main Shut-Off (gate) valve.
Instruction message 1 - Open the Shut-Off (gate) valve.
- If failure exists further, inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value

 Main key switch 20S001 ON.

The engine is stopped, Yes Go to next step.

because the main gate Open the main gate
1 Verify if the main gate valve is fully open or not.
valve at the hydraulic valve completely and
oil tank is not fully open Is the main gate valve fully open? No verify that trouble code
G00001 is not set
again.
 Main key switch 20S001 ON.
Gap:
Yes Go to next step. approx.
The gap between the 3 - 5mm
proximity switch Adjust the gap.
Check for the proper gap between the
40B031 and the open 2
proximity switch and the open main gate valve. Make sure that the
main gate valve is too
large Does the gap meet the specification? proximity switch does
No not touch the gate
valve when the gate
valve is completely
open.
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
Disconnect the cable connector from the prox- Umin 22V
3 imity switch 40B031 and insert the T-box. Mea- Yes Go to step 6.
Umax 24V
sure the supply voltage at the connector
terminal A.
No Go to next step.
Incorrect or no supply Is supply voltage present?
voltage at the proximity Umin 22V
switch 40B031 Yes Go to next step.
Umax 24V
Check if supply voltage is present at the power
Check circuit between
4 supply line 11F212.
11F200 and 11F212.
Is supply voltage present? No Locate the problem
and repair as neces-
sary.

7 -2 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00001 - Trouble Shut-Off (gate) valve

[2/4]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF
Yes Go to next step. Rmax 1Ω
Defective supply wir- Refer to the wiring diagram and check the wire
Disconnection in any
ing between proximity segments for continuity:
wire segment (includ-
switch 40B031 and cir- – From circuit breaker 11F212, ing connectors)
cuit breaker 11F212 5 between proximity
– via relay 11K005 (switch contacts),
(disconnection or No switch 40B031 and cir-
defective contact in any – via diode 11R019, cuit breaker 11F212.
connector) – to proximity switch 40B031 terminal A, Locate the problem
Is continuity present? and repair as neces-
sary.
 Main key switch 20S001 OFF
Yes Go to next step. Rwire
Defective wiring Disconnection or short max. 1Ω
between circuit breaker Refer to the wiring diagram and check the wire circuit to ground in any
11F015, relay 11K057 segments for continuity: wire segment (includ-
and pump controller ing connectors)
6 – From circuit breaker 11F015,
10K032 between circuit
– via relay 11K057 (switch contacts), No breaker 11F015 and
(disconnection or pump controller
defective contact in any – to pump controller 10K032.
10K032.
connector) Is continuity present?
Locate the problem
and repair as neces-
sary.
 Main key switch 20S001 OFF
Yes Go to next step. Rwire
– Wiring: max. 1Ω
If necessary, repair Rrelay
Defective signal wiring or replace the wir- 557 ± 1.0Ω
Refer to the wiring diagram and check the wire
between proximity
segments for continuity: ing/connections of
switch 40B031, relay
– From proximity switch 40B031 terminal C, 40B031.
11K057 and GND 7
– via relay 11K057 (coil), – Relay 11K057:
(disconnection or No
defective contact in any If the resistance of
– to GND. the coil is not as
connector)
Is continuity present? specified, replace
the relay.
Go to final check (last
step).
 Main key switch 20S001 OFF
Yes Go to next step. Rwire
Defective ground con- Disconnection in any max. 1Ω
nection at the proxim- wiring segment (includ-
ity switch 40B031 Disconnect the cable connector from the prox- ing connectors)
8 imity switch 40B031 and check for proper between proximity
(disconnection or ground connection at the connector terminal B. No switch 40B031 and
defective contact in any
Is the ground connection OK? GND.
connector)
Locate the problem
and repair as neces-
sary.
Defective relay 11K005 Yes Go to next step.
Check the relay’s contacts for proper switching
or 11K057
9 function refer to section 5.2 on page 5-4. Replace the defective
(weld shut or failing No
Is the switching function OK? relay.
switch contacts)

SHOP-40 06279-xD-GB-1 PC3000-6 7 -3

 Troubleshooting by KOMTRAX Plus trouble code

G00001 - Trouble Shut-Off (gate) valve

[3/4]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
If the switch function is Closed:
not as specified USignal
Defective proximity replace the proximity
10 Disconnect the sensor connector and insert the T-box. 0V
switch 40B031 switch 40B031 and
Measure the signal voltage at terminal C with closed verify that the repair Open:
and open gate valve. was successful.
USignal
Go to final check (last
22-24V
step).
Bring the machine back into the original condition. Start the machine and verify
Final check 11
that the trouble message does not arise again.

View onto the gap of proximity switch 40B031

Legend for Fig. 7-1:

(1) Proximity switch (40B031)

(A) Gap 3 - 5 mm

Fig. 7-1 Gap at the proximity switch

40B031

Input signal of the proximity switch 40B031 on the REAL TIME MONITOR

Fig. 7-2 Input signal of the proximity switch 40B031 on the REAL TIME MONITOR

7 -4 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (40B031) for trouble code G00001 (Main gate valve open)
[4/4]

Fig. 7-3 Wiring Diagram (40B031) for trouble code G00001 (Main gate valve open)

SHOP-40 06279-xD-GB-1 PC3000-6 7 -5

 Troubleshooting by KOMTRAX Plus trouble code

G00002 - Test speed 1800 1/min engine 1

[1/2]
Trouble code
Message Test speed 1800 1/min engine 1
G00002
Test speed 1800 rpm is activated by switch 10S041-1 [NO*] in the cab base.
Contents of trouble
*NO = Normally Open
– If the Quantum engine control module is switched to ground, the engine speed is fixed at
Related information 1800 rpm.
– The system assumes that the switch 11S041-1 and its wiring circuit are not defective.
– Background colour of the trouble code information: blue
Action of controller
– 7 segment LED-Code at K+ controller: M231
Problem that appears
In this condition the engine speed is not changeable.
on the machine

Instruction message 37 Switch Testspeed in cab base forces the engine to run constantly 1800 1/min.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
The function "test No further trouble-
Yes
speed 1800 rpm" shooting necessary.
Check the switch setting.
is activated (switch 1
11S041-1 is closed) Is the test speed function disabled?
No Go to next step.

 K+ Service Menu ON.

1. Engine OFF
2. 20S001 ON
3. REAL TIME MONITOR (refer to Fig. 7-4)
 01 Engine 1
– In case of malfunction refer to the Wir-
Switch 11S041-1 or its  Screen 3/5
2 ing Diagram.
wiring is defective
4. Check the input signal of 11S041-1 – If a sporadic interruption exists, further
on the K+ monitor. inspection of the circuit is required.
1 = ON  input  speed fixed
0 = OFF  no input  speed not fixed
The displayed input must change over (0 1)
when you toggle the switch.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

Input signal of the switch 11S041-1 on the REAL TIME MONITOR

Fig. 7-4 Input signal of the switch 11S041-1 on the REAL TIME MONITOR

7 -6 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (11S041-1) for trouble code G00002

[2/2]

Fig. 7-5 Wiring Diagram (11S041) for trouble code G00002

SHOP-40 06279-xD-GB-1 PC3000-6 7 -7

 Troubleshooting by KOMTRAX Plus trouble code

G00007 - Trouble hydraulic oil level

[1/4]
Trouble code
Message Trouble hydraulic oil level
G00007
Sensor 40B004 [NO*] indicates that the hydraulic oil level is below the minimum refill level.
Contents of trouble
*NO = Normally Open
– If the sensor 40B004 does not sense oil, its signal voltage turns to 0V.
Related information
– If the sensor signal voltage continues to be 0V for 3 seconds, trouble code G00007 is set.
– Background colour of the trouble code information: red
Action of controller – Engine shutdown (option)
– 7 segment LED-Code at K+ controller: M581
Problem that appears – Risk, to run out of hydraulic oil.
on the machine – Engine shutdown is possible.

Instruction message 2 Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Check with stopped engine and the attachment in its defined position.
1. Check the hydraulic oil level at the sight glass and fill up hydraulic oil.
Hydraulic oil needs Observe the hydraulic oil temperature and refill oil up to the appropriate
1
refilling level. Sight glass
2. Verify if other trouble messages concerning the hydraulic oil are displayed.
If other messages are displayed follow their instructions as necessary.
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
Disconnect the cable connector from the oil Umin 22V
2 level sensor 40B004, insert the T-box, and Yes Go to step 5.
Umax 24V
measure the supply voltage at the cable con-
nector terminal A.
Incorrect or no supply No Go to next step.
Is supply voltage present?
voltage in the circuit of
the oil level sensor Umin 22V
40B004 Yes Go to next step.
Umax 24V
Check if supply voltage is present at the power
Check circuit between
3 supply line 11F212.
11F200 and 11F212.
Is supply voltage present? No Locate the problem
and repair as neces-
sary.
 Main key switch 20S001 OFF
Yes Go to next step. Rwire
Defective wiring Refer to the wiring diagram and check the wire Disconnection in any max. 1Ω
between oil level sen- segments for continuity: wiring segment (includ-
sor 40B004 and power ing connectors)
supply line from circuit – From circuit breaker 11F212,
between oil level sen-
breaker 11F212 4 – via relay 11K005 (switch contacts), sor 40B004 and line
No from circuit breaker
(disconnection or – via diode 11R019,
defective contact in any 11F212.
– to proximity switch 40B004 terminal A.
connector) Locate the problem
Is continuity present? and repair as neces-
sary.

7 -8 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00007 - Trouble hydraulic oil level

[2/4]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF
Yes Go to next step. Rwire
Defective wiring Disconnection in any max. 1Ω
between circuit breaker Refer to the wiring diagram and check the wire wire segment (includ-
11F015, relay 11K011 segments for continuity: ing connectors)
and pump controller – From circuit breaker 11F015, between circuit
10K032 5
breaker 11F015 and
– via relay 11K011 (switch contacts), No
(disconnection or pump controller
defective contact in any – to pump controller 10K032. 10K032.
connector) Is continuity present? Locate the problem
and repair as neces-
sary.
 Main key switch 20S001 OFF
Yes Go to next step. Rwire
– Wiring: max. 1Ω
If necessary, repair Rrelay
Defective signal wiring or replace the wir- 557 ± 1.0Ω
Refer to the wiring diagram and check the wire
between oil level sen-
segments for continuity: ing/connections of
sor 40B004, relay
– From proximity switch 40B004 terminal C, 40B004.
11K011 and GND 6
– via relay 11K011 (coil), – Relay 11K011:
(disconnection or No
defective contact in any If the resistance of
– to GND. the coil is not as
connector)
Is continuity present? specified, replace
the relay.
Go to final check (last
step).
 Main key switch 20S001 OFF
Yes Go to next step. Rwire
Defective ground con- Disconnection in any max. 1Ω
nection at the oil level Disconnect the cable connector from the oil wiring segment (includ-
sensor 40B004 level sensor 40B004. ing connectors)
7 between oil level sen-
(disconnection or Check for proper ground connection at the
No sor 40B004 and the
defective contact in any connector terminal B.
ground line (-).
connector) Is the ground connection OK?
Locate the problem
and repair as neces-
sary.
Defective relay 11K005 Yes Go to next step.
Check the relay’s contacts for proper switching
or 11K057
8 function refer to section 5.2 on page 5-4. Replace the defective
(weld shut or failing No
Is the switching function OK? relay.
switch contacts)

SHOP-40 06279-xD-GB-1 PC3000-6 7 -9

 Troubleshooting by KOMTRAX Plus trouble code

G00007 - Trouble hydraulic oil level

[3/4]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
A sporadic malfunc- USignal
tion may exist. Further open: 0V
inspection is required.
(consider weld shut or
Using the T-box measure the signal voltage at Yes failing switch contacts USignal
the connector terminal C of the oil level sensor at relays) closed:
Defective oil level sen- 40B004 when the sensor is dipped into oil
9 22 - 24V
sor 40B004 Go to final check (last
(sensor closed), and when it is not touching
step).
any oil (sensor open).
Replace the oil level
Do the measurements meet the specifica-
sensor 40B004 and
tions?
verify that the repair
No was successful.
Go to final check (last
step).
Bring the machine back into the original condition.
Final check 10
Start the machine and verify that the trouble code does not arise again.

7 - 10 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (40B004) and the defined position of the attachment (G00007)
[4/4]

Fig. 7-6 Wiring Diagram (40B004) and the defined position of the attachment (G00007)

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 11

 Troubleshooting by KOMTRAX Plus trouble code

G00012 - Central lubrication system grease level too low

G00013 - Slew ring gear lubr. system grease level too low
[1/6]
Trouble code G00012 - Central lubrication system grease level too low
Message
G00012 & G00013 G00013 - Slew ring gear lubr. system grease level too low
– Monitoring of CLS (Central Lubrication System) grease level - 62B108b.
Contents of trouble – Monitoring of SLS (Slew ring gear Lubrication System) grease level - 62B109b.
– The reserve level in the CLS grease barrel respectively in the SLS grease barrel is reached.
– The grease level sensors do not trigger the bucket cut-off function.
– Background colour of the trouble code information: yellow
[62B108a] Level sensor - full CLS
[62B108b] Level sensor - pre-warning CLS
[62B108c] Level sensor - empty CLS
[62B109a] Level sensor - full SLS
Related information [62B109b] Level sensor - pre-warning SLS
[62B108c] Level sensor - empty SLS

Problem that appears

Risk, to run out of grease.
on the machine
– Background colour of the trouble code information: yellow
Action of controller
– 7 segment LED-Code at K+ controller: M541 (G00012), M542 (G00013)

Instruction message 17 Inform service till end of shift and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
Using the dipstick, verify if the grease level Press the cancel
in the concerned barrel corresponds button and refill the
to the displayed message. specified grease.
Yes
Is the grease level too low? Verify that trouble code
G00012 or G00013 is
not displayed again.
Definition of the grease levels

The concerned grease

barrel (CLS or SLS) 1
needs refilling

No Go to next step.

7 - 12 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00012 - Central lubrication system grease level too low

G00013 - Slew ring gear lubr. system grease level too low
[2/6]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
1. Remove the cover of the junction box for Umin 22V
CLS or for SLS on top of the concerned Yes Go to step 4.
Umax 24V
grease barrel.
2
2. Refer to the wiring diagram (junction box).
3. Measure the supply voltage at terminal No Go to next step.
X1.3 inside the junction box.
Is supply voltage present?
Incorrect or no supply Umin 22V
voltage in the circuit at Yes Go to next step.
the concerned grease Umax 24V
level sensor (62B108b Disconnection, short
or 62B109b) circuit, or fault in the
wiring between con-
Check if supply voltage is present at the power nector XB.A at the
3 supply line 11F025. junction box and cir-
Is supply voltage present? cuit breaker 11F025.
No
If necessary, check the
segments of the volt-
age supply wiring sep-
arately, locate the
problem, and repair as
necessary.
 Main key switch 20S001 OFF
Defective signal wiring
between the concerned 1. Disconnect the signal line of the concerned Yes Go to next step.
grease level sensor grease level sensor from the pump control-
62B108b or 62B109b ler 10K032. Disconnection or short
and pump controller circuit to ground in any
2. Refer to the wiring diagram and check the
10K032. wiring segment of the
4 signal wiring segments for continuity: signal line (including
(disconnection or connectors and junc-
– From the concerned grease level sen- No
defective contact in any tion box)
sor (62B108b or 62B109b),
connector or in the
junction box on top of – to the relating input terminal at pump Locate the problem
the concerned grease controller 10K032. and repair as neces-
barrel) sary.
Is continuity present?

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 13

 Troubleshooting by KOMTRAX Plus trouble code

G00012 - Central lubrication system grease level too low

G00013 - Slew ring gear lubr. system grease level too low
[3/6]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
REMARKS: For checking the level sensor 62B108b or
62B109b, it is necessary to remove the
cover of the concerned grease barrel.
1. Check the proximity switch by dipping it into grease.
Defective grease level If the proximity switch is OK, the proximity switch is
sensor 62B108b or closed.
62B109b 5 Replace the defective grease level
2. Use the REAL TIME MONITOR for verification
(provided that the sen- sensor 62B108b or 62B109b.
(refer to Fig. 7-35 on page 7-56).
sor wiring is OK)  07 Central Lube System 1 (CLS) or Go to final check (last step).
 08 Slew Ring Gear Lube System (SLS)
 Screen 1/1

REAL TIME MONITOR shows "1" at 62B108b or

62B109b respectively if proximity switch is OK
(dipped it into grease).
1. Bring the machine back into the original condition.
2. Run engine at high idle.
Final check 6
3. Recheck the function of the lubrication system by manual actuation of a lube
cycle and verify that the fault message does not arise again.

7 - 14 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Input signals of grease level sensors 62B108b & 62B109b on the REAL TIME MONITOR
[4/6]

Fig. 7-7 Input signal of grease level sensors 62B108b & 62B109b on the REAL TIME MONITOR

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 15

 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram for trouble codes G00012 & G00013

[5/6]

Fig. 7-8 Wiring Diagram for trouble codes G00012 & G00013

7 - 16 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (junction box) for trouble codes G00012 & G00013
[6/6]

Fig. 7-9 Wiring Diagram (junction box) for trouble codes G00012 & G00013

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 17

 Troubleshooting by KOMTRAX Plus trouble code

G00031 - Set engine to low idle

[1/2]
Trouble code
Message Set engine to low idle.
G00031

Contents of trouble Engine speed switch 20S030 is set to High Idle. Switch location: RH hand lever.

– During the engine start sequence this switch prevents the engine to run directly at high idle
Related information after engine startup.
– The system assumes that the switch 20S030 and its wiring circuit are not defective.
– Background colour of the trouble code information: blue
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M232
Problem that appears
Engine start is blocked.
on the machine

Instruction message 0 ---

Nominal
Possible cause Step Test condition & Inspection Procedure
value
Toggle the switch
to Low Idle.
Switch 20S030 Check the switch setting. Yes
1 Go to final check (last
is set to High Idle Is the switch set to High Idle? step).
No Go to next step.
 K+ Service Menu ON.
1. Engine OFF
2. 20S001 ON
3. REAL TIME MONITOR
(refer to Fig. 7-11 on page 7-19)
– In case of malfunction refer
 01 Engine 1
Switch 20S030 or its to the Wiring Diagram.
2  Screen 3/5
wiring is defective – If a sporadic interruption
4. Check the input signal of 20S030
exists, further inspection
on the K+ monitor.
of the circuit is required.
1 = ON  input  High Idle
0 = OFF  no input  Low Idle
The displayed input must change over (0 1)
when you toggle the switch.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

7 - 18 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (20S030) for trouble code G00031

[2/2]

Fig. 7-10 Wiring Diagram (20S030) for trouble code G00031

Input signal of the resistor 11T080 on the REAL TIME MONITOR

Fig. 7-11 Input signal of the switch 20S030 on the REAL TIME MONITOR

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 19

 Troubleshooting by KOMTRAX Plus trouble code

G00060 - Fire in the power house

[1/3]
Trouble code
Message Fire in the power house
G00031
– Monitoring of the emergency shut-off and fire suppression system (optional equipment).
Contents of trouble
– If fire alarm is initiated the engines are shutdown.
All relevant information about the fire suppression system, i.e. placing the system in service,
Related information daily inspection, functional tests, maintenance, and troubleshooting are contained in the separate
manuals of your shovel.
– Background colour of the trouble code information: red
Action of controller
– 7 segment LED-Code at K+ controller: M492
– Case A - Fire activated the fire suppression system.
Problem that appears
– Case B - False alarm caused the activation of the fire suppression system.
on the machine
– Case C - False alarm was cancelled by the operator.
The fire suppression system has been actuated. - Inform the fire brigade. - Evacuate
Instruction message 6
endangered persons. - Fight the fire. - Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
Remove the residues
of the extinguishing
agent and clean the
power house as neces-
sary.
Fire alarm was initi- Identify the cause of the false fire alarm. The detection and
ated and the fire sup- actuation system and
pression system was the fire suppression
A REMARKS: Also refer to the troubleshooting
activated in order to systems must be
extinguish a fire in the procedures which are described in the checked, recharged,
power house. manual of the system manufacturer. and approved by
authorized service per-
sonnel immediately
after operation.
Rectify the cause for
the false fire alarm.
Remove the residues
of the extinguishing
agent and clean the
power house as neces-
sary.
Identify the cause of the false fire alarm. The detection and
Fire alarm was initi-
actuation system and
ated due to a false
the fire suppression
alarm and the fire sup- B REMARKS: Also refer to the troubleshooting systems must be
pression system was procedures which are described in the checked, recharged,
activated. manual of the system manufacturer. and approved by
authorized service per-
sonnel immediately
after operation.
Rectify the cause for
the false fire alarm.

7 - 20 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00060 - Fire in the power house

[2/3]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
False fire alarm was
The detection and
initiated and the
actuation system and
operator cancelled the Identify the cause of the false fire alarm. the fire suppression
alarm by pushing the
systems must be
reset button at the
C checked and approved
CHECKFIRE SC-N REMARKS: Also refer to the troubleshooting
by authorized service
control module. procedures which are described in the
personnel only.
The fire suppression manual of the system manufacturer.
Rectify the cause for
system was not
the false fire alarm.
activated.
Bring the machine back into the original condition.
Final check
Start the machine and verify that the trouble code does not arise again.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 21

 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (fire alarm & safety circuit) for trouble code G00060
[3/3]

Fig. 7-12 Wiring Diagram (fire alarm & safety circuit) for trouble code G00060

7 - 22 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00065 - Very low hydraulic oil level

[1/1]
Trouble code
Message Very low hydraulic oil level
G00065

Contents of trouble Hydraulic oil level is very low, Hydraulic oil needs refilling.

– The hydraulic oil level dropped below the refilling oil level (below 5%).
Related information – The hydraulic oil level is still above the minimum oil level (sensor 40B004).
– Sensor 40B050 generates the message.
– Background colour of the trouble code information: yellow
Action of controller
– 7 segment LED-Code at K+ controller: M582
Problem that appears
Risk, to run out of hydraulic oil.
on the machine

Instruction message 2 Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Check with stopped engine and the attachment in its defined position.
1. Check the hydraulic oil level at the sight glass and fill up hydraulic oil.
Hydraulic oil needs Observe the hydraulic oil temperature and refill oil up to the appropriate
1
refilling level. Sight glass
2. Verify if other trouble messages concerning the hydraulic oil are displayed.
If other messages are displayed follow their instructions as necessary.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the trouble code does not arise again.

View onto the hydraulic oil level label

Fig. 7-13 View onto the hydraulic oil level label

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 23

 Troubleshooting by KOMTRAX Plus trouble code

G00066 - Trouble hydraulic oil temperature

[1/4]
Trouble code
Message Trouble hydraulic oil temperature
G00066
– The hydraulic oil temperature sensor 59B015 detects an oil temperature >T4.
Contents of trouble
– Bucket function is disabled.
The hydraulic oil temperature sensor 59B015 detects an oil temperature above the maximum per-
Related information
missible operating temperature according to Table 7-1 on page 7-26.
– Background colour of the trouble code information: yellow
Action of controller – On condition that the engine is running: the fan speed is set to max. speed.
– 7 segment LED-Code at K+ controller: M590
Problem that appears
The hydraulic oil is overheated and the bucket movement is blocked.
on the machine

Instruction message 2 Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle, with max. fan speed.

Using a laser temperature meter check the Yes Go to step 6.

hydraulic oil temperature at the temperature
The hydraulic oil sensor 59B015. Check for other Refer to
1 relating trouble codes Table 7-1
is overheated For the defined hydraulic oil temperatures refer
and follow the relating on
to Table 7-1 on page 7-26. No troubleshooting chart page 7-26.
Does the measured hydraulic oil temperature as necessary.
indicate overheating as well?
Go to next step.
 Main key switch 20S001 OFF
Yes Go to next step.
Adjust 11K039 to the
correct switching point.
Refer to SHOP MAN- Refer to
Wrong setting of tem- Check the temperature setting in relation to the UAL part 10 STRUC-
perature switch point at 2 hydraulic oil viscosity used in the machine. Table 7-1
TURE & FUNCTION, on
converter relay 11K039 Values are given in Table 7-1 on page 7-26. No chapter 9, section page 7-26.
Are the oil viscosity settings correct? "TEMPERATURE
CONTROL" for setting SHOP
instructions. MANUAL

Go to final check (last

step).
 Main key switch 20S001 OFF
Refer to the wiring diagram. Yes Go to next step.
Defective hydraulic oil
Disconnect the connector from the hydraulic oil Replace hydraulic oil Refer to
temperature sensor
3 temperature sensor 59B015. temperature sensor PT100
59B015
(PT100 type) Check hydraulic oil temperature sensor No 59B015. tempera-
59B015 according to the standard value table. Go to final check (last ture charts
Is the test result OK? step).

7 - 24 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00066 - Trouble hydraulic oil temperature

[2/4]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF
1. Refer to the PARTS & SERVICE NEWS Converter module
AH07527 (latest version) and check func- 11K039
Defective converter tion and wiring of converter relay 11K039. Repair or replace as
relay 11K039 or defec- necessary.
2. Check all wiring segments for continuity:
tive wiring in the sensor Wiring of sensor circuit
circuit 4 – From temperature sensor 59B015, Yes Refer to the Wiring
(disconnection or – via converter relay 11K039, Diagram. Locate the
defective contact in any problem and repair as
– to K+ controller 14K300.
connector) necessary.
Could you identify any trouble? Go to final check (last
step).
No Go to next step.
 Engine OFF & maintenance safety switch 50S058 OFF + locked
REMARKS: This test step must only be 1. Clean the hydrau-
performed if the engine lic oil cooler with a
is standing still. water pressure
Any clogged hydraulic Perform a visual inspection of the hydraulic oil cleaner as neces-
oil cooler caused the cooler. Also open the swing out doors of the sary.
5 cooler frame and check for deposits between Yes
overheating of the 2. Continue to work
hydraulic oil these door wings.
and monitor the
Is intense pollution present? hydraulic oil tem-
perature on the K+
display.
No Go to next step.
 Engine running at high idle.
Maximum fan speed is achieved if no voltage Yes Go to next step.
(0V) is applied at both solenoid valves
57K506a and 57K506b. Therefore disconnect
the cable connectors from both solenoid
valves 57K506a and 57K506b.
If the setting is not as
If the fan speed does not increase, check the specified follow the RPMmax
The fan is not driven hydraulic settings for the fan speed (refer to adjustment and/or
6 1250±50
at max. speed SHOP MANUAL part 10 STRUCTURE & inspection procedures
FUNCTION, chapter 6, section "CHECKS No SHOP
in SHOP MANUAL
AND ADJUSTMENTS OF THE COOLER FAN part 10 STRUCTURE MANUAL
DRIVE SPEEDS" ). & FUNCTION
Connect both cable connectors to the solenoid as necessary.
valves 57K506a and 57K506b again.
Is the hydraulic setting for max. fan speed cor-
rect?
Yes Go to next step.
Adjust back pressure
Check the pressure setting of the back pres- valve to the correct
sure valve according to the instructions given pressure.
in the SHOP MANUAL part 10 STRUCTURE & Refer to the SHOP 8±5bar
Wrong back pressure FUNCTION , chapter 6, section "CHECKS
7 MANUAL part 10 SHOP
valve adjustment AND ADJUSTMENT OF THE BACK PRES- No
STRUCTURE & MANUAL
SURE VALVE" . FUNCTION for setting
Is the pressure setting correct? instructions.
Go to final check (last
step).

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 25

 Troubleshooting by KOMTRAX Plus trouble code

G00066 - Trouble hydraulic oil temperature

[3/4]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
Yes Go to next step.
Defective solenoid Check the electrical and mechanical function Replace solenoid valve Standard
valve 40K601 for back 8 of the solenoid valve 40K601. 40K601. Value
pressure valve control No
Is the function ok? Go to final check (last Table
step).
 Engine running at high idle, with max. fan speed.
Overheating due to any Continue to work and
malfunction in the 9 Check the hydraulic system by performing the monitor the hydraulic PM-
hydraulic system PM-Clinic. oil temperature on the CLINIC
K+ display.
Bring the machine back into the original condition.
Final check 10
Start the machine and verify that the trouble code does not arise again.

Hydraulic oil temperature table - 11K039 adjustment (T4 switch point)

Shell Tellus Shell Tellus

Arctic Arctic
ISO oil viscosity grade VG 22 VG 32 VG 46 VG 68 VG 100
S4VX32 S4VX32
(new) (stabilized)
11K039 adjust temperature limit value
58°C 69°C 79°C 85°C 85°C 85°C 81°C
to switching point (T4)

Table 7-1

7 - 26 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (59B015 and 11K039) for G00066

[4/4]

Fig. 7-14 Wiring Diagram (59B015 and 11K039) for G00066

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 27

 Troubleshooting by KOMTRAX Plus trouble code

G00067 - Trouble battery voltage too high

[1/2]
Trouble code
Message Trouble battery voltage too high
G00067

Contents of trouble Via the resistor 11T080 the system detects too high battery voltage.

– If the battery voltage at 11T080 is >=29V for 5s, the trouble code is set.
Related information – The system assumes that resistor 11T080 and its wiring are not defective.
– Use the REAL TIME MONITOR for verification (04 Electrical Equipm., screen 1/1)
– Background colour of the trouble code information: yellow
Action of controller
– 7 segment LED-Code at K+ controller: M991
Problem that appears
-
on the machine

Instruction message 2 Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at low idle.
A Measure the charging voltage between Ucharge
alternator terminal "B+" and chassis Yes Go to next step. min. 27.5V
(body ground). max. 29V
B Also see the charging voltage value which
is shown on the REAL TIME MONITOR
(KOMTRAX Plus).
The voltage regulator
in the alternator may 1. Engine OFF
be defective and 1 2. 20S001 ON
causes the battery Replace the alternator.
over voltage 3. REAL TIME MONITOR
(refer to Fig. 7-11 on page 7-19) No Go to final check (last
 04 Electrical Equipm. step).
 Screen 1/1
4. Check the input signal of 11T080 on the
REAL TIME MONITOR.
Does the charging voltage meet the
specification?
 Engine OFF & maintenance safety switch 50S058 OFF + locked
Resistor 11T080 or its 1. Measure both resistors inside the module. – If a resistor is defective, replace 11T080.
wiring may be the
2 2. Refer to the wiring diagram and check for – if necessary, repair or replace the wiring/
cause for the battery
over voltage proper cable connections. connections of 11T080.
Go to final check (last step).
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

7 - 28 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Input signal of the resistor 11T080 on the REAL TIME MONITOR

[2/2]

Fig. 7-15 Input signal of the resistor 11T080 on the REAL TIME MONITOR

Wiring Diagram (11T080) for G00067

Fig. 7-16 Wiring Diagram (11T080) for G00067

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 29

 Troubleshooting by KOMTRAX Plus trouble code

G00070 - Trouble oil temperature gear (PTO 1)

[1/4]
Trouble code
Message Trouble oil temperature gear (PTO 1)
G00070
Contents of trouble The PTO gear oil temperature sensor 57B049 (PT100 type) signals overheating.
– PTO gear oil temperature is too high for >3 seconds
Related information
– A problem with the gear oil temperature sensor 57B049 or its wiring may also cause the trouble.
– Background colour of the trouble code information: yellow
Action of controller
– 7 segment LED-Code at K+ controller: M591
Problem that appears – The PTO gear oil is overheated.
on the machine – Lubrication capability of the gear oil is reduced. Risk of PTO gear damage.

Instruction message 2 Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle, with max. fan speed.

Using a laser temperature meter, verify if the Yes Go to step 5.

PTO gear oil temperature at the temperature
PTO gear oil sensor 57B049 is too high. Check for other Refer to
1 relating trouble codes Table 7-2
overheated For the definition of the PTO gear oil tempera-
and follow the relating on
tures refer to Table 7-2.on page 7-32. No troubleshooting chart page 7-32.
Does the measured hydraulic oil temperature as necessary.
indicate overheating as well?
Go to next step.
 Main key switch 20S001 OFF
Yes Go to next step.
Adjust 11K143 to the
correct switching point. Refer to
Wrong setting of tem-
Check the temperature setting in relation to the Refer to SHOP MAN- Table 7-2
perature switch point
2 hydraulic oil viscosity used in the machine. UAL part 10 STRUC- on
TG2 at converter relay
Values are given in Table 7-2 on page 7-32. No TURE & FUNCTION, page 7-32.
11K143
Are the oil viscosity settings correct? chapter 4, section SHOP
"PTO GEAR OIL TEM- MANUAL
PERATURE CON-
TROL" for setting
instructions.
 Main key switch 20S001 OFF
1. Refer to the PARTS & SERVICE NEWS Converter relay
Defective converter AH07527 (latest version) and check func- 11K143
relay 11K143 or defec- tion and wiring of converter relay 11K143. Repair or replace as
tive wiring in the sensor necessary.
2. Check all wiring segments for continuity:
circuit 3 Yes Sensor circuit
(disconnection or – From temperature sensor 57B049, Refer to the Wiring
defective contact in any – via converter relay 11K143, Diagram. Locate the
connector) problem and repair as
– to K+ controller 14K300.
necessary.
Could you identify any trouble? No go to next step.

7 - 30 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00070 - Trouble oil temperature gear (PTO 1)

[2/4]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF
Refer to the wiring diagram. Yes Go to next step.
Defective hydraulic oil
temperature sensor Disconnect the connector from the hydraulic oil Refer to
57B049 4 temperature sensor 57B049. Replace hydraulic oil PT100
Check hydraulic oil temperature sensor No temperature sensor tempera-
(PT100 type)
59B049 according to the standard value table. 59B049. ture charts
Is the test result OK?
 Check with stopped engine and the attachment in its defined position.
Yes Go to next step.
Check the PTO gear oil level with the dipstick Refill or drain PTO
PTO gear oil level as described in the OPERATION & gear oil until the target
5
too low MAINTENANCE MANUAL. level is reached. OM/M
No
Is the PTO gear oil level within the specified Then monitor the PTO
range? gear oil temperature
again.
 Engine OFF & maintenance safety switch 50S058 OFF + locked
REMARKS: This test step must only be 1. Clean the hydrau-
performed if the engine lic oil cooler with a
is standing still. water pressure
Any clogged hydraulic Perform a visual inspection of the hydraulic oil cleaner as neces-
oil cooler caused the cooler. Also open the swing out doors of the sary.
6 cooler frame and check for deposits between Yes
overheating of the 2. Continue to work
hydraulic oil these door wings.
and monitor the
Is intense pollution present? hydraulic oil tem-
perature on the K+
display.
No Go to next step.
 Engine running at high idle.
Maximum fan speed is achieved if no voltage Yes Go to next step.
(0V) is applied at both solenoid valves
57K506a and 57K506b. Therefore disconnect
the cable connectors from both solenoid
valves 57K506a and 57K506b. If the setting is not as
If the fan speed does not increase, check the specified follow the RPMmax
The fan is not driven adjustment and/or
7 hydraulic settings for the fan speed (refer to 1250±50
at max. speed inspection procedures
SHOP MANUAL part 10 STRUCTURE & No SHOP
FUNCTION, chapter 6, section "CHECKS in the SHOP MANUAL
part 10 STRUCTURE MANUAL
AND ADJUSTMENTS OF THE COOLER FAN
DRIVE SPEEDS" ). Connect both cable & FUNCTION as nec-
connectors to the solenoid valves 57K506a essary.
and 57K506b again.
Is the setting for max. fan speed correct?

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 31

 Troubleshooting by KOMTRAX Plus trouble code

G00070 - Trouble oil temperature gear (PTO 1)

[3/4]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
1. Carry out adjustments as neces-
sary.
2. Verify that the PTO gear oil
Overheating due to Refer to the SHOP MANUAL part
temperature is in normal range.
any malfunction in the 8 10 STRUCTURE & FUNCTION, chapter 4,
PTO lubrication system No 3. If any other relating trouble code
section "PTO" and follow the given adjustment
procedures. is present, follow the trouble-
shooting procedures of the cor-
responding troubleshooting
chart.
Bring the machine back into the original condition.
Final check 9
Start the machine and verify that the trouble code does not arise again.

PTO gear oil temperature table - 11K143 adjustment

Hypoid oil
ISO oil viscosity grade HLP T32 CLP 150
75W-140
11K143 adjust temperature limit value to switching point (TG2) 60°C 95°C 95°C

Table 7-2

Input signal of 57B049 on the REAL TIME MONITOR

Fig. 7-17 Input signal of 57B049 on the REAL TIME MONITOR

7 - 32 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (59B049 / 11K143) for G00070

[4/4]

Fig. 7-18 Wiring Diagram (59B049 / 11K143) for G00070

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 33

 Troubleshooting by KOMTRAX Plus trouble code

G00071 - Trouble gear lubrication (PTO 1)

[1/4]
Trouble code
Message Trouble gear lubrication (PTO 1)
G00071
Pressure sensor 57B017 (NC*) signals, that there is no pressure in the PTO gear lubrication
Contents of trouble system for >5 seconds, even the engine is running.
*NC = Normally Close

Basic sensor data (57B017)

REAL TIME MONITOR
Condition State
Signal
Related information
No pressure Switch closed 0
Pressure present Switch open 1
Switch point 0.5 bar

– Background colour of the trouble code information: yellow

Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M592
Problem that appears
Risk, to operate the machine without PTO gear lubrication (PTO overheating).
on the machine

Instruction message 2 Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
Yes Go to next step.
Refer to the SHOP MANUAL part
10 STRUCTURE & FUNCTION, chapter 4, Carry out adjustments
as necessary. 7.5 bar
section "CHECKS AND ADJUSTMENTS -
1 PTO LUBRICATION PRESSURE" and follow After that recheck if the SHOP
No PTO gear lubrica- No
the given adjustment procedures. PTO gear lubrication MANUAL
tion pressure present /
Are the pressure adjustments as specified? pressure is in normal
adjustment of PTO
range.
valve block incorrect
 Main key switch 20S001 OFF

2 Continue to work and verify that

Check the PTO gear oil type and viscosity and
trouble code G00071 is not set
correct if necessary.
again.
 Main key switch 20S001 OFF
Yes Go to next step.
Adjust 11K182 to the
Wrong setting of tem- correct switching point.
perature switch point Check the PTO gear oil settings (viscosity). Refer to the OPERA- Refer to
3 TION & Table 7-3
TG1 at converter relay Values are given in Table 7-3 on page 7-36.
11K182 No MAINTENANCE MAN- on
Are the oil viscosity settings correct? UAL for setting instruc- page 7-36.
tions.
Go to final check (last
step).

7 - 34 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00071 - Trouble gear lubrication (PTO 1)

[2/4]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 K+ Service Menu ON.
Pressure switch 57B017 disconnected.
Yes Go to next step.
Refer to the wiring dia-
REAL TIME MONITOR gram and locate the
(refer to Fig. 7-21 on page 7-37) Problem:
 02 PTO 1
– Wiring:
Pressure switch  Screen 1/1
If necessary, repair
57B017 or its wiring 4 Check the input signal of 57B017 on the K+ or replace the wir- Wiring
defective monitor under the following conditions:
No ing/connections. Diagram
– Engine running in low idle – Pressure switch
– Engine OFF. 57B017:
Does the displayed input change over (0 1) Replace the pres-
when you shut OFF the engine? sure switch.
Go to final check (last
step).
 Main key switch 20S001 OFF
Refer to the wiring diagram. Yes Go to next step.
Defective PTO oil tem-
Disconnect the connector from the hydraulic oil Replace PTO oil tem- Refer to
perature sensor
5 temperature sensor 57B182. perature sensor PT100
57B182
(PT100 type) Check hydraulic oil temperature sensor No 57B182. tempera-
57B182 according to the standard value table. Go to final check (last ture charts
Is the test result OK? step).
 PTO gear oil at operating temperature and main key switch 20S001 OFF
1. Check if the LED at the converter relay
11K182 is ON. Converter module defective, LED is ON, and
2. Check if solenoid valve 57K553 is ener- solenoid valve 57K553 energized:
Defective converter Replace converter relay 11K182.
gized.
relay 11K182 causes 6
the trouble The solenoid valve must not be energized Wiring :
at gear oil at operating temperature. Locate the problem, if necessary, repair or
replace the wiring/connections.
3. Refer to the PARTS & SERVICE NEWS
AH07527 (latest version) and check func- Go to final check (last step).
tion and wiring of converter relay 11K182.
Bring the machine back into the original condition.
Final check 7
Start the machine and verify that the trouble code does not arise again.

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 Troubleshooting by KOMTRAX Plus trouble code

PTO gear oil temperature table - 11K182 adjustment

[3/4]
Hypoid oil
ISO oil viscosity grade HLP T32 CLP 150
75W-140
11K182 adjust temperature limit value to switching point (TG1) 15°C 48°C 54°C

Table 7-3

Wiring Diagram (57B017) for trouble code G00071

Fig. 7-19 Wiring Diagram (57B017) for trouble code G00071

7 - 36 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (57B182 & 11K182) for G00071

[4/4]

Fig. 7-20 Wiring Diagram (57B182 & 11K182) for G00071

Input signal of 57B017 on the REAL TIME MONITOR

Fig. 7-21 Input signal of 57B017 on the REAL TIME MONITOR

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 Troubleshooting by KOMTRAX Plus trouble code

G00091 - Pilot control cut out

[1/2]
Trouble code
Message Pilot control cut out
G00091

Contents of trouble Pilot control is locked.

Pilot control is locked if:

– Refilling arm and/or ladder is down.
Related information
– Refilling arm and/or ladder is not in end position.
– Lock lever is pulled up.
– Background colour of the trouble code information: blue
Action of controller
– 7 segment LED-Code at K+ controller: M593
Problem that appears
Hydraulic operation is not possible.
on the machine
Ladder end switch or lock lever contact open or service arm down or unlocked.
Instruction message 9
- If failure exists further, inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON.
The lock lever is not Yes Go to next step.
pushed down or its Check the position of the lock lever (down). Push the lock lever
1
switch 20S105 is Is the lock lever pushed down in its operating down in its operating
not closed No
position? position and continue
to work.
Yes Go to next step.
Replace the switch if Rwire
it is defective. max. 1Ω
If the wiring has a Rrelay
Lock lever switch Refer to the Wiring Diagram and check the problem, locate the 443 ± 1.0Ω
20S105 or its wiring switch function and the belonging wiring. problem and repair
2
(including relay No as necessary.
11K111) is defective Are the switch and its wiring ok?
replace relay11k111 if
necessary.
After repair recheck
the system for proper
function.
If no refilling process
takes place, move the
refilling arm back into
Yes its upper end position.
Verify that the trouble
message is no longer
displayed.
The refilling arm is Check the refilling arm position. For detailed informa-
not in the upper 3 tion on the adjustment
end position Is the refilling arm in the upper end position?
of the proximity switch
55B023 at the refilling
arm (end position),
No
refer to the latest ver-
sion of PARTS & SER-
VICE NEWS AH05539
(latest version) and fol-
low the instructions.

7 - 38 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00091 - Pilot control cut out

[2/2]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
Move the access ladder up and
check the following:
(a) The trouble message is no
Yes longer displayed.
(b) The excavator can be operated
The access ladder Check if the access ladder is down.
4 normally (hydraulic operation is
is down Is the access ladder down? no longer blocked).
For detailed information concerning
the access ladder function refer to
No your SHOP MANUAL part
10 STRUCTURE & FUNCTION
chapter 12.
Bring the machine back into the original condition.
Final check 5
Start the machine and verify that the trouble code does not arise again.

View onto the lock lever and the cover of 20S105 (G00091)
Legend for Fig. 7-22:

(1) Lock lever

(2) Cover of lock lever switch 20S105 at the right side
of operator’s seat

[F] UNLOCKED - lock lever down in operation position

[L] LOCKED - lock lever up, pilot control is locked

Fig. 7-22 Lock lever and cover of 20S105

Wiring Diagram (20S105 and wiring) for G00091

Fig. 7-23 Wiring Diagram 1 (emergency switches) for G00091

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 39

 Troubleshooting by KOMTRAX Plus trouble code

G00092 - Emergency shut-down at access ladder

G00093 - Emergency shut-down at valve block
G00095 - Emergency shut-down in cabin
G00097 - Emergency shut-down at counterweight

[1/3]
Trouble code G00092 - Emergency shut-down at access ladder
G00093 - Emergency shut-down at valve block
Message
G00092 ~ G00097 G00095 - Emergency shut-down in cabin
G00097 - Emergency shut-down at counterweight
Emergency shut-down switch was activated when the engine is standing still.
The involved emergency shut-down switches are as follows:

Emergency shut-down switch Location Trouble code

Contents of trouble 70S033a Ladder G00092
61S033b Valve block G00093
20S036 Operator´s cab G00095
51S033d Counterweight G00097

Related information Engine start is blocked.

– Background colour of the trouble code information: red
– Engine start is blocked.
Action of controller
– 7 segment LED-Code at K+ controller: M482 - G00092, M594 - G00093, M483 - G00095,
M484 - G00097
Problem that appears
It needs to be checked why the relating emergency shut-down switch was activated.
on the machine
Emergency shut-down switch was actuated.
Instruction message 10 Unlock before restarting.
If failure exist further, inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
Rectify the cause or
problem.
Any emergency Check the cause for the emergency activation. Yes After that, release the
shut-off button 1 concerned emergency
was activated Is any cause present? shut-off switch(es) and
reset the safety circuit.
No Go to next step.
Refer to the Wiring
Diagram. Repair or
The concerned Refer to the Wiring Diagram. replace the concerned
emergency shut-off switch or its wiring as
2 Visually inspect the concerned switch, the switch
button or its wiring necessary.
may be defective contacts, and the respective wiring.
After repair go to
final step 3.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

7 - 40 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram 1 (emergency switches) for G00092~G00095

[2/3]

Fig. 7-24 Wiring Diagram 1 (emergency switches) for G00092~G00095

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 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram 2 (emergency switches signal lines) for G00092~G00095

[3/3]

Fig. 7-25 Wiring Diagram 2 (emergency switches signal lines) for G00092~G00095

7 - 42 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00100 - Maintenance Safety Switch

[1/2]
Trouble code
Message Maintenance Safety Switch
G00100

Contents of trouble If the maintenance safety switch 50S058 is switched OFF, the engine is turned off / standing still.

– Engine start is blocked for safety reasons.

Related information
– 50S058 is the maintenance safety switch which can be secured with padlocks.
– Background colour of the trouble code information: blue
Action of controller
– 7 segment LED-Code at K+ controller: MA01
Problem that appears
For safety reasons the engine start is made impossible via the safety switch 50S058.
on the machine

Instruction message 11 Engine switched off by Maintenance Safety Switch in the engine room.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001OFF.
The maintenance Check the condition of the maintenance safety Contact your supervi-
safety switch 50S058 1 switch. Yes sor and clarify the
is locked intentionally Is the maintenance safety switch switched situation.
OFF and locked with a padlock? No Go to next step.
 Main key switch 20S001OFF.
Switch 50S058
Repair or replace as
necessary.

Yes Wiring of 50S058

The maintenance Refer to the Wiring
Refer to the Wiring Diagram and check the Diagram. Locate the
safety switch 50S058
2 function of the maintenance safety switch and problem and repair as
or its wiring may be
its wiring. necessary.
defective
Could you identify any trouble? Check the segments of
the voltage supply
wiring separately,
No
locate the problem,
and repair as
necessary.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

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 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (50S058) for trouble code G00100

[2/2]

Fig. 7-26 Wiring Diagram (50S058) for trouble code G00100

7 - 44 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00104 - Trouble battery current

[1/4]
Trouble code
Message Trouble battery current
G00104
– The discharging current at converter 11T117 is too high (< -200A for >5 sec.).
Contents of trouble – At the shunt resistor 71T003 a discharging current of less than -200A is present
(the engine is standing still).
– For this test step a clamp-on ammeter is required (Ampere).
Related information – The discharge current is abnormally high.
– Use the REAL TIME MONITOR for verification (04 Electrical Equipm., screen 1/1)
– Background colour of the trouble code information: yellow
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M995
Problem that appears
Risk to discharge batteries completely.
on the machine

Instruction message 15 Load of the batteries too high. - Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON - Engine OFF.
REMARKS: Before taking the following mea- Replace the alternator.
surements check for the correct Yes Go to final check (last
order of the cable connections at step).
71T003 "B" and 71T003 "L".

In case the cable connections are

mixed up, connect them in the
correct order.

B = battery side
L = alternator side
The alternator Using a clamp-on ammeter measure the
(52G005) is defective 1 current in front of and behind the shunt
(short circuit to ground) resistor 71T003.

No Go to next step.

Do you measure a negative current flow

< -200A between 71T003 & 52G005
and between 71T003 & the batteries?

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 Troubleshooting by KOMTRAX Plus trouble code

G00104 - Trouble battery current

[2/4]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON - Engine OFF
– If the current flow at one of both
starter motors is too high, both
starter motors have to be
Refer to the Wiring Diagram.
Using a clamp-on ammeter: replaced.
After repair recheck the system
The starter motors 1. Measure the current between terminal block
for proper function.
52M001-1 & 52M002-1 2 71X_71-4 and starter motor 52M001-1.
– If no problem could be found,
are defective 2. Measure the current between terminal block
check if other trouble codes
71X_71-4 and starter motor 52M002-1.
relating to the charging system
3. Measure the current between the starter motors are pending.
and ground. If so, follow the relevant
troubleshooting procedures.
Go to final check (last step).
1. Refer to the Wiring Diagram and check for proper – Wiring:
cable connections: If necessary, repair
– 11T117 power supply or replace the wir-
ing/connections of
– 11T117 ground connections 51T017.
– Signal line between 11T117 and K+ controller – Module 11T117:
14K300 If the function
– Wiring between 11T117 and 71T003 of 11T117 is not Wiring
Module 11T117 or its according to the Diagram
3 2. Check the converter module according to the
wiring is defective conversion chart, Conver-
conversion chart:
replace the con- sion chart
Conversion chart (11T117) verter module.
Charge / discharge current Go to final check (last
step).
Input -150 mV 0 +150 mV
Output 2V 6V 10 V
Current -150 A 0A 250 A
Bring the machine back into the original condition.
Final check 4
Start the machine and verify that the trouble code does not arise again.

Input signal of the converter 11T117 on the REAL TIME MONITOR

Fig. 7-27 Input signal of the converter 11T117 on the REAL TIME MONITOR

7 - 46 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram 1 (71T003 & 52G005) for trouble code G00104

[3/4]

Fig. 7-28 Wiring Diagram 1 (71T003 & 52G005) for trouble code G00104

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 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram 2 (52G005, 52M001-1 & 52M002-1) for trouble code G00104
[4/4]

Fig. 7-29 Wiring Diagram 2 (52G005, 52M001-1 & 52M002-1) for trouble code G00104

7 - 48 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00105 - Trouble battery charging current too low

[1/4]
Trouble code
Message Trouble battery current
G00104
– Engines running at high idle.
– The charging current from the alternator (52G005) is too low.
Contents of trouble – The monitoring system detected via:
– 11T117 → charging current below 4A for 2 seconds
– 11T080 → battery voltage dropped below 23V
– For this test step a clamp-on ammeter is required (Ampere).
Related information
– Use the REAL TIME MONITOR for verification (04 Electrical Equipm., screen 1/1)
– Background colour of the trouble code information: yellow
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M996
Problem that appears
Risk to discharge batteries completely.
on the machine

Instruction message 15 Load of the batteries too high. - Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engines running at high idle.
REMARKS: Before taking the following mea- Umin 27.5V
surements check for the correct Yes Go to next step.
Umax 29.5V
order of the cable connections at
71T003 "B" and 71T003 "L".

In case the cable connections are

mixed up, connect them in the
1 correct order.
Replace the alternator.
B = battery side No Go to final check (last
L = alternator side step).
Measure the charging voltage between alter-
nator terminal B+ and ground.

The alternator Does the measurement reading meet the

(52G005) or its wiring specification?
is defective  Main key switch 20S001 ON - Engine OFF.
Using a clamp-on ammeter measure the Icharge
charging current in front of and behind the Yes Go to next step.
25-35A
shunt resistor 71T003.

2
Replace the alternator.
No Go to final check (last
step).

Is the measured charging current within the

specified range?

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 Troubleshooting by KOMTRAX Plus trouble code

G00105 - Trouble battery charging current too low

[2/4]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON - Engine OFF
1. Measure both resistors inside the module. – If a resistor is defective, replace 11T080.
Module 11T080 or its
3 2. Refer to the wiring diagram and check for – if necessary, repair or replace the wiring/
wiring is defective
proper cable connections. connections of 11T080.
Go to final check (last step).
1. Refer to the Wiring Diagram and check for proper – Wiring:
cable connections: If necessary, repair
– 11T117 power supply or replace the wir-
ing/connections of
– 11T117 ground connections 51T017.
– Signal line between 11T117 and K+ controller – Module 11T117:
14K300 If the function
– Wiring between 11T117 and 71T003 of 11T117 is not Wiring
Module 11T117 or its according to the Diagram
4 2. Check the converter module according to the
wiring is defective conversion chart, Conver-
conversion chart.
replace the con- sion chart
Conversion chart (11T117) verter module.
Charge / discharge current Go to final check (last
step).
Input -150 mV 0 +150 mV
Output 2V 6V 10 V
Current -150 A 0A 250 A
Bring the machine back into the original condition.
Final check 5
Start the machine and verify that the trouble code does not arise again.

Input signals of 11T080 & 11T117on the REAL TIME MONITOR

Fig. 7-30 Input signals of 11T080 & 11T117 on the REAL TIME MONITOR

7 - 50 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram 1 (71T003 & 11T117) for trouble code G00105

[3/4]

Fig. 7-31 Wiring Diagram 1 (71T003 & 52G005) for trouble code G00105

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 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram 2 (11T080) for trouble code G00105

[4/4]

Fig. 7-32 Wiring Diagram 2 (11T080) for trouble code G00105

7 - 52 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00164 - Trouble air cleaner 1

[1/2]
Trouble code
Message Trouble air cleaner 1
G00164
– The message is displayed if the sensors 52B018-1 & 52B019-1 of the engine air filters detect
clogged air filters.
Contents of trouble
– The system assumes that the monitoring circuits of the engine air filter sensors are not dis-
turbed.
Sensors 52B018-1 & 52B019-1 watch the vacuum pressure in the inlet manifolds between air filters
Related information
and engine.
– Background colour of the trouble code information: yellow
Action of controller
– 7 segment LED-Code at K+ controller: M485
With clogged air filter(s) the following problems occur:
– Loss in rated engine power
– Poor exhaust emission quality
– Increased fuel consumption
Problem that appears
on the machine – Increased exhaust gas temperature
– Reduced engine lifetime
REMARKS: If machines are operated at locations higher than 3600 m, they sooner will be
affected by the above mentioned effects, even though the system does not yet
display any trouble message.

Instruction message 17 Inform service till end of shift and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF – Engine OFF – Maintenance safety switch
50S058 OFF & locked
Replace the outer filter elements (4 pieces) and check the inner filter elements at
the service indicators.
If necessary or if the indicators are switched to red, replace the inner filter
elements.

How to identify a clogged outer engine air filter element

The only correct method to identify the clogged condition of an
outer engine air filter element is to compare the weights of a
new and a clogged outer air filter element.
The engine air filters
are clogged Example:
1 Weight of a new air filter element: approx. 9 kg
(inner and outer
elements) Weight of a clogged air filter element: approx. 20 kg

– The replacement interval depends on the respective environmental

conditions. Always monitor the engine air filter elements according to
your local operations conditions.
– After every 2nd replacement of the outer engine air filter elements the
inner air filter elements must be replaced too.
– The air filter box must be cleaned thoroughly after the period of
every 1000 operating hours.
Go to final check (last step) 2.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the trouble code does not arise again.

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 Troubleshooting by KOMTRAX Plus trouble code

View onto the engine air cleaner (G00164)

[2/2]

Fig. 7-33 View onto the engine air cleaner (G00164)

(1) Wing nut (4) Outer air filter element

(2) Lock washer (5) Indicator

(3) Washer (6) Inner air filter element

7 - 54 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00165 - Trouble breather filter hydraulic oil tank

[1/2]
Trouble code
Message Trouble breather filter hydraulic oil tank
G00165
The trouble message is displayed if sensor 40B024 (NO*) detects a clogged breather filter at the
Contents of trouble hydraulic oil tank.
*NO = Normally Open
Sensor 40B024 watches the vacuum pressure of the breather and ventilation of the hydraulic oil
Related information
tank.
– Background colour of the trouble code information: yellow
Action of controller
– 7 segment LED-Code at K+ controller: M585
Problem that appears
A clogged breather adversely affects the circulation of the hydraulic oil in the tank.
on the machine

Instruction message 17 Inform service till end of shift and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF.
Replace the breather filter(s) as necessary.
For details refer to the OPERATION & MAINTENANCE
MANUAL, section HYDRAULIC SYSTEM - FILTER
SERVICE.
A breather filter REMARKS: Only use steel made filter elements.
1 Go to final check (last
is clogged If this trouble message appears frequently in-between step).
the replacement intervals, make sure that:
(a) the hydraulic oil tank is not overfilled when the
machine is in its defined position.
(b) consider the dependency on the temperature
range.
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
Disconnect the connector from the pressure sensor
40B024.
The pressure sensor
Use the REAL TIME MONITOR for verification Remove the sensor and replace it
40B024 is defective
2 (refer to Fig. 7-35 on page 7-56). by a new one.
(pressure sensor has  03 Hydraulic After that recheck the system for
an internal stuck)  Screen 2/3 proper function.
REAL TIME MONITOR shows "1" with sensor con- Go to final check (last step).
nected and "0" with sensor disconnected
(confirmation of trouble).
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

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 Troubleshooting by KOMTRAX Plus trouble code

View onto the pressure sensor 40B024 (G00165)

[2/2]

Fig. 7-34 View onto the pressure sensor 40B024 (G00165)

Input signal of 40B024 (filter clogged) on the REAL TIME MONITOR

Fig. 7-35 Input signal of 40B024 (filter clogged) on the REAL TIME MONITOR

7 - 56 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00166 - Trouble oil filter gear (PTO 1)

[1/2]
Trouble code
Message Trouble oil filter gear (PTO 1)
G00166
Pressure sensor 57B027 (NO*) signals, that the filter for the PTO gear lubrication system is
Contents of trouble clogged.
*NO = Normally Open
– The trouble code is not set until the hydraulic oil temperature reached reached T3 (adjusted set
Related information point of converter relay 11K026), refer to Table 7-4.
– A problem with the pressure sensor 57B027 or its wiring may also cause the trouble.
– Background colour of the trouble code information: yellow
Action of controller
– 7 segment LED-Code at K+ controller: M596
Problem that appears
Unfiltered PTO gear oil flows through the bypass of the filter.
on the machine

Instruction message 17 Inform service till end of shift and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF - Engine OFF - Maintenance safety switch
50S058 OFF & locked
Replace the filter
element if necessary.
The PTO gear oil filter
1 Screw off the filter case and check for If the filter element was
is clogged Yes
clogging. clogged check the
Is the filter element clogged? PTO lubrication pump
for wear.
No Go to next step.
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
Disconnect the connector from the pressure sensor
57B027.
The pressure sensor
Use the REAL TIME MONITOR for verification Remove the sensor and replace it
57B027 is defective
2 (refer to Fig. 7-37 on page 7-58). by a new one.
(pressure sensor has
 02 PTO 1 After that recheck the system for
an internal stuck)
 Screen 1/1 proper function.
REAL TIME MONITOR shows "1" with sensor con- Go to final check (last step).
nected and "0" with sensor disconnected
(confirmation of trouble).
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

Hydraulic oil temperature table - 11K026 adjustment (T3 switch point)

Shell Tellus Shell Tellus

Arctic Arctic
ISO oil viscosity grade VG 22 VG 32 VG 46 VG 68 VG 100
S4VX32 S4VX32
(new) (stabilized)
11K026 adjust temperature limit value
32°C 41°C 50°C 58°C 67°C 46°C 39°C
to switching point (T3)

Table 7-4

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 57

 Troubleshooting by KOMTRAX Plus trouble code

View onto the PTO 1 gear oil filter with pressure sensor 57B027 (G00166)
[2/2]

Fig. 7-36 View onto the PTO 1 gear oil filter with pressure sensor 57B027 (G00166)

Input signal of 57B027 (filter clogged) on the REAL TIME MONITOR

Fig. 7-37 Input signal of 57B027 (filter clogged) on the REAL TIME MONITOR

7 - 58 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00169 - Trouble return oil filter hydraulic oil tank

[1/2]
Trouble code
Message Trouble return oil filter hydraulic oil tank
G00169
Pressure sensor 40B026 (NO*) signals, that the back pressure in the return oil filter is higher than
Contents of trouble 2 bar for > 3 seconds.
*NO = Normally Open
– The trouble code is not set until the hydraulic oil temperature reached reached T3 (adjusted set
Related information point of converter relay 11K026), refer to Table 7-5.
– A problem with the pressure sensor 40B026 or its wiring may also cause the trouble.
– Background colour of the trouble code information: yellow
Action of controller
– 7 segment LED-Code at K+ controller: M597
Problem that appears
Unfiltered return oil flows through the bypass of the filter into the hydraulic oil tank.
on the machine

Instruction message 17 Inform service till end of shift and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF - Engine OFF - Maintenance safety switch
50S058 OFF & locked
Replace return oil
filters as described in
Remove filter cover retainers on top of the
the OPERATION &
The return oil filter hydraulic oil tank.
1 MAINTENANCE
is clogged For details refer to the OPERATION & MAIN- Yes MANUAL.
TENANCE MANUAL, section HYDRAULIC
Locate the cause of
SYSTEM - FILTER SERVICE.
the contamination and
Are one or more filters clogged? rectify the problem.
No Go to next step.
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
Disconnect the connector from the pressure sensor
40B026.
The pressure sensor
Use the REAL TIME MONITOR for verification Remove the sensor and replace it
40B026 is defective
2 (refer to Fig. 7-39 on page 7-60). by a new one.
(pressure sensor has  03 Hydraulic After that recheck the system for
an internal stuck)  Screen 2/3 proper function.
REAL TIME MONITOR shows "1" with sensor con- Go to final check (last step).
nected and "0" with sensor disconnected
(confirmation of trouble).
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

Hydraulic oil temperature table - 11K026 adjustment (T3 switch point)

Shell Tellus Shell Tellus

Arctic Arctic
ISO oil viscosity grade VG 22 VG 32 VG 46 VG 68 VG 100
S4VX32 S4VX32
(new) (stabilized)
11K026 adjust temperature limit value
32°C 41°C 50°C 58°C 67°C 46°C 39°C
to switching point (T3)

Table 7-5

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 59

 Troubleshooting by KOMTRAX Plus trouble code

View onto the pressure sensor 40B026 (G00169)

[2/2]

Fig. 7-38 View onto the pressure sensor 40B026 (G00169)

Input signal of 40B026 (filter clogged) on the REAL TIME MONITOR

Fig. 7-39 Input signal of 40B026 (filter clogged) on the REAL TIME MONITOR

7 - 60 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00170 - Trouble leak oil filter hydraulic oil tank

[1/2]
Trouble code
Message Trouble leak oil filter hydraulic oil tank
G00170
Pressure sensor 40B025 (NO*) signals, that the leak oil filter in the hydraulic tank is clogged.
Contents of trouble
*NO = Normally Open
– The trouble code is not set until the hydraulic oil temperature reached reached T3 (adjusted set
Related information point of converter relay 11K026), refer to Table 7-6.
– A problem with the pressure sensor 40B164 or its wiring may also cause the trouble.
– Background colour of the trouble code information: yellow
Action of controller
– 7 segment LED-Code at K+ controller: M598
Problem that appears
Unfiltered leak oil flows through the bypass of the filter into the hydraulic oil tank.
on the machine

Instruction message 17 Inform service till end of shift and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF - Engine OFF - Maintenance safety switch
50S058 OFF & locked
Replace the leak oil
filter as described in
Remove filter cover retainers on top of the
the OPERATION &
The leak oil filter hydraulic oil tank.
1 MAINTENANCE
is clogged For details refer to the OPERATION & MAIN- Yes MANUAL.
TENANCE MANUAL, section HYDRAULIC
Locate the cause of
SYSTEM - FILTER SERVICE.
the contamination and
Is the leak oil filter clogged? rectify the problem.
No Go to next step.
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
Disconnect the connector from the pressure sensor
40B025.
The pressure sensor
Use the REAL TIME MONITOR for verification Remove the sensor and replace it
40B025 is defective
2 (refer to Fig. 7-39 on page 7-60). by a new one.
(pressure sensor has  03 Hydraulic After that recheck the system for
an internal stuck)  Screen 2/3 proper function.
REAL TIME MONITOR shows "1" with sensor con- Go to final check (last step).
nected and "0" with sensor disconnected
(confirmation of trouble).
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

Hydraulic oil temperature table - 11K026 adjustment (T3 switch point)

Shell Tellus Shell Tellus

Arctic Arctic
ISO oil viscosity grade VG 22 VG 32 VG 46 VG 68 VG 100
S4VX32 S4VX32
(new) (stabilized)
11K026 adjust temperature limit value
32°C 41°C 50°C 58°C 67°C 46°C 39°C
to switching point (T3)

Table 7-6

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 61

 Troubleshooting by KOMTRAX Plus trouble code

View onto the pressure sensor 40B025 (G00170)

[2/2]

Fig. 7-40 View onto the pressure sensor 40B025 (G00170)

Input signal of 40B025 (filter clogged) on the REAL TIME MONITOR

Fig. 7-41 Input signal of 40B025 (filter clogged) on the REAL TIME MONITOR

7 - 62 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00176 - Trouble battery voltage too low

[1/3]
Trouble code
Message Trouble battery voltage too low
G00176

Contents of trouble Via the resistor 11T080 the system detects too low battery voltage.

– If the battery voltage at 11T080 is <18 V for 5 seconds, the trouble code is set.
– The system assumes that the resistor 11T080 and its wiring is not defective.
Related information
– If any other trouble code is displayed which indicates a problem with the alternator or the
batteries, consider the influence of this malfunction before starting troubleshooting.
– Background colour of the trouble code information: yellow
Action of controller
– 7 segment LED-Code at K+ controller: M992
Problem that appears
Another engine start may be impossible.
on the machine

Instruction message 17 Inform service till end of shift and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Ucharge
Using a multimeter measure the charging
Yes Go to next step. min. 27.5V
The alternator is voltage at terminal B of the shunt resistor
1 max. 29.5V
defective 71T003.
Replace the alternator
Does the charging voltage meet the
No and recheck for proper
specification?
charging voltage.
 Engine running at high idle.
Using a multimeter measure the charging Ucharge
voltage between alternator terminal B+ and Yes Go to next step. min. 27.5V
chassis (body ground). max. 29.5V
Also see the charging voltage value which is
shown on the K+ display:
REAL TIME MONITOR
 03 Electrical Equipm.
 Screen 1/1
The shunt resistor
2
71T003 is defective Replace the shunt
resistor and recheck
No
for proper charging
voltage.

Does the charging voltage meet the

specification?

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 63

 Troubleshooting by KOMTRAX Plus trouble code

G00176 - Trouble battery voltage too low

[2/3]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF.
Check the clamps at
Any battery is defective Battery information the battery poles for
(or batteries) Battery Location Function proper contact and
secure fixation.
71G001 UBATTERY
REMARKS: Yes In case of any poor min. 10V
71G002 condition, rework the
If the machine is Cat walk Battery charging max. 12V
not equipped with 3 71G003 affected battery pole
maintenance-free and reconnect clamps
71G004
batteries, first check which are not fixed
the battery acid level Disconnect each battery and measure the correctly.
and correct if battery voltage. Replace any defective
necessary. battery/batteries
Does the voltage of each battery meet the No
according to your
specification?
local regulations.
Bring the machine back into the original condition.
Final check 4
Start the machine and verify that the trouble code does not arise again.

7 - 64 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (71T003) for trouble code G00176

[3/3]

Fig. 7-42 Wiring Diagram (71T003) for trouble code G00176

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 65

 Troubleshooting by KOMTRAX Plus trouble code

G00177 - Trouble battery charging circuit

[1/2]
Trouble code
Message Trouble battery charging circuit
G00177
– The system detected at 11T117 that the batteries are charged even the engine is standing still.
Contents of trouble – At the shunt resistor 71T003 a charging current of more than 4 A is detected while the engine
is standing still.
– For this test step a clamp-on ammeter is required (Ampere).
Related information
– Use the REAL TIME MONITOR for error verification (07 Electrical Equipm. screen 1/1).
– Background colour of the trouble code information: yellow
Action of controller
– 7 segment LED-Code at K+ controller: M997
Problem that appears
---
on the machine

Instruction message 17 Inform service till end of shift and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value

The shunt resistor  Main key switch 20S001 ON - Engine OFF

71T003 is defective or If the measurement
1 Using a clamp-on ammeter, measure the current at the
the battery cables are reading is above 4A,
mixed up shown measuring points 1-3 in Fig. 7-42 on page 7-65.
go to next step.
 Main key switch 20S001 OFF.
Battery cables disconnected from the shunt resistor 71T003.
Measure the resistance of the shunt resistor.
The shunt resistor If the measurement does not meet the specification, replace the shunt resistor.
71T003 is defective or
2 Refer to the Wiring Diagram. Disconnect all battery connections between the
the battery cables are RShunt
mixed up or damaged particular batteries, between the starter motors, and between the alternator and
4.5±0.5Ω
the shunt resistor.
Locate the problem in the main battery wiring and repair as necessary.
If no problem can be found, go to next step
1. Refer to the Wiring Diagram and check for proper – Wiring:
cable connections: If necessary, repair
– 11T117 power supply or replace the wir-
ing/connections of
– 11T117 ground connections 51T017.
– Signal line between 11T117 and K+ controller – Module 11T117:
14K300 If the function
– Wiring between 11T117 and 71T003 of 11T117 is not Wiring
Module 11T117 or its according to the Diagram
3 2. Check the converter module according to the
wiring is defective conversion chart, Conver-
conversion chart.
replace the con- sion chart
Conversion chart (11T117) verter module.
Charge / discharge current Go to final check (last
step).
Input -150 mV 0 +150 mV
Output 2V 6V 10 V
Current -150 A 0A 250 A

Bring the machine back into the original condition.

Final check 4
Start the machine and verify that the trouble code does not arise again.

7 - 66 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (measuring points 1-3) for trouble code G00177

[2/2]

Fig. 7-43 Wiring Diagram (measuring points 1-3) for trouble code G00177

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 67

 Troubleshooting by KOMTRAX Plus trouble code

G00178 - Trouble battery charging current too high

[1/2]
Trouble code
Message Trouble battery charging current too high
G00178
The system detected at 11T117 that the charging current from the alternator via the shunt resistor
Contents of trouble
71T003 is too high (higher than 200A).
– For this test step a clamp-on ammeter is required (Ampere).
Related information
– Use the REAL TIME MONITOR for error verification (07 Electrical Equipm. screen 1/1).
– Background colour of the trouble code information: yellow
Action of controller
– 7 segment LED-Code at K+ controller: M998
Problem that appears
Batteries may be destroyed if they are overcharged for a longer period.
on the machine

Instruction message 17 Inform service till end of shift and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Using a clamp-on ammeter measure the charging current in front of the shunt Icharge
resistor 71T003 (between alternator and shunt resistor). max. 200A

The charging current

of the alternator 1
is too high

If the measurement is higher than 200A, replace the alternator.

Verify that none of the batteries has an internal short-circuit.
1. Refer to the Wiring Diagram and check for proper – Wiring:
cable connections: If necessary, repair
– 11T117 power supply or replace the wir-
ing/connections of
– 11T117 ground connections 51T017.
– Signal line between 11T117 and K+ controller – Module 11T117:
14K300 If the function Wiring
Module 11T117 or its – Wiring between 11T117 and 71T003 of 11T117 is not Diagram
2 according to the
wiring is defective 2. Check the converter module according to the Conver-
conversion chart. conversion chart, sion chart
replace the con-
Conversion chart (11T117) verter module.
Charge / discharge current Go to final check (last
step).
Input -150 mV 0 +150 mV
Output 0V 2V 10 V

Bring the machine back into the original condition.

Final check 3
Start the machine and verify that the trouble code does not arise again.

7 - 68 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (71T003 & 11T117) for trouble code G00178

[2/2]

Fig. 7-44 Wiring Diagram (71T003 & 11T117) for trouble code G00178

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 69

 Troubleshooting by KOMTRAX Plus trouble code

G00184 - Central lubrication system empty

G00187 - Slew ring gear lubrication system empty
[1/7]
Trouble code G00184- Central lubrication system empty
Message
G00284 & G00187 G00187 - Slew ring gear lubrication system empty
– Monitoring of CLS (Central Lubrication System) grease level - 62B108c.
Contents of trouble – Monitoring of SLS (Slew ring gear Lubrication System) grease level - 62B109c.
– The message is displayed if the corresponding grease barrel needs refilling.
– The grease level sensors do not trigger the bucket cut-off function.
– Background colour of the trouble code information: yellow
[62B108a] Level sensor - full CLS
[62B108b] Level sensor - pre-warning CLS
[62B108c] Level sensor - empty CLS
[62B109a] Level sensor - full SLS
Related information [62B109b] Level sensor - pre-warning SLS
[62B108c] Level sensor - empty SLS

Problem that appears

Risk, to run out of grease.
on the machine
– Background colour of the trouble code information: yellow
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M538 (G00184), M539 (G00187)

Instruction message 17 Inform service till end of shift and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
Using the dipstick, verify if the relating grease Press the cancel
barrel needs refilling. button and refill the
specified grease.
Is the grease level too low? Yes
Verify that trouble code
G00184 or G00187 is
Definition of the grease levels
not displayed again.

The concerned grease

barrel (CLS or SLS) 1
needs refilling

No Go to next step.

7 - 70 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00184 - Central lubrication system empty

G00187 - Slew ring gear lubrication system empty
[2/7]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
1. Remove the cover of the junction box for Umin 22V
CLS or for SLS on top of the concerned Yes Go to step 4.
Umax 24V
grease barrel.
2
2. Refer to the wiring diagram (junction box).
3. Measure the supply voltage at terminal No Go to next step.
X1.2 inside the junction box.
Is supply voltage present?
Incorrect or no supply Umin 22V
voltage in the circuit at Yes Go to next step.
the concerned grease Umax 24V
level sensor 62B108c Disconnection, short
or 62B109c circuit, or fault in the
wiring between con-
Check if supply voltage is present at the power nector XB.A at the
3 supply line 11F025. junction box and cir-
Is supply voltage present? cuit breaker 11F025.
No
If necessary, check the
segments of the volt-
age supply wiring sep-
arately, locate the
problem, and repair as
necessary.
 Main key switch 20S001 OFF
Defective signal wiring Yes Go to next step. Rwire
1. Disconnect the signal line of the concerned
between the concerned – Wiring: max. 1Ω
grease level sensor grease level sensor from the pump control-
ler 10K032. If necessary, repair Rrelay
62B108c or 62B109c,
or replace the wir- 557 ± 1.0Ω
relays 11K136 or 2. Refer to the wiring diagram and check the
11K138 and ground ing/connections of
signal wiring segments for continuity:
4 40B031.
(disconnection or – From the concerned grease level sen- No – Relay 11K136 or
defective contact in any sor (62B108c or 62B109c),
connector or in the 11K138:
junction box on top of – via relay (coil) 11K136 or 11K138, If the resistance of
the concerned grease – to GND. the coil is not as
barrel) specified, replace
Is continuity present?
the relay.
 Main key switch 20S001 OFF
Yes Go to next step. Rwire
Refer to the wiring diagram and check the wire
Defective wiring Disconnection in any max. 1Ω
segments for continuity (consider weld shut or
between circuit breaker wire segment (includ-
failing switch contacts at relays):
11F015, relay 11K136 ing connectors)
or 11K138 and pump – From circuit breaker 11F015,
5 between circuit
controller 10K032 – via relay (switch contacts) 11K136 or breaker 11F015 and
(disconnection or 11K138, No pump controller
defective contact in any 10K032.
– to the relating input terminal at pump con-
connector) Locate the problem
troller 10K032.
and repair as neces-
Is continuity present?
sary.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 71

 Troubleshooting by KOMTRAX Plus trouble code

G00184 - Central lubrication system empty

G00187 - Slew ring gear lubrication system empty
[3/7]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
Defective relay 11K136 Yes Go to next step.
Check the relay’s contacts for proper switching
or 11K138
6 function refer to section 5.2 on page 5-4. Replace the defective
(weld shut or failing No
Is the switching function OK? relay.
switch contacts)
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
REMARKS: For checking the level sensor 62B108c or
62B109c, it is necessary to remove the
cover of the concerned grease barrel.
1. Check the proximity switch by dipping it into grease.
If the proximity switch is OK, the following condi-
tions must be matched:
Defective grease level
– proximity switch is closed.
sensor 62B108c or
62B109c 7 – 24V applied on 11K136 of CLS or 11K138 of Replace the defective grease level
(provided that the sen- SLS sensor 62B108c or 62B109c.
sor wiring is OK) 2. Use the REAL TIME MONITOR for verification Go to final check (last step).
(refer to Fig. 7-48 on page 7-76).
 07 Central Lube System 1 (CLS) or
 08 Slew Ring Gear Lube System (SLS)
 Screen 1/1

REAL TIME MONITOR shows "1" at 62B108c or

62B109c respectively if proximity switch is OK
(dipped it into grease).
1. Bring the machine back into the original condition.
2. Start the engine and run at high idle. Verify that the fault message does not
Final check 8 arise again.
3. Recheck the function of the lubrication system by manual actuation of a lube
cycle.

7 - 72 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram 1 (62B108c & 62B109c) for trouble codes G00184 & G00187
[4/7]

Fig. 7-45 Wiring Diagram 1 (62B108c & 62B109c) for trouble codes G000184 & G00187

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 73

 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram 2 (wiring to 14K300) for trouble codes G00184 & G00187
[5/7]

Fig. 7-46 Wiring Diagram 2 (wiring to 14K300) for trouble codes G000184 & G00187

7 - 74 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram 3 (junction box) for trouble codes G00184 & G00187
[6/7]

Fig. 7-47 Wiring Diagram 3 (junction box) for trouble codes G000184 & G00187

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 75

 Troubleshooting by KOMTRAX Plus trouble code

Input signals of grease level sensors 62B108c & 62B109c on the REAL TIME MONITOR
[7/7]

Fig. 7-48 Input signal of grease level sensors 62B108c & 62B109c on the REAL TIME MONITOR

7 - 76 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00185 - Trouble central lubrication system

[1/10]
Trouble code
Message G00185 - Trouble central lubrication system
G00185
– The lubrication cycle time is too long (trouble code generated by relay 11K030).
Contents of trouble
– No power supply. Interrupted wiring connections (trouble code generated by relay 11K028).
– It is not possible to build up the grease pressure (CLS) in the pre-set time frame.
– For further details concerning the lubrication system refer to the SHOP MANUAL part
10 STRUCTURE & FUNCTION, chapter 17.
Related information – Service level, REAL TIME MONITOR for CLS is selected.
– Manual lube cycle runs as long as 20S124 is actuated.
– Lubrication system is reset at any power cut-off, i.e. when battery main switch (master switch) is
switched OFF.
– Background colour of the trouble code information: yellow
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M536
Problem that appears – Risk, to run the machine without CLS lubrication.
on the machine – Bucket cut-off after 4.2 hours.

Instruction message 20 Inform service and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
The problem is solved,
Refill the grease barrel through a filter.
The grease may Yes perform the final check
1 Is grease pressure built up with clean grease (last step).
be soiled
within specification?
No Go to next step.
Leakage at any Make a visual inspection of all grease injectors Repair or replace as
Yes
lubrication line or 2 and lubrication lines. necessary.
grease injector Could you identify any leakage? No Go to next step.
Check all lubrication points for excessive Replace the concerned
Defective grease Yes
3 grease discharge. grease injector.
injector
is any excessive grease discharge present? No Go to next step.

The electrical function Check the electrical function of the vent valve Yes Go to next step.
of the vent valve 4 62Q507a.
Replace the vent valve
62Q507a is disturbed Is the electrical function OK? No
62Q507a.
1. Remove the mechanical part from the elec-
trical part of the vent valve 62Q507a. Yes Go to next step.
The mechanical
function of the vent 2. Disassemble and check the lower part and
5
valve 62Q507a is clean as necessary.
disturbed No Go to step 7.
Is the mechanical part of the pressure release
valve blocked?
1. Repair or replace the mechanical part of the vent
The mechanical part of valve 62Q507a as necessary.
the vent valve 6 Go to next step.
2. Clean the respective contaminated grease system.
62Q507a is defective
3. Replace the grease filter and the screen.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 77

 Troubleshooting by KOMTRAX Plus trouble code

G00185 - Trouble central lubrication system

[2/10]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Qvolume
Check the performance of the relating grease 16-19
pump and arrange preparations for testing the double-
grease pressure. strokes/
min.
Grease pump: For detailed test & adjustment procedures
refer to the SHOP MANUAL part Yes Go to next step. Ppump drive
– malfunction
7 10 STRUCTURE & FUNCTION chapter 17, hydr.pressure
– worn section "ADJUSTMENT OF LUBE PUMP 45 + 5 bar
– defective SPEED". Grease
max. second-
Make sure that the vent valve 62Q507a is
ary pressure
closed. 295 bar
Does the grease pump build up grease pres- Grease pump defec-
sure as specified? No tive, replace the
grease pump.
 Engine running at high idle.
1. Check the input signal of 11K030 on the K+ Automatic control cir-
display. Yes cuit disturbed.
REAL TIME MONITOR Go to step 11.
 07 Central Lube System 1
 Screen 1/1

Automatic control cir-

8
cuit disturbed
Malfunction in the
No power supply.
Go to next step.

2. Reset the lubrication system.

Refer to the SHOP MANUAL part
10 STRUCTURE & FUNCTION chapter
17, section "RESETTING A FAULTY
LUBRICATION SYSTEM".
Does the input signal of 11K030 show "1" and
can the lubrication pump be started manually?

7 - 78 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00185 - Trouble central lubrication system

[3/10]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with engine running at high idle.
Umin 22V
Yes Go to next step.
Umax 24V
Disconnection in any
Disconnect the connector from end-line pres-
wiring segment
9 sure switch 80B043 and insert the T-box. Mea-
between circuit
sure the supply voltage at the connector
breaker 11F023 and
No power supply or terminal A.
No end-line pressure
interrupted wiring to/ Is supply voltage present? switch 80B043.
from end-line pressure
switch 80B043: Locate the problem
Fail-safe relay 11K028 and repair as neces-
is not energized sary.
Umin 22V
(disconnection or Yes Go to next step.
defective contact in any Umax 24V
connector) Disconnection in any
wiring segment
Check if supply voltage is present at fail-safe
between end-line pres-
10 relay 11K028 terminal A1.
sure switch 80B043
Is supply voltage present? No and fail-safe relay
11K028.
Locate the problem
and repair as neces-
sary.
 Engine running at high idle.

End-line pressure Refer to the SHOP MANUAL part Yes Go to next step.
switch 80B043 10 STRUCTURE & FUNCTION, chapter 17,
(grease main line): section "CLS & SLS END-LINE SWITCH 180 ± 5 bar
11 Replace the end-line
ADJUSTMENT" and follow the adjustment pro- SHOP
wrong adjustment or cedure. No pressure switch
defective MANUAL
80B043.
Did you need to correct any wrong adjust-
ment?
Check the adjustment of timing relay 11K004 Yes Go to next step.
according to the values in PM-Clinic.
Wrong adjustment of Adjust setting of timing PM-Clinic
For detailed adjustment procedures refer to
timing relay 11K004 relay 11K004 to the
12 the SHOP MANUAL part 10 STRUCTURE & SHOP
(monitoring time), set- No correct time setting.
FUNCTION, chapter 17, section "AUTOMATIC MANUAL
ting is too low Go to final check (last
LUBRICATION MODE ADJUSTMENTS".
step).
Is the relay setting correct?

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 79

 Troubleshooting by KOMTRAX Plus trouble code

G00185 - Trouble central lubrication system

[4/10]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Perform a complete lube cycle manually with Timing relay 11K004
switch 20S124 on the dashboard and check defective.
the input signal of 11K030 on the K+ display. Yes
Replace the timing
REAL TIME MONITOR relay.
 07 Central Lube System 1
 Screen 1/1

Defective timing relay

11K004 13
(monitoring time)

No Go to next step.

Does the input signal of 11K030 still show "1"?

 Main key switch 20S001 OFF
Check the setting of the Function scale at Yes Go to next step.
interval time relay 11K103.
Set the Function scale
Faulty Function scale For detailed adjustment procedures refer to
setting of the interval 14 the SHOP MANUAL part 10 STRUCTURE & to position
Setting:
time relay 11K103 (ON-delay with Time
FUNCTION, chapter 17, section "AUTOMATIC No ON-delay
adjusted time delay).
LUBRICATION MODE ADJUSTMENTS".
Go to final step (last
Is the Function scale set to position
step)
(ON-delay with Time adjusted time delay)?
 Engine running at high idle.
Provided that the end-line pressure switch Yes Go to next step.
80B046 and timing relay 11K004 are OK!
Check timer relay 11K103 for proper function:
Defective interval time
relay 11K103 – LED "U/T" blinking (time delay is running)
Interval time relay
15
(including weld shut or – LED "U/T" ON (only when switched) 11K103 defective.
No
failing switch contacts) – LED "R1" ON (only when switched) Replace the timing
relay.
– 22-24 V present at 11K004 terminal A1.
Does the function of timer relay 11K103 meet
the above specification?

7 - 80 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00185 - Trouble central lubrication system

Bucket cut-off after 4.2 hours [5/10]
 Engine running at high idle.
REMARKS: Timer relay 11K139 switches Relay
bucket cut-off if no lube cycle Yes Go to next step. switched,
occurs for 4.2 hours. LED R1 ON
The bucket cut-off is a normal
function if the machine was in use
for this period with active trouble
16 code G00185.
Timing relay 11K139
Check switch status of timer relay 11K139:
No defective, replace the
– LED "U/T" ON (permanently) timing relay.
– LED "R1" ON (relay has switched)
Does the function of timer relay 11K139 meet
No lubrication during the above specification?
the last 4.2 working
 Engine running at high idle.
hours
Refer to the wiring diagram and check if relay Timing relay 11K139
(bucket movement dis- defective (weld shut
abled) 11K050 is energized: 11K050
Yes contacts).
17 – 22-24 V present at terminal A1 energized
Replace the timing
– Power-LED ON. relay.
Does the function of relay 11K050 meet the
above specification? No go to next step.

 Engine running at high idle.

Normal function of the Usolenoid
Yes
bucket cut-off. 22- 24V
Refer to the wiring diagram and measure volt-
18 Relay 11K050 defec-
age at solenoid valve 10K511a terminal 1.
tive (weld shut or fail-
Is supply voltage present? No ing switch contacts).
Replace the relay.
1. Bring the machine back into the original condition.
2. Start the engine and run at high idle. Verify that the fault message does not
arise again.
Final check 19 3. Reset the function of the lubrication system by manual actuation of a com-
plete lube cycle.
4. Verify that the operation cycles of the lubrication system correspond to the
diagram shown in Fig. 7-53 on page 7-86.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 81

 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram 1 (relays) for trouble code G00185

[6/10]

Fig. 7-49 Wiring Diagram 1 (relays) for trouble code G00185

7 - 82 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram 2 (11K50 & trouble signal circuit CLS/SLS) for trouble code G00185
[7/10]

Fig. 7-50 Wiring Diagram 2 (11K50 & trouble signal circuit CLS/SLS) for trouble code G00185

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 83

 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram 3 (10K511a) for trouble code G00185

[8/10]

Fig. 7-51 Wiring Diagram 3 (10K511a) for trouble code G00185

7 - 84 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

View onto the vent valve 62Q507a

[9/10]

Fig. 7-52 View onto the vent valve 62Q507a

(1) Plug screw (5) Vent valve

(2) O-ring (6) Pressure relief valve

(3) Grease outlet filter (7) Grease pump return line (into barrel)

(4) Control & filter block (8) Cable connector at vent valve

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 85

 Troubleshooting by KOMTRAX Plus trouble code

Action chart for lube cycles

[10/10]

Fig. 7-53 Action chart for lube cycles

PT Pause Time S- Switch point OFF - end-line pressure switch

PI Pressure Increasing (grease supply line) PR Pressure Relieve

S+ Switch point ON - end-line pressure switch

7 - 86 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00187 - Slew ring gear lubrication system empty

Refer to the troubleshooting procedure G00184 on page 7-70.

G00188 - Trouble slew ring gear lubrication system

[1/12]
Trouble code
Message G00188 - Trouble slew ring gear lubrication system
G00188
– The lubrication cycle time is too long (trouble code generated by relay 11K038).
Contents of trouble
– No power supply. Interrupted wiring connections (trouble code generated by relay 11K035).
– It is not possible to build up the grease pressure (SLS) in the pre-set time frame.
– For further details concerning the lubrication system refer to the SHOP MANUAL part
10 STRUCTURE & FUNCTION, chapter 17.
Related information – Service level, REAL TIME MONITOR for SLS is selected
– Manual lube cycle runs as long as 20S126 is pressed.
– Lubrication system is reset at any power cut-off, i.e. when battery main switch (master switch) is
switched OFF.
– Background colour of the trouble code information: yellow
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M537
Problem that appears – Risk, to run the machine without SLS lubrication.
on the machine – Bucket cut-off after 4.2 hours.

Instruction message 20 Inform service and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
The problem is solved,
Refill the grease barrel through a filter.
The grease may Yes perform the final check
1 Is grease pressure built up with clean grease (last step).
be soiled
within specification?
No Go to next step.
Leakage at any Make a visual inspection of all grease injectors Repair or replace as
Yes
lubrication line or 2 and lubrication lines. necessary.
grease injector Could you identify any leakage? No Go to next step.
Check all lubrication points for excessive Replace the concerned
Defective grease Yes
3 grease discharge. grease injector.
injector
is any excessive grease discharge present? No Go to next step.

The electrical function Check the electrical function of the vent valve Yes Go to next step.
of the vent valve 4 62Q509a.
Replace the vent valve
62Q509a is disturbed Is the electrical function OK? No
solenoid 62Q509a.
1. Remove the mechanical part from the elec-
trical part of the vent valve 62Q509a. Yes Go to next step.
The mechanical
function of the vent 2. Disassemble and check the lower part and
5
valve 62Q509a is clean as necessary.
disturbed No Go to step 8.
Is the mechanical part of the vent valve
blocked?
1. Repair or replace the mechanical part of the vent
The mechanical part of valve 62Q509a as necessary.
the vent valve 6 Go to next step.
2. Clean the respective contaminated grease system.
62Q509a is defective
3. Replace the grease filter and the screen.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 87

 Troubleshooting by KOMTRAX Plus trouble code

G00188 - Trouble slew ring gear lubrication system

[2/12]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
1. Check the performance of the relating Qvolume
grease pump and arrange preparations for 16-19
testing the grease pressure. double-
strokes/
For detailed test & adjustment procedures min.
Grease pump:
refer to the SHOP MANUAL part Yes Go to next step. Ppump drive
– malfunction
7 10 STRUCTURE & FUNCTION chapter hydr.pressure
– worn 17, section "ADJUSTMENT OF LUBE 45 + 5 bar
– defective PUMP SPEED". Grease
max. second-
2. Make sure that the vent valve 62Q509a is ary pressure
closed. 295 bar
Does the grease pump build up grease pres- Grease pump defec-
sure as specified? No tive, replace the
grease pump.
 Engine running at high idle.
1. Check the input signal of 11K038 on the K+ Automatic control cir-
display. Yes cuit disturbed.
REAL TIME MONITOR Go to step 11.
 08 Slew Ring Gear Lube System
 Screen 1/1

Automatic control cir-

8 SHOP
cuit disturbed
Malfunction in the MANUAL
No power supply.
Go to next step.

2. Reset the lubrication system.

Refer to the SHOP MANUAL part
10 STRUCTURE & FUNCTION chapter
17, section "RESETTING A FAULTY
LUBRICATION SYSTEM".
Does the input signal of 11K038 show "1" and
can the lubrication pump be started manually?

7 - 88 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00188 - Trouble slew ring gear lubrication system

[3/12]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with engine running at high idle.
Umin 22V
Yes Go to next step.
Umax 24V
Disconnection in any
Disconnect the connector from end-line pres-
wiring segment
9 sure switch 62B046 and insert the T-box. Mea-
between circuit
sure the supply voltage at the connector
breaker 11F025 and
No power supply or terminal A.
No end-line pressure
interrupted wiring to/ Is supply voltage present? switch 62B046.
from end-line pressure
switch 62B046: Locate the problem
Fail-safe relay 11K035 and repair as neces-
is not energized sary.
Umin 22V
(disconnection or Yes Go to next step.
defective contact in any Umax 24V
connector) Disconnection in any
wiring segment
Check if supply voltage is present at fail-safe
between end-line pres-
10 relay 11K035 terminal A1.
sure switch 62B046
Is supply voltage present? No and fail-safe relay
11K035.
Locate the problem
and repair as neces-
sary.
 Engine running at high idle.

End-line pressure Refer to the SHOP MANUAL part Yes Go to next step.
switch 62B046 10 STRUCTURE & FUNCTION, chapter 17,
(grease main line): section "CLS & SLS END-LINE SWITCH 180 ± 5 bar
11 Replace the end-line
ADJUSTMENT" and follow the adjustment pro- SHOP
wrong adjustment or cedure. No pressure switch
defective MANUAL
62B046.
Did you need to correct any wrong adjust-
ment?
Check the adjustment of timing relay 11K008 Yes Go to next step.
according to the values in PM-Clinic.
Wrong adjustment of Adjust setting of timing PM-Clinic
For detailed adjustment procedures refer to
timing relay 11K008 relay 11K008 to the
12 the SHOP MANUAL part 10 STRUCTURE & SHOP
(monitoring time), set- No correct time setting.
FUNCTION, chapter 17, section "AUTOMATIC MANUAL
ting is too low Go to final check (last
LUBRICATION MODE ADJUSTMENTS".
step).
Is the relay setting correct?

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 89

 Troubleshooting by KOMTRAX Plus trouble code

G00188 - Trouble slew ring gear lubrication system

[4/12]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with engine running at high idle.
Perform a complete lube cycle manually with Timing relay 11K008
switch 20S126 on the dashboard and check defective.
the input signal of 11K038 on the K+ display. Yes
Replace the timing
REAL TIME MONITOR relay.
 08 Slew Ring Gear Lube System
 Screen 1/1
Defective timing relay
11K008 13
(monitoring time)

No Go to next step.

Does the input signal of 1K038 still show "1"?

 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with engine running at high idle.
Refer to the wiring diagram. Standard
Yes Go to next step. Value
14 Disconnect the connector from the pressure Table
switch 10B047 and check the pressure switch
according to the standard value table. Remove the sensor
No and replace it by a new
Is the test result OK? one.
Pressure switch
 Engine running at high idle.
10B047 or its wiring
defective Yes Go to next step.
Disconnection in any
Perform a slewing motion and check if relay wiring segment
11K073 is energized (power-LED ON) while between circuit
15
slewing. breaker 11F028, relay
No 11K073 and ground.
Is relay 11K073 energized while performing a
slewing motion? Locate the problem
and repair as neces-
sary.
 Engine running at high idle.
Relay 11K073 defec- Check relay 11K073 for proper function refer to Yes Go to next step.
16
tive section 5.2 on page 5-4.
No Replace relay 11K073.
Does relay 11K073 function properly?

7 - 90 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00188 - Trouble slew ring gear lubrication system

[5/12]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF
Check the setting of the Function scale at Yes Go to next step.
interval time relay 11K007.
Set the Function scale
Faulty Function scale For detailed adjustment procedures refer to
setting of the interval 17 the SHOP MANUAL part 10 STRUCTURE & to position
Setting:
time relay 11K007 (ON-delay with Time
FUNCTION, chapter 17, section "AUTOMATIC No ON-delay
adjusted time delay).
LUBRICATION MODE ADJUSTMENTS".
Go to final step (last
Is the Function scale set to position
step)
(ON-delay with Time adjusted time delay)?
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with engine running at high idle.
Yes Go to next step.
Provided that the following components
and their wirings are OK:
– End-line pressure switch 62B046
– Pressure switch 10B047
– Relays 11K037 & 11K073
– Timing relay 11K008
18
Interval time relay
Check timer relay 11K007 for proper function: No 11K007 defective.
Defective interval time
– LED "U/T" blinking (time delay is running) Replace the time relay.
relay 11K007
(including weld shut or – LED "U/T" ON (not blinking when switched)
failing switch contacts) – LED "R1" ON (only when switched)
– Relay 11K037 not energized
(Power-LED OFF).
Does the function of timer relay 11K007 meet
the above specification?
Precondition: 11K037
Yes Go to next step.
Relay 11K007 has switched energized
(LED "U/T" ON (permanently). Interval time relay
19 Perform a slewing motion and check if relay 11K007 defective
11K037 gets energized (power-LED ON). NO (weld shut or failing
switch contacts).
Is relay 11K037 energized after performing a
slewing motion? Replace the time relay.
 Engine running at high idle.
Yes Go to next step.
Provided that the following components and
their wirings are OK:
– Pressure switch 62B049
– Relay 11K073
Relay 11K037 defec-
Defective relay 11K037 20
– Timing relay 11K007 tive (weld shut or fail-
No ing switch contacts).
Perform a slewing motion and check if relay
11K037 & timing relay 11K008 get energized Replace the relay.
(power-LED ON) and relay 11K037 stays ener-
gized after performing a slewing motion.
Do the relays meet the above specification?

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 91

 Troubleshooting by KOMTRAX Plus trouble code

G00188 - Trouble slew ring gear lubrication system

Bucket cut-off after 4.2 hours [6/12]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
REMARKS: Timer relay 11K140 switches Relay
bucket cut-off if no lube cycle Yes Go to next step. switched,
occurs for 4.2 hours. LED R1 ON
The bucket cut-off is a normal
function if the machine was in use
for this period with active trouble
21 code G00187.
Timing relay 11K140
Check switch status of timer relay 11K139:
No defective, replace the
– LED "U/T" ON (permanently) timing relay.
– LED "R1" ON (relay has switched)
Does the function of timer relay 11K139 meet
the above specification?
No lubrication during
 Prepare with main key switch 20S001 OFF.
the last 4.2 working
Then carry out troubleshooting with engine running at high idle.
hours
Refer to the wiring diagram and check if relay Timing relay 11K140
(bucket movement dis- defective (weld shut
abled) 11K050 is energized: 11K050
22 Yes contacts).
– 22-24 V present at terminal A1 energized
Replace the timing
– Power-LED ON. relay.
Does the function of relay 11K050 meet the
above specification? No go to next step.

 Prepare with main key switch 20S001 OFF.

Then carry out troubleshooting with engine running at high idle.
Normal function of the Usolenoid
Yes
bucket cut-off. 22- 24V
23 Refer to the wiring diagram and measure volt-
age at solenoid 10K511a terminal 1. Relay 11K050 defec-
tive (weld shut or fail-
Is supply voltage present? No ing switch contacts).
Replace the relay.
1. Bring the machine back into the original condition.
2. Start the engine and run at high idle. Verify that the fault message does not
arise again.
Final check 24 3. Reset the function of the lubrication system by manual actuation of a com-
plete lube cycle.
4. Verify that the operation cycles of the lubrication system correspond to the
diagram shown in Fig. 7-59 on page 7-98.

7 - 92 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram 1 (relays) for trouble code G00188

[7/12]

Fig. 7-54 Wiring Diagram 1 (relays) for trouble code G00188

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 93

 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram 2 (11K50 & trouble signal circuit CLS/SLS) for trouble code G00188
[8/12]

Fig. 7-55 Wiring Diagram 2 (11K50 & trouble signal circuit CLS/SLS) for trouble code G00188

7 - 94 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram 3 (10K511a) for trouble code G00188

[9/12]

Fig. 7-56 Wiring Diagram 3 (10K511a) for trouble code G00188

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 95

 Troubleshooting by KOMTRAX Plus trouble code

View onto the pressure switch 10B047 and wiring Diagram 3 for trouble code G00188
[10/12]

Fig. 7-57 View onto the pressure switch 10B047 and wiring Diagram 3 for trouble code G00188

7 - 96 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

View onto the vent valve 62Q509a

[11/12]

Fig. 7-58 View onto the vent valve 62Q509a (G00188)

(1) Plug screw (5) Vent valve solenoid

(2) O-ring (6) Pressure relief valve (vent valve)

(3) Grease outlet filter (7) Grease pump return line (into barrel)

(4) Control & filter block (8) Cable connector at vent valve

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 97

 Troubleshooting by KOMTRAX Plus trouble code

Action chart for lube cycles

[12/12]

Fig. 7-59 Action chart for lube cycles

PT Pause Time S- Switch point OFF - end-line pressure switch

PI Pressure Increasing (grease supply line) PR Pressure Relieve

S+ Switch point ON - end-line pressure switch

7 - 98 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00207 - Engine remote oil tank 1 empty

[1/1]
Trouble code
Message Engine remote oil tank 1 empty
G00207
– Sensor 63B103 in the remote engine oil tank signals that the tank is nearly empty.
Contents of trouble – The system assumes that the level sensor 63B103 in the remote engine oil tank or the wiring
of this monitoring circuit system is not defective.
The remote engine oil tank is part of the engine oil management system.
Related information
REMARKS: The remote engine oil tank is also equipped with an oil level sight gauge.
– Background colour of the trouble code information: yellow
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M233
Problem that appears
Risk, to run out of remote engine oil.
on the machine

Instruction message 2 Inform service.

Nominal
Possible cause Test condition & Inspection Procedure
value
 Main key switch 20S001 ON.
Check the remote engine oil level at the sight gauge of the tank and refill specified
engine oil as necessary. Do not overfill.

Information - Engine oil management

For the engine oil management system an engine oil consumption
(for internal lubrication) of max.1% of the fuel flow-rate is determined.
The engine remote If the engine oil consumption considerably exceeds the specification,
oil tank is empty contact the Cummins service.

Information - Engine oil specifications

For the engine oil specifications refer to the Cummins Operation and
Maintenance Manual QSK 38 Series Engines, section
Cummins Engine recommended fluids and lubricants.
The minimum oil quality requirement is CF-4 and higher.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 99

 Troubleshooting by KOMTRAX Plus trouble code

G00222 - Load limiting clam defective

[1/3]
Trouble code
Message Load limiting clam defective
G00222
– Load limiting clam is optional equipment.
Contents of trouble This function is only available if the components are equipped on the machine (FSA).
– 8.5 bar pressure cut-off for clam close is defective.
Failure detection criteria:
Related information Pressure of at the clam cylinder’s piston side reaches 22 bar while performing the clam close func-
tion.
– Background colour of the trouble code information: yellow
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M486
Problem that appears
In this condition the 8.5 bar pressure cut-off for clam close is inoperative.
on the machine

Instruction message 2 Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
Umin 22V
Yes Go to next step.
Umax 24V

Disconnect the connector from pressure Disconnection, short

switch 10B155. circuit, or fault in the
1 wiring between pres-
Measure the voltage between terminals 1 and sure switch 10B155
GND. and circuit breaker
No
Is supply voltage present? 11F028.
Locate the problem
and repair as neces-
Harness & connector sary.
disconnection in wiring  Main key switch 20S001 OFF
or connector of pres-
sure switch 10B155 Yes Go to next step. Rwire
Refer to the Wiring Diagram. – Wiring: max. 1Ω
If necessary, repair Rrelay
1. Disconnect connector of pressure switch
or replace the wir- 557 ± 1.0Ω
10B155.
ing/connections of
2. Check all relevant cable segments and the 10B155.
2 relay 11K191 for continuity:
– Relay 11K191:
– From connector terminal 2, No
If the resistance of
– via relay 11K191 (coil), the coil is not as
specified, replace
– to GND.
the relay.
Is continuity of the relevant wiring circuit OK?
Go to final check (last
step).
 Main key switch 20S001 OFF
Defective relay 11K191 Yes Go to next step. Rmax 1Ω
Check the relay’s contacts for proper switching
(weld shut or failing 3 Replace relay 11K191.
function refer to section 5.2 on page 5-4.
switch contacts) No Go to final check (last
Is the switching function OK?
step).

7 - 100 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00222 - Load limiting clam defective

[2/3]
Nominal
Possible cause Test condition & Inspection Procedure
value
 Engine running at high idle.
1. Disconnect connector of pressure switch Uclam open
Yes Go to next step.
10B155 and insert the T-box. 0V
2. Connect a pressure gauge at pressure port Uclam close
M54.1. 22 - 24V
3. Open clam and measure voltage between PM54.1
Defective pressure
4 terminals 1 and 2. 8.5 bar
switch 10B155
4. Close clam and measure voltage between Replace pressure
No
terminals 1 and 2. switch 10B155.
Also check the pressure at pressure port
M54.1 when clam is closed.
Do the measurement readings meet the
specifications?
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with engine running at high idle.
Disconnect the connector from pressure switch
10B156.
Use the REAL TIME MONITOR for verification
 03 Other Items
 Screen 1/2

The pressure switch

Remove the pressure switch and
10B156 is defective
5 replace it by a new one.
(pressure sensor has
After that recheck the system for
an internal stuck)
proper function.
Go to final check (last step).

REAL TIME MONITOR shows "1" with sensor con-

nected and "0" with sensor disconnected
(confirmation of trouble).
Bring the machine back into the original condition.
Final check 6
Start the machine and verify that the trouble code does not arise again.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 101

 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (10B155 & 10B156) for trouble code G00222

[3/3]

Fig. 7-60 Wiring Diagram (10B155 & 10B156) for trouble code G00222

7 - 102 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00243 - Fill up fuel tank

[1/1]
Trouble code
Message Fill up fuel tank
G00243
– The fuel tank sensor 31B063 indicates that the fuel is on minimum level.
Contents of trouble
– The system assumes that the fuel tank sensor 31B063 and its wiring circuit are not defective.

Related information ---

– Background colour of the trouble code information: blue

Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M487
Problem that appears
Risk, to run out of fuel.
on the machine

Instruction message 23 A fuel reserve only is still in the tank - Order tanker.

Nominal
Possible cause Test condition & Inspection Procedure
value
 Main key switch 20S001 ON.
– Refill fuel according to the specification in the CUMMINS ENGINE OPERATION &
MAINTENANCE MANUAL.
– Do not overfill.

Information for Diesel fuel specifications

The fuel tank For the Diesel fuel specifications refer to the Cummins Operation &
is nearly empty Maintenance Manual QSK 38 Series Engines,
section Fuel Recommendations and Specifications.
Cummins recommends the use of ASTM number 2 Diesel fuel.
The viscosity of the Diesel fuel must be kept above 1.3 cSt to provide
adequate fuel system lubrication.
For a more detailed description of the Diesel fuel properties also refer to the
Cummins Service Bulletin 3379001-10, Fuel for Cummins Engines.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 103

 Troubleshooting by KOMTRAX Plus trouble code

G00245 - Engine shutdown from ground

[1/1]
Trouble code
Message Engine shutdown from ground
G00245
– Engine shut down from ground is optional equipment.
Contents of trouble This function is only available if the components are equipped on the machine
– The engine has been stopped from the ground manually via switch 54S051 or 54S052.
– If switch 54S051 or 54S052 is activated from ground while the engine is running, the engine
shuts down.
Related information – After switch 54S051 or 54S052 has been activated from ground under condition "Engine OFF &
main key switch 20S001 ON", engine start is not possible.
– Although there are two switches the K+ only shows 54S051 for both switch conditions.
– Background colour of the trouble code information: red
Action of controller
– 7 segment LED-Code at K+ controller: M234
Problem that appears The engine is shut off and restart is not possible until switch 54S051 or 54S052 is manually
on the machine switched back into its neutral position.

Instruction message 24 Engine shutdown has been actuated from ground man.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON.
1. Contact your
supervisor and
clarify the situation.

Check the cause for the manually activated 2. After the cause for
The engine shutdown
was manually activated 1 engine shutdown. Yes the engine shut-
from ground down is clarified,
Was switch 54S051 or 54S052 manually acti-
release switch
vated from ground?
54S051 or 54S052
and restart
the engine.
No Go to next step.
 Main key switch 20S001 ON.
Actuate switch 54S051 or 54S052 and verify Switche(s) may have been acti-
the input signal via K+: Yes vated accidently.
REAL TIME MONITOR. Go to final check (last step).
 06 Manual Switch
 Screen 1/1

1. Refer to the Wiring Diagram and

Switch 54S051 or
2 check switch 54S051 or 54S052
54S052 defective
and its wiring.
No 2. Locate the problem and repair
as necessary.
3. After repair, recheck switches
for proper function.

Does the input signal of 54S051 change from

"0" to "1"?
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

7 - 104 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

G00256 - Operator warning system

[1/1]

Trouble code
Message Trouble screen at hydraulic cooler entry clogged
G00256
– Operator warning system is optional equipment.
This function is only available if the components are equipped on the machine.
Contents of trouble
– This message informs the operator via switch 54S007 or 54S008 that i.e. anybody wants to
enter the machine.

Related information ---

– Background colour of the trouble code information: blue

Action of controller
– 7 segment LED-Code at K+ controller: MA02
Problem that appears
Risk, to run the machine with insufficient cooling of the hydraulic oil.
on the machine

Instruction message 45 Operator warning system from ground level.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
The operator warning  Main key switch 20S001 ON.
was manually activated 1 Check the cause for the manually actuation of switch
from ground Clarify the situation.
54S007 or 54S008.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the trouble code does not arise again.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 105

 Troubleshooting by KOMTRAX Plus trouble code

G00262 - Trouble screen at hydr. cooler entry clogged

[1/2]
Trouble code
Message Trouble screen at hydraulic cooler entry clogged
G00262
– Pressure sensor 40B165 signals a pressure difference of more than 2 bar (before ↔ behind the
Contents of trouble strainer in the intermediate pipe leading to the hydraulic oil cooler).
– The system assumes that the strainer is clogged if the pressure difference exceeds 2 bar.

Related information The system assumes that the pressure sensors 40B165 and its wiring are not defective.

– Background colour of the trouble code information: yellow

Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M599
Problem that appears
Risk, to run the machine with insufficient cooling of the hydraulic oil.
on the machine

Instruction message 20 Inform service and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
Replace the faulty
Check pressure sensor 40B165 for proper
Pressure sensor pressure sensor and
function according to PARTS & SERVICE Yes
40B165 may have a 1 recheck for proper
NEWS AH07524 (latest version).
malfunction function.
Is pressure sensor 40B165 faulty?
No Go to next step.
 Engine OFF & maintenance safety switch 50S058 OFF + locked
The strainer in the 1. Remove the oil strainer in the intermediate pipe.
intermediate pipe (oil
2 2. Clean or replace the strainer as necessary.
flow → to the oil cooler)
is clogged REMARKS: If the strainer is clogged, the cause for the clogging needs to be
found. Locate the problem and take adequate measures.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

7 - 106 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Location of 40B165 and the strainer at the intermediate pipe (G00262)

[2/2]

Fig. 7-61 Location of 40B165 and the strainer at the intermediate pipe

(1) Strainer

(2) Intermediate pipe

(3) Return oil distributor manifold (to oil coolers)

[40B165] Pressure switch - oil cooler strainer clogged

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 107

 Troubleshooting by KOMTRAX Plus trouble code

G00422 - Can-net sys (J1939)

[1/2]
Trouble code
Message Can-net sys (J1939)
G00422

Contents of trouble The KOMTRAX Plus controller does not receive any signal from the QUANTUM ECM
(engine control) via CAN BUS #1.
Failure detection criteria:
– KOMTRAX Plus controller fails to communicate with at least one of Cummins engine controllers
for >10 seconds.
Related information
– The digital input d_in8, "Hour meter drive", is ON for >10 seconds.
– The source voltage is >19.5 V for >30 seconds.
– Engine speed >300 1/min
– Background colour of the trouble code information: yellow
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M801
Problem that appears
Real time monitoring of the engine is not possible.
on the machine

Instruction message 2 Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
The connection  Main key switch 20S001 ON.
between K+ controller Check wiring, connectors, and pins between K+ controller 14K300 and the
1 Wiring
and QUANTUM ECM QUANTUM ECM 52K014 for proper order and connection.
is inoperative Diagram
Repair or replace components according to the Wiring Diagram.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the trouble code does not arise again.

7 - 108 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (CAN-BUS) for trouble code G00422

[2/2]

Fig. 7-62 Wiring Diagram (CAN-BUS) for trouble code G00422

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 109

 Troubleshooting by KOMTRAX Plus trouble code

G00491 - Communication failure MH800 <=> K+ Controller

[1/2]
Trouble code
Message Communication failure MH800 <=> K+-Controller
G00491
The CAN BUS communication between K+ monitor and K+ controller is inoperative.
Trouble code is set if one of the following conditions becomes true:
Contents of trouble – KOMTRAX Plus controller fails to communicate with the monitor for >180 seconds after main
key switch 20S001 ON.
– KOMTRAX Plus controller fails to communicate with the monitor for >31 seconds.
Communication between K+ monitor and K+ controller takes place via CAN BUS:
– At the K+ monitor the CAN BUS is connected to the CN2 port via connectors:
Related information
20X335e, 20X335d, 14X302, 14X335b, and the end resistor 14R101 at connector 14X300a.
– At the K+ controller the CAN BUS is connected to the CN4A port.
– Background colour of the trouble code information: yellow
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: -
Problem that appears
Communication between K+ monitor and K+ controller is impossible.
on the machine

Instruction message 2 Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF.
– Visually check the condition of the CAN Yes Go to next step.
BUS harness.
Disconnection in the – Visually check all connectors/pins for
Locate the problem
CAN BUS wiring proper crimping and connection.
and repair as
between K+ monitor
1 – Make sure that the cables are fixed in the necessary.
and K+ controller,
or the contact in any correct sequence inside the connectors. No If any CAN BUS
connector is defective. Is the CAN BUS harness in good condition? segment is damaged,
replace the relating
Is the contact of connectors/pins alright?
cable segment.
Is the cable allocation in the connectors
correct?
 Main key switch 20S001 OFF.
1. Separate the CAN BUS segments and Re-program MH801 CAN BUS:
measure their continuity. and/or the K+ Rmax 1Ω
controller, or replace
2. In addition separate resistor 14R101 from 14R101:
the units if necessary.
connector 10X300a and measure its 120Ω
The CAN BUS har- If further information is
ness or the belonging resistance.
Yes required:
resistor 14R101 Is the continuity of the CAN BUS segments Please note the serial
may be defective 2 alright? numbers of K+ moni-
(no continuity, wrong Does the resistance of 14R101 meet the tor & controller and
resistance) specification? contact your dealer or
KMG.
Replace the defective
CAN BUS segment or
No
the end resistor
14R101 as necessary.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

7 - 110 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (K+ monitor (MH801) → K+ controller) for trouble code G00491
[2/2]

Fig. 7-63 Wiring Diagram (K+ monitor (MH801) → K+ controller) for trouble code G00491

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 111

 Troubleshooting by KOMTRAX Plus trouble code

DBBQKR - Communication failure CR710 <=> KOMTRAX Plus Controller

[1/2]
Trouble code
Message Communication failure CR710 <=> KOMTRAX Plus Controller
DBBQKR
The communication between K+ controller and pump controller is inoperative.
Trouble code is set if both of the following conditions become true:
Contents of trouble
– Battery voltage > 19.5V
– No connection to pump controller for >30 seconds.

Related information Communication between K+ controller and pump controller takes place via CAN BUS

– Background colour of the trouble code information: yellow

Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M802
Problem that appears
Communication between pump controller and K+ controller is impossible.
on the machine

Instruction message 2 Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
The connection  Main key switch 20S001 ON.
between K+ and the Check wiring, connectors, and pins between K+ controller 14K300 and the pump
1 Wiring
pump controller controller 10K032 for proper order and connection.
is inoperative Diagram
Repair or replace components according to the Wiring Diagram.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the trouble code does not arise again.

7 - 112 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (CR710 <=> KOMTRAX Plus) for trouble code DBBQKR
[2/2]

Fig. 7-64 Wiring Diagram (CR710 <=> KOMTRAX Plus) for trouble code DBBQKR

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 113

 Troubleshooting by KOMTRAX Plus trouble code

DBB3KK - Abnormality in VBAT voltage (KOMTRAX Plus VBAT<10V)

[1/1]
Trouble code
Message Abnormality in VBAT voltage (KOMTRAX Plus VBAT<10V)
DBB3KK
The power supply for the K+ controller is faulty:
Contents of trouble
Disconnection in the wiring of the steady plus or tripped circuit breaker 11F015a
Trouble code is set if both of the following conditions become true for more than 30 seconds:
Related information – Battery voltage < 10 V
– 20S001 key switch voltage > 10 V
– Background colour of the trouble code information: yellow
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M905
Problem that appears
KOMTRAX Plus monitoring system disturbed.
on the machine

Instruction message 2 Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
Short circuit to GND in  Main key switch 20S001 OFF.
the power supply wiring Locate the short circuit
of the K+ controller Check the condition of circuit breaker Wiring
1 Yes and repair as
11F015a. Diagram
(tripped circuit breaker necessary.
11F015a) Is circuit breaker 11F015a tripped?
No Go to next step.
 Main key switch 20S001 ON.
Disconnection in the
Check wiring, connectors, and contacts 6...9 in connector CN1 at the K+ control-
power supply wiring of 2 Wiring
ler 14K300 for proper connection.
the K+ controller Diagram
Repair or replace components according to the Wiring Diagram.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

Wiring Diagram (11F015a <=> KOMTRAX Plus) for trouble code DBB3KK

Fig. 7-65 Wiring Diagram (11F015a <=> KOMTRAX Plus) for trouble code DBB3KK

7 - 114 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

DBB0KK - KOMTRAX Plus source voltage Error

[1/2]
Trouble code
Message KOMTRAX Plus source voltage Error
DBB0KK

Contents of trouble K+ controller senses too low supply voltage while engine is running.

– Failure detection criteria:

– Battery voltage < 19.5 V
– Input signal on terminal CN3A.1 (Hour Meter active) at K+ controller is ON for > 1 second
Related information
– Engine speed > 499 rpm
– Verify if other trouble messages concerning the charging system are active (i.e. G00105 or
G00176). If other messages are displayed follow their instructions as necessary.
– Background colour of the trouble code information: yellow
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M901
Problem that appears
KOMTRAX Plus monitoring system disturbed.
on the machine

Instruction message 2 Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON.
Open REAL TIME MONITOR Refer to the Wiring
 03 Electrical Equipm. Diagram.
 Screen 1/1 Check 11T080 and its
Yes
circuit. Locate the
problem and repair or
replace as necessary.
Battery voltage too low 1
UBATT 24V

No Go to next step.

Does the voltage value of 11T080 confirm the

error message, criterion a)?
 Main key switch 20S001 ON.
Measure voltage: Yes Replace K+ controller.
24V supply voltage or – Between K+ controller (11K300) terminals
GND connection at K+ CN1.6/7 and 14GND at K+ terminals Refer to the Wiring
controller faulty CN1.11/12/19/20. Diagram.
2
Locate the problem UBATT 24V
(including connectors – Between K+ controller (11K300) terminals No
and pins) and repair or replace
CN1.6/7 and housing GND.
faulty 24V wiring or
Are supply voltage inputs & GND connections faulty GND connection.
at 11K300 OK?
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 115

 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram - K+ controller 24V supply and GND connections

[2/2]

Fig. 7-66 Wiring Diagram - K+ controller 24V supply and GND connections

7 - 116 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

DBB0KQ - KOMTRAX Plus Connector Mismatch

[1/1]
Trouble code
Message KOMTRAX Plus Connector Mismatch
DBB0KG
– The cable connectors at the KOMTRAX Plus controller are mixed up.
It is also possible that single wires of any wire harness at the KOMTRAX Plus controller are
Contents of trouble connected to wrong connector pins.
– The wiring to the KOMTRAX Plus controller may be damaged (or short cut).
– It is necessary to check the repair history.
– In case any repair has been done at the KOMTRAX Plus wiring, the wiring needs a double-
check.
Related information
– Trouble code is set if one of the following conditions become true for more than 10 seconds:
– Digital input cn_sel2 is OFF
– Digital input cn_sel3 is OFF
– Background colour of the trouble code information: yellow
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: MF11
Problem that appears
The monitoring system is disturbed.
on the machine

Instruction message 2 Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF.
– Refer to the Wiring Diagram and to SHOP Yes Go to next step.
MANUAL part 10 STRUCTURE & FUNC-
The cable connectors TION, chapter 16, section "WIRING OF
at the KOMTRAX Plus THE KOMTRAX PLUS CONTROLLER".
1 SHOP
controller may be Plug in the connectors
mixed up. – Check the cable connectors at the No MANUAL
in their correct order.
KOMTRAX Plus controller for their correct
connection order.
Are all connectors orderly plugged in?
 Main key switch 20S001 OFF.
– In case any repair has been done at the Yes Go to next step.
system before, check if all cables are
connected to their conforming connector
Cables may be pins.
connected to wrong 2 – Refer to the Wiring Diagram and to SHOP SHOP
connector pins Reconnect the cables
MANUAL part 10 STRUCTURE & FUNC- MANUAL
No to their conforming
TION, chapter 16, section "WIRING OF pins.
THE KOMTRAX PLUS CONTROLLER".
Are all cables connected to their conforming
pins?
 Main key switch 20S001 OFF.
– Refer to the Wiring Diagram and check the cables
The wiring at the and their connectors at the KOMTRAX Plus control- Replace any defective
KOMTRAX Plus
3 ler for any damage. component or repair Wiring
controller is damaged
(or short cut) – Disconnect the connectors from the KOMTRAX any wiring malfunction Diagram
Plus controller and measure the wire harnesses for as necessary.
continuity.
Bring the machine back into the original condition.
Final check 4
Start the machine and verify that the trouble code does not arise again.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 117

 Troubleshooting by KOMTRAX Plus trouble code

DGH2KA - Hyd. Oil Temp. Sensor Failure

[1/2]
Trouble code
Message Hyd. Oil Temp. Sensor Failure
DGH2KA
Disconnection in the wiring of temperature sensor 59B032-1.
Failure detection criteria:
– Battery voltage > 19.5 V
Contents of trouble
– Signal voltage on terminal CN2A.11 (H. Oil Temp.) at K+ controller > 4.929 V for > 1 second
– Input signal on terminal CN3A.1 (Hour Meter active) at K+ controller is ON for > 1 second
– Engine speed > 499 rpm

Related information Use the REAL TIME MONITOR for verification (03 Hydraulic., screen 3/3)

– Background colour of the trouble code information: yellow

Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M521
Problem that appears
The hydraulic oil temperature cannot be displayed in the K+ main gauge screen.
on the machine

Instruction message 2 Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF
Refer to the Wiring Diagram. Yes Go to next step. Rmax 1Ω
1. Disconnect connector of temperature sen-
sor 59B032-1.
2. Disconnect connector CNA2 with pin 11
and CN1 with pin 20 (GND) from K+ con-
Harness & connector
disconnection in wiring troller.
1 Locate the problem
or connector of temper- 3. Check all relevant cable segments for con-
ature sensor 59B032-1 tinuity: No and repair as neces-
sary.
– Between connector CN2A.11 and sen-
sor terminal 1.
– Between sensor terminal 2 and control-
ler terminal CN1.20 (GND).
Is continuity of the relevant wiring circuit OK?
 Main key switch 20S001 OFF
Defective hydraulic oil
temperature sensor Check hydraulic oil temperature sensor 59B032-1 according to the standard Refer to
2 PT100
59B032-1 value table.
(PT100 type) tempera-
Replace the temperature sensor as necessary. ture charts
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

7 - 118 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (59B032-1) for trouble code DGH2KA

[2/2]

Fig. 7-67 Wiring Diagram (59B032-1) for trouble code DGH2KA

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 119

 Troubleshooting by KOMTRAX Plus trouble code

DGH2KB - Hyd. Oil Temp. Sensor Failure

[1/2]
Trouble code
Message Hyd. Oil Temp. Sensor Failure
DGH2KB
Short circuit in the wiring of temperature sensor 59B032-1.
Failure detection criteria:
Contents of trouble
– Battery voltage > 19.5 V
– Signal voltage on terminal CN2A.11 (H. Oil Temp.) at K+ controller < 0.1 V for > 1 second

Related information Use the REAL TIME MONITOR for verification (03 Hydraulic., screen 3/3)

– Background colour of the trouble code information: yellow

Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M522
Problem that appears
The hydraulic oil temperature cannot be displayed in the K+ main gauge screen.
on the machine

Instruction message 2 Inform service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF
Refer to the Wiring Diagram. Rwire
Yes Go to next step.
1. Disconnect connector of temperature sen- max.1Ω
sor 59B032-1.
2. Disconnect connector CNA2 with pin 11
and CN1 with pin 20 (GND) from K+ con-
Short circuit in wiring troller. If Rwire is in the range
or connector of temper- 1
3. Check all relevant cable segments for con- of ∞Ω, repair or
ature sensor 59B032-1
tinuity: replace the defective
No
wire segment or
– Between connector CN2A.11 and sen- connector as
sor terminal 1. necessary.
– Between sensor terminal 2 and control-
ler terminal CN1.20 (GND).
Is continuity of the relevant wiring circuit OK?
 Main key switch 20S001 OFF
Defective hydraulic oil
temperature sensor Check hydraulic oil temperature sensor 59B032-1 according to the standard Refer to
2 PT100
59B032-1 value table.
(PT100 type) tempera-
Replace the temperature sensor as necessary. ture charts
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

7 - 120 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (59B032-1) for trouble code DGH2KB

[2/2]

Fig. 7-68 Wiring Diagram (59B032-1) for trouble code DGH2KB

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 121

 Troubleshooting by KOMTRAX Plus trouble code

J100KA - Pilot Press. Sensor Failure

[1/3]
Trouble code
Message Pilot Press. Sensor Failure
J100KA
Poor terminal contact or any disconnected connector in the wiring of pressure transducer 57B086.
Failure detection criteria:
Contents of trouble
– Battery voltage > 19.5 V
– Signal voltage on terminal CN2A.1 (X2 Pressure) at K+ controller < 0.5 V for > 1 second
– Within a pressure range of 0 - 50 bar the X2-pressure transducer 57B086 generates a signal
Related information voltage of 0.5 -9.5V.
– Use the REAL TIME MONITOR for verification (03 Hydraulic., screen 1/3)
– Background colour of the trouble code information: yellow
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M511
Problem that appears
The monitoring circuit for the X2-pressure is inoperative.
on the machine

Instruction message 17 Inform service till end of shift and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
1. Disconnect the connector from the X2- Umin 22V
Incorrect or no supply
pressure transducer and insert the Deutsch Yes Go to step 3.
voltage at the X2-pres- Umax 24V
1 T-box.
sure transducer
57B086 2. Measure the voltage between the trans-
ducer terminals A and C. No Go to next step.
Is supply voltage present?
 Main key switch 20S001 OFF.
Yes Go to next step. Rmax 1Ω
Disconnection in the Disconnection or short
wiring between circuit circuit in the wiring
breaker 11F070 and Refer to the Wiring Diagram and check the (including connectors)
X2-pressure trans- wiring between circuit breaker and connector between circuit
ducer 57B086 2 breaker and cable
terminal A at the X2 pressure transducer for
continuity. No connector terminal A
(disconnection or
at the X2-pressure
defective contact in any Is continuity present? transducer.
connector)
Locate the problem
and repair as
necessary.
 Main key switch 20S001 OFF.
Yes Go to next step. Rmax 1Ω
Disconnection or short
Disconnection in the circuit in the wiring
Refer to the Wiring Diagram and check for
shield wiring between (including connectors)
3 continuity between the shield terminal and
shield terminal between shield
GND.
11X257-P and GND No terminal and GND.
Is continuity present?
Locate the problem
and repair as
necessary.

7 - 122 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

J100KA - Pilot Press. Sensor Failure

[2/3]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF.
Yes Go to next step. Rmax 1Ω

Disconnection in the If the resistance is too

signal wiring between high, refer to the Wir-
X2-pressure trans- Check for continuity in the signal wiring ing Diagram and locate
ducer and K+ controller between sensor terminal B and controller ter- the problem in the sig-
4
minal CN2A.1 (X2 Pressure). nal wiring of the X2-
(disconnection or No pressure transducer.
defective contact in Is continuity present?
any connector) Repair as necessary.
After successful repair
go to final check (last
step).
 Engine running at high idle.
Check the input signal of 57B086 on the K+ display.
Defective X2 pressure REAL TIME MONITOR If the reading does not match the
transducer 57B086 5  03 Hydraulic. specification replace the X2-
(internal malfunction)  Screen 1/3 pressure sensor and verify that the
REAL TIME MONITOR must show X2-pilot pressure: repair was successful.
35 ± 3.0 bar
Bring the machine back into the original condition.
Final check 6
Start the machine and verify that the trouble code does not arise again.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 123

 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (57B086) for trouble code J100KA

[3/3]

Fig. 7-69 Wiring Diagram (57B086) for trouble code J100KA

7 - 124 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

J100KB - Pilot Press. Sensor Failure

[1/2]
Trouble code
Message Pilot Press. Sensor Failure
J100KB
Short circuit in the wiring of X2 pressure transducer 57B086.
Failure detection criteria:
Contents of trouble
– Battery voltage > 19.5 V
– Signal voltage on terminal CN2A.1 (X2 Pressure) at K+ controller > 4.9 V for > 1 second
– Within a pressure range of 0 - 50 bar the X2-pressure transducer 57B086 generates a signal
Related information voltage of 0.5 -9.5V.
– Use the REAL TIME MONITOR for verification (03 Hydraulic., screen 1/3)
– Background colour of the trouble code information: yellow
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M512
Problem that appears
The monitoring circuit for the X2-pressure is inoperative.
on the machine

Instruction message 17 Inform service till end of shift and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
Usignal
Yes Go to next step.
0.5V
If any higher Voltage is
Short circuit to PWR in present on the signal
Disconnect the connector from the X2-pres- line, a short circuit to
wiring or connector of
1 sure transducer and measure the signal line PWR in the wiring
X2 pressure transducer
voltage at the connector terminals B and C. (including connectors)
57B086
Does the measurement reading meet the No between X2-pressure
specification? transducer and K+
controller is present.
Locate the problem
and repair as
necessary.
 Engine running at high idle.
Check the input signal of 57B086 on the K+ display.
Defective X2 pressure REAL TIME MONITOR If the reading does not match the
transducer 57B086 2  03 Hydraulic. specification replace the X2-
(internal malfunction)  Screen 1/3 pressure sensor and verify that the
REAL TIME MONITOR must show X2-pilot pressure: repair was successful.
35 ± 3.0 bar
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 125

 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (57B086) for trouble code J100KB

[2/2]

Fig. 7-70 Wiring Diagram (57B086) for trouble code J100KB

7 - 126 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

J100L6 - Abnomal Pilot Pump press

[1/2]
Trouble code
Message Abnomal Pilot Pump press
J100L6
– X2 pilot pressure is too high or too low
Contents of trouble
– The system assumes that the sensor pressure 57B086 and its wiring are not defective
– Failure detection criteria:
– Battery voltage >19.5 V
Related information – X2 pilot pressure is >41 bar or <25.5 bar for >2 seconds
– Engine running at high idle
– Use the REAL TIME MONITOR for verification (03 Hydraulic., screen 1/3)
– Background colour of the trouble code information: yellow
Action of controller – The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
– 7 segment LED-Code at K+ controller: M571
Problem that appears
X2 pilot pressure is not within the specifications
on the machine

Instruction message 17 Inform service till end of shift and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Check the adjustment of the pressure regu- Yes Go to next step.
lating valve according to the values in
Wrong X2 -pressure PM-Clinic. Adjust setting of pres- PM-Clinic
reducing valve 1 – Refer to the SHOP MANUAL part sure regulating valve
adjustment 10 STRUCTURE & FUNCTION, chapter 7, No to the correct pressure. SHOP
section "PILOT PRESSURE SUPPLY AND MANUAL
Go to final check (last
ADJUSTMENTS". step).
Is the relay setting correct?
 Engine running at high idle.
Check the input signal of 57B086 on the K+ Yes Go to next step. PM-Clinic
display.
Defective X2 pressure
transducer 57B086 2 REAL TIME MONITOR Replace the pressure
 03 Hydraulic. transducer and verify
(internal malfunction) No
 Screen 1/3 that the repair was
Does the REAL TIME MONITOR show the successful.
correct value according to the PM-Clinic?
Bypass to the 60 bar
Bypass to the 60 bar X4 pilot pressure line.
X4 pilot pressure line Check the pressure at measuring port M1.2 at
Yes Locate the problem PM-Clinic
inside the support 3 the control and filter plate.
and repair as neces-
plate at the control Is the pressure reading approx. 60 bar? sary.
and filter plate
No Go to next step.
Check if the pump reaches at least 60 bar.
Defective pilot oil pump 4
Replace the pilot oil pump as necessary.
Bring the machine back into the original condition.
Final check 5
Start the machine and verify that the trouble code does not arise again.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 127

 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (57B086) for trouble code J100L6

[2/2]

Fig. 7-71 Wiring Diagram (57B086) for trouble code J100L6

7 - 128 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

DGE5KA - Ambient air temp Sensor Failure

[1/2]
Trouble code
Message Ambient air temp Sensor Failure
DGE5KA
Disconnection in the wiring of temperatur sensor 13B090.
Failure detection criteria:
Contents of trouble
– Battery voltage > 19.5 V
– Signal voltage on terminal CN2A.10 (Ambient Temp.) at K+ controller > 4.929 V for > 1 second

Related information Use the REAL TIME MONITOR for verification (10 Other Items, screen 1/2)

– Background colour of the trouble code information: yellow

Action of controller
– 7 segment LED-Code at K+ controller: M401
Problem that appears
The ambient air temperature cannot be displayed in the K+ main gauge screen.
on the machine

Instruction message - -

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF
Refer to the Wiring Diagram. Yes Go to next step. Rmax 1Ω
1. Disconnect connector of ambient air tem-
perature sensor 13B090.
2. Disconnect connector CNA2 with pin 10
and CN1 with pin 20 (GND) from K+ con-
Harness & connector
disconnection in wiring troller.
1 Locate the problem
or connector of temper- 3. Check all relevant cable segments for con-
ature sensor 13B090 tinuity: No and repair as neces-
sary.
– Between connector CN2A.10 and sen-
sor terminal 1.
– Between sensor terminal 2 and control-
ler terminal CN1.20 (GND).
Is continuity of the relevant wiring circuit OK?
 Main key switch 20S001 OFF
Defective ambient air
temperature sensor Check ambient air temperature sensor 13B090 according to the standard value Refer to
2 PT100
13B090 table.
(PT100 type) tempera-
Replace the temperature sensor as necessary. ture charts
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 129

 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (13B090) for trouble code DGE5KA

[2/2]

Fig. 7-72 Wiring Diagram (13B090) for trouble code DGE5KA

7 - 130 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

DGE5KB - Ambient air temp Sensor Failure

[1/2]
Trouble code
Message Ambient air temp Sensor Failure
DGE5KB
Disconnection in the wiring of temperature sensor 13B090.
Failure detection criteria:
Contents of trouble
– Battery voltage > 19.5 V
– Signal voltage on terminal CN2A.10 (Ambient Temp.) at K+ controller < 0.1 V for > 1 second

Related information Use the REAL TIME MONITOR for verification (10 Other Items, screen 1/2)

– Background colour of the trouble code information: yellow

Action of controller
– 7 segment LED-Code at K+ controller: M402
Problem that appears
The ambient air temperature cannot be displayed in the K+ main gauge screen.
on the machine

Instruction message - -

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF
Refer to the Wiring Diagram. Rwire
Yes Go to next step.
1. Disconnect connector of temperature sen- max.1Ω
sor 13B090.
2. Disconnect connector CNA2 with pin 10
and CN1 with pin 20 (GND) from K+ con-
Short circuit in wiring troller. If Rwire is in the range
or connector of temper- 1
3. Check all relevant cable segments for con- of ∞Ω, repair or
ature sensor 13B090
tinuity: replace the defective
No
wire segment or
– Between connector CN2A.10 and sen- connector as
sor terminal 1. necessary.
– Between sensor terminal 2 and control-
ler terminal CN1.20 (GND).
Is continuity of the relevant wiring circuit OK?
 Main key switch 20S001 OFF
Defective ambient air
temperature sensor Check ambient air temperature sensor 13B090 according to the standard value Refer to
2 PT100
13B090 table.
(PT100 type) tempera-
Replace the temperature sensor as necessary. ture charts
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 131

 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (13B090) for trouble code DGE5KB

[2/2]

Fig. 7-73 Wiring Diagram (13B090) for trouble code DGE5KB

7 - 132 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

F@DANS - Trouble High Exhaust Temperature Cylinder RB1

F@DBNS - Trouble High Exhaust Temperature Cylinder RB2
F@DCNS - Trouble High Exhaust Temperature Cylinder RB3
F@DDNS - Trouble High Exhaust Temperature Cylinder RB4
F@DENS - Trouble High Exhaust Temperature Cylinder RB5
F@DFNS - Trouble High Exhaust Temperature Cylinder RB6
F@DGNS - Trouble High Exhaust Temperature Cylinder LB1
F@DHNS - Trouble High Exhaust Temperature Cylinder LB2
F@DJNS - Trouble High Exhaust Temperature Cylinder LB3
F@DKNS - Trouble High Exhaust Temperature Cylinder LB4
F@DLNS - Trouble High Exhaust Temperature Cylinder LB5
F@DMNS - Trouble High Exhaust Temperature Cylinder LB6
[1/3]
Trouble code Trouble High Exhaust Temperature Cylinder RB(1...6)
Message
F@D(A...M)NS Trouble High Exhaust Temperature Cylinder LB(1...6)
An exhaust temperature sensor 52B243-1...6 or 52B244-1...6 detects s too high exhaust tempera-
ture at an engine cylinder.
Contents of trouble Trouble code is displayed as long as all of the following conditions are met:
– Battery Voltage > 19.5 V
– Engine running at > 499 rpm and exhaust temperature ≥ 731°C for > 5 sec
– Use the REAL TIME MONITOR for verification (01 Engine 1, screen 4/5 & 5/5)
Related information
– The system assumes that the exhaust temperature sensors and amplifier module are OK.
– Background colour of the trouble code information: red
– The K+ buzzer (20P022) is beeping, when the engine start switch is turned to ON
Action of controller – 7 segment LED-Code at K+ controller: M651 (F@DANS), M652 (F@DBNS), M653 (F@DCNS),
M654 (F@DDNS), M655 (F@DENS), M656 (F@DFNS), M641 (F@DGNS), M642 (F@DHNS),
M643 (F@DJNS), M644 (F@DKNS), M645 (F@DLNS), M646 (F@DMNS)
Problem that appears
The exhaust temperature of an engine cylinder is too high.
on the machine

Instruction message 32 Stop engine call service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF
1. Check for inactive / active engine related Carry out troubleshoot-
trouble codes (also stored trouble codes in Yes ing with the Cummins
the memory.) Service.
1
2. Connect the Cummins tester and check
with the "Insite" software tool. No Go to next step.
The exhaust tempera- Are engine related trouble codes present?
ture at the concerned
 Main key switch 20S001 OFF
cylinder is too high
There is a problem
with the engine’s cylin-
Check the KOMTRAX Plus memory for further der/combustion.
2 occurences of the same trouble code. Yes
Carry out troubleshoot-
Is the same trouble code present several ing with the Cummins
times? Service.
No Go to next step.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 133

 Troubleshooting by KOMTRAX Plus trouble code

F@DANS - Trouble High Exhaust Temperature Cylinder RB1

F@DBNS - Trouble High Exhaust Temperature Cylinder RB2
F@DCNS - Trouble High Exhaust Temperature Cylinder RB3
F@DDNS - Trouble High Exhaust Temperature Cylinder RB4
F@DENS - Trouble High Exhaust Temperature Cylinder RB5
F@DFNS - Trouble High Exhaust Temperature Cylinder RB6
F@DGNS - Trouble High Exhaust Temperature Cylinder LB1
F@DHNS - Trouble High Exhaust Temperature Cylinder LB2
F@DJNS - Trouble High Exhaust Temperature Cylinder LB3
F@DKNS - Trouble High Exhaust Temperature Cylinder LB4
F@DNNS - Trouble High Exhaust Temperature Cylinder LB5
F@DMNS - Trouble High Exhaust Temperature Cylinder LB6
[2/3]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
Disconnection in any  Main key switch 20S001 OFF
wiring segment or con- Rwire
nector between Yes Go to next step.
max.1Ω
exhaust temperature Refer to the Wiring Diagram and check all rele-
sensor vant cable segments for continuity: If Rwire is in the range
52B243-1...6 or 3
– Between the concerned temperature sen- of ∞Ω, repair or
52B244-1...6 sor and its amplifier module. replace the defective
No
and amplifier module wire segment or
Is continuity of the relevant wiring circuit OK? connector as
52T243-1...6 or necessary.
52T244-1...6
Defective amplifier  Main key switch 20S001 OFF
module
4
52T243-1...6 or Replace any defective amplifier moduler as necessary.
52T244-1...6
Bring the machine back into the original condition.
Final check 5
Start the machine and verify that the trouble code does not arise again.

Input signals of the engine cylinder temperature sensors on the REAL TIME MONITOR

Fig. 7-74 Input signals of the engine cylinder temperature sensors on the REAL TIME MONITOR

7 - 134 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram for trouble codes F@D(A...M)NS

[3/3]

Fig. 7-75 Wiring Diagram exhaust temperature sensors

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 135

 Troubleshooting by KOMTRAX Plus trouble code

DGTAKX - Trouble monitoring Exhaust Temp Cylinder RB1

DGTBKX - Trouble monitoring Exhaust Temp Cylinder RB2
DGTCKX - Trouble monitoring Exhaust Temp Cylinder RB3
DGTDKX - Trouble monitoring Exhaust Temp Cylinder RB4
DGTEKX - Trouble monitoring Exhaust Temp Cylinder RB5
DGTFKX - Trouble monitoring Exhaust Temp Cylinder RB6
DGTGKX - Trouble monitoring Exhaust Temp Cylinder LB1
DGTHKX - Trouble monitoring Exhaust Temp Cylinder LB2
DGTJKX - Trouble monitoring Exhaust Temp Cylinder LB3
DGTKKX - Trouble monitoring Exhaust Temp Cylinder LB4
DGTLKX - Trouble monitoring Exhaust Temp Cylinder LB5
DGTMKX - Trouble monitoring Exhaust Temp Cylinder LB6
[1/3]
Trouble code Trouble monitoring Exhaust Temp Cylinder RB(1...6)
Message
DGT(A...M)KX Trouble monitoring Exhaust Temp Cylinder LB(1...6)
Trouble code is set if both of the following conditions are met:
Contents of trouble – Battery Voltage > 19.5 V
– Sensor input voltage < 0.5 V or sensor input voltage > 4.5 V

Related information – Use the REAL TIME MONITOR for verification (01 Engine 1, screen 4/5 & 5/5)

– Background colour of the trouble code information: yellow

Action of controller – 7 segment LED-Code at K+ controller: M721 (DGTAKX), M722 (DGTBKX), M723 (DGTCKX),
M724 (DGTDKX), M725 (DGTEKX), M726 (DGTFKX), M671 (DGTGKX), M672 (DGTHKX),
M673 (DGTJKX), M674 (DGTKKX), M675 (DGTLKX), M676 (DGTMKX)
Problem that appears
Exhaust temperature of the cylinder can not be transmitted by the ORBCOMM system.
on the machine

Instruction message 31 Continue shift but advise service.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
Incorrect or no supply 1. Disconnect the connector from the con- Umin 22V
voltage at amplifier cerned amplifier module and insert the Yes Go to next step.
Umax 24V
module 1 Deutsch T-box.
Locate the problem
52T243-1...6 or 2. Measure the voltage between the trans-
and repair or replace
52T244-1...6 ducer terminals A and C.
No the defective wire seg-
Is supply voltage present? ment or connector as
necessary.
 Main key switch 20S001 OFF
Defective cylinder tem- Refer to the wiring diagram. Yes Go to next step.
perature sensor
Disconnect the connector from the concerned Refer to
52B243-1...6 2 temperature sensor. PT100
52B244-1...6 Replace defective tem- tempera-
Check temperature sensor according to the No
perature sensor. ture charts
(PT100 type) standard value table.
Is the test result OK?

7 - 136 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

DGTAKX - Trouble monitoring Exhaust Temp Cylinder RB1

DGTBKX - Trouble monitoring Exhaust Temp Cylinder RB2
DGTCKX - Trouble monitoring Exhaust Temp Cylinder RB3
DGTDKX - Trouble monitoring Exhaust Temp Cylinder RB4
DGTEKX - Trouble monitoring Exhaust Temp Cylinder RB5
DGTFKX - Trouble monitoring Exhaust Temp Cylinder RB6
DGTGKX - Trouble monitoring Exhaust Temp Cylinder LB1
DGTHKX - Trouble monitoring Exhaust Temp Cylinder LB2
DGTJKX - Trouble monitoring Exhaust Temp Cylinder LB3
DGTKKX - Trouble monitoring Exhaust Temp Cylinder LB4
DGTLKX - Trouble monitoring Exhaust Temp Cylinder LB5
DGTMKX - Trouble monitoring Exhaust Temp Cylinder LB6
[2/3]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF
Refer to the Wiring Diagram and check all rele- Rwire
Yes Go to next step.
Disconnection or sho- vant cable segments for continuity: max.1Ω
ert circuit in any – Between the concerned temperature sen-
wiring segment or con-
sor and its amplifier module.
nector between cylin-
der temperature sensor – Between the concerned amplifier module If Rwire is in the range
3
terminal B and the corresponding controller of ∞Ω, repair or
52B243-1...6 or
terminal. replace the defective
52B244-1...6 No
wire segment or
and K+ controller – Between the concerned amplifier module connector as
14K300 terminal C and controller terminal CN2B.9 necessary.
(GND).
Is continuity of the relevant wiring circuit OK?
Defective amplifier  Main key switch 20S001 OFF
module
4
52T243-1...6 or Replace any defective amplifier moduler as necessary.
52T244-1...6
Bring the machine back into the original condition.
Final check 5
Start the machine and verify that the trouble code does not arise again.

Input signals of the engine cylinder temperature sensors on the REAL TIME MONITOR

Fig. 7-76 Input signals of the engine cylinder temperature sensors on the REAL TIME MONITOR

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 137

 Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram for trouble codes DGT(A...M)KX

[3/3]

Fig. 7-77 Wiring Diagram exhaust temperature sensors

7 - 138 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

DJF1KX - Trouble monitoring fuel level

[1/3]
Trouble code
Message Trouble monitoring fuel level
DJF1KX
– Defective wiring or defective pressure transducer 31B063.

Contents of trouble – Failure detection criteria:

Signal voltage on terminal CN2A.8 (level fuel tank) at K+ controller < 0.25 V or > 9.75V
for > 10 seconds
– Within a pressure range of 0 - 0.4 bar the pressure transducer 31B063 generates a signal volt-
Related information age of 0.5 -9.5V.
– Use the REAL TIME MONITOR for verification (10 Other Items, screen 1/2)
– Background colour of the trouble code information: yellow
Action of controller
– 7 segment LED-Code at K+ controller: M580
Problem that appears – Risk to run out of fuel.
on the machine – The fuel level cannot be displayed in the K+ main gauge screen.

Instruction message 17 Inform service till end of shift and then press cancel button.

Nominal
Possible cause Step Test condition & Inspection Procedure
value

Open the shut-off cock between fuel tank and Yes Go to next step.
The fuel shut-off cock pressure transducer 31B063 to allow pressure End of troubleshooting.
1 compensation.
is closed No Go to final check (last
Is trouble code DJF1KX still present? step).
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
1. Disconnect the connector from the pres- Umin 22V
Incorrect or no supply sure transducer and insert the Deutsch T- Yes Go to step 4.
voltage at pressure 2 Umax 24V
box.
transducer 31B063
2. Measure the voltage between the trans-
ducer terminals A and C. No Go to next step.
Is supply voltage present?
 Main key switch 20S001 OFF.
Yes Go to next step. Rmax 1Ω
Disconnection in the Disconnection or short
wiring between circuit circuit in the wiring
breaker 11F070 and Refer to the Wiring Diagram and check the (including connectors)
pressure transducer wiring between circuit breaker and connector between circuit
31B063 3 breaker and cable
terminal A at the pressure transducer for
continuity. No connector terminal A
(disconnection or
at the pressure trans-
defective contact in any Is continuity present? ducer 31B063.
connector)
Locate the problem
and repair as
necessary.

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 139

 Troubleshooting by KOMTRAX Plus trouble code

DJF1KX - Trouble monitoring fuel level

[2/3]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF.
Yes Go to next step. Rmax 1Ω
Disconnection or short
Disconnection in the circuit in the wiring
Refer to the Wiring Diagram and check for
shield wiring between (including connectors)
4 continuity between the shield terminal and
shield terminal between shield
GND.
11X031-D and GND No terminal and GND.
Is continuity present?
Locate the problem
and repair as
necessary.
 Main key switch 20S001 OFF.
Yes Go to step 7. Rmax 1Ω
Disconnection in the If the resistance is too
signal wiring between high, refer to the Wir-
pressure transducer ing Diagram and locate
31B063 and K+ con- Check for continuity in the signal wiring the problem in the sig-
troller 5
between transducer terminal B and controller nal wiring of pressure
(disconnection or terminal CN2A.8 (level fuel tank). No transducer 31B063.
defective contact in Repair as necessary.
any connector).
After successful repair
go to final check (last
step).
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
Usignal
Yes Go to next step.
0.5 - 9.5V
If any higher voltage is
present on the signal
Short circuit to PWR in line a short circuit to
Disconnect the connector from the X2-pres-
wiring or connector of PWR in the wiring
6 sure transducer and measure the signal line
pressure transducer (including connectors)
voltage at the connector terminals B and C.
31B063 between pressure
Does the measurement reading meet the No transducer 31B063
specification? and K+ controller is the
problem.
Locate the problem
and repair as
necessary.
 Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
1. Disconnect the connector from the pressure trans-
Defective pressure ducer and insert the Deutsch T-box. If the signal voltage does not match
transducer 31B063 7 2. Disconnect connector CNA2 with pin 10 from the the given specifications replace
(internal malfunction) K+ controller. pressure transducer 31B063.
3. Measure the signal voltage at the transducer After successful repair go to final
terminals B and C. check (last step).
The signal voltage must be 0.5 - 9.5V.
Bring the machine back into the original condition.
Final check 8
Start the machine and verify that the trouble code does not arise again.

7 - 140 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by KOMTRAX Plus trouble code

Wiring Diagram (31B063) for trouble code DJF1KX

[3/3]

Fig. 7-78 Wiring Diagram (31B063) for trouble code DJF1KX

SHOP-40 06279-xD-GB-1 PC3000-6 7 - 141

 Troubleshooting by KOMTRAX Plus trouble code

Please continue reading on the next page.

7 - 142 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms

8 TROUBLESHOOTING BY
SYMPTOMS

SHOP-40 06279-xD-GB-1 PC3000-6 8 -1

Symptoms of the engine and related electrical system Troubleshooting by Symptoms

8.1 SYMPTOMS OF THE ENGINE AND RELATED

ELECTRICAL SYSTEM

SEL001 - Engine does not start (engine does not rotate)

[1/5]
Trouble code
Trouble Engine does not start (engine does not rotate)
SEL001
– The engine does not start (the engine does not rotate).
Contents of trouble
– Corresponding trouble messages are not displayed.
If engine start is impossible (engine does not rotate), the following provided engine start blocking
mechanisms or malfunctions may be the cause:
– No or not enough battery power is present (below 17 Volt).
– The safety lock lever is in down position during engine start.
Related information
– The safety lock lever switch (20S105) is faulty.
– The pre-lube process is not started or stopped.
– The starter motors have an internal short circuit.
– The starter motors are mechanically blocked (breakdown).
Problem that appears
The engine does not start (the engine does not rotate).
on the machine
– Missing battery maintenance, internal short circuit in any battery or low battery voltage (<17V)
– Handling error by the operator, safety lock lever in the wrong (down) position
– Safety lock switch (20S105) or its wiring faulty
Possible causes
– The pre-lube process is disturbed (it is not started or stopped)
– Component's lifetime exceeded: starter motors internal disconnection or short circuit
– Component's lifetime exceeded: starter motors internal disconnection or damage

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF & Maintenance safety switch 50S058 locked.
Ubatt >24V
(under
Neglected battery
load no
maintenance.
drop below
Internal short circuit in Check the capacity and condition of batteries Replace the concerned 20V)
1 Yes
any battery or low 71G001–71G004. battery/batteries.
Electrolyte
battery voltage Is any battery defective?
specific
(below 17 V)
gravity
>1.26
No Go to next step.
 Main key switch 20S001 ON.
Handling error by the
operator Check for the correct lock lever position (UP) Yes Go to next step.
2 during engine start.
Safety lock lever in the Move the lock lever in
wrong (down) position Is lock lever 20S105 in the correct position No the UP position and
(UP) for engine start? repeat the engine start.
 Main key switch 20S001 OFF & Maintenance safety switch 50S058 locked.
Refer to the Wiring Diagram. Yes Go to next step.
Safety lock switch
(20S105) or its wiring 3 Check the switch function (20S105) and the
Wiring
faulty belonging wiring. Repair or replace as
No Diagram
Are safety lock switch 20S105 and its wiring necessary.
ok?

8 -2 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the engine and related electrical system

SEL001 - Engine does not start (engine does not rotate)

[2/5]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON & Engine start switch 20S004 activated.
When the start switch 20S004 is activated, the Yes Go to next step.
pre-lube pump 52G006 must start and run until
an oil pressure of 0.17 bar is built up in the
engine.
The pre-lube process is As soon as the specified engine oil pressure is
disturbed reached at the pressure switch 52B093, the
4
(it is not started or pre-lube timing relay 52K030 initiates the start See the troubleshoot-
stopped) signal to the starter relay 52Q002a of the No
ing chart of SEL001a.
starter motors.
Refer to the Wiring Diagram and check the
pre-lube process.
Is the pre-lube function OK, does it start and
stop as specified?
 Main key switch 20S001 ON & Engine start switch 20S004 activated.
Component's lifetime Check the relay 52Q002a for Vbatt Replace the starter
Yes
exceeded (approx. 24 V) input/power supply. motors.
Vbatt
(starter motors internal 5 Refer to the Wiring
Is Vbatt present at the input and output of the (approx.
disconnection or short Diagram.
relay? No 24V)
circuit) Repair/ replace the
Is Vbatt present at the starter motors? wiring as necessary.
 Main key switch 20S001 OFF & Battery switches 71Q003 & 71Q004 OFF.
Replace the starter
motors and recheck
Yes
the system for proper
function.
Component's lifetime
Check the engine
exceeded
Disassemble or replace both starter motors flywheel for free
(starter motors internal 6
and inspect them. mechanical rotation.
disconnection or
damage) Is any mechanical fault detectable? Also refer to the
No Cummins Trouble-
shooting and Repair
Manual.
Repair or replace as
necessary.
Bring the machine back into the original condition.
Final check 7
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 -3

Symptoms of the engine and related electrical system Troubleshooting by Symptoms

Wiring Diagram 1 (engine start) for trouble code SEL001 & SEL001a
[3/5]

Fig. 8-1 Wiring Diagram 1 (engine start) for trouble code SEL001 & SEL001a

8 -4 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the engine and related electrical system

SEL001a - Engine does not start (Pre-lube does not stop)

[1/1]
Trouble code
Trouble Engine does not start (Pre-lube does not stop)
SEL001a
Engine does not start as the pre-lube operation does not stop.
Contents of trouble
No trouble code displayed.
The following engine start blocking mechanisms are provided in the engine start circuit:
– The pre-lube function must start and build up engine oil pressure up to 0.17 bar.
Related information
– As long as this minimum pre-lube oil pressure is not reached the start mechanism is blocked
and the pre-lube operation does not stop.
Problem that appears
The engine does not start & the pre-lube operation does not stop.
on the machine
– Pre-lube operation does not stop because pressure switch 52B093 is defective.
Possible causes
– Pre-lube operation does not stop because the built up engine oil pressure is not high enough.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON & Engine start switch 20S004 activated.
Yes Go to next step.
1. Refer to Wiring
Diagram.

When the start switch is activated, the pre-lube 2. Check the following
pump 52G006 must start and run until an oil components and
pressure of 0.17 bar is built up. the relating wiring:
Pre-lube operation
As soon as the specified engine oil pressure is – Pre-lube pump
does not stop because Wiring
1 reached at pressure switch 52B093, the pre- 52G006
pressure switch Diagram
52B093 is defective lube timing relay 52Q030a initiates the start No – Engine oil
signal to the starter relay 52Q002a for the refer to
pressure switch
starter motors. Fig. 8-1
52B093 (incl.
Is the pre-lube function OK, does it start and switch function)
stop as specified?
– Pre-lube timing
relay 52K030
– Starter relays
52Q002a
 Main key switch 20S001 ON & Engine start switch 20S004 activated.
When the start switch is activated, the pre-lube Check pre-lube pump
Pre-lube operation
pump 52G006 must start and run until an oil 52G006-1 and
does not stop because Yes
pressure of 0.17 bar is built up. pressure switch Switch
the built up engine oil 2
If 0.17 bar are not reached the pre-lube is not 52B093-1. point poil =
pressure is not high
stopped. 0.17 bar
enough Contact the Cummins
Does the engine oil pressure reach 0.17 bar? No
service.
(Use a digital gauge)
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 -5

Symptoms of the engine and related electrical system Troubleshooting by Symptoms

SEL002 - Engine stops while in operation

[1/2]
Trouble code
Trouble Engine stops while in operation
SEL002
– During operation the engine suddenly stops.
Contents of trouble
– A corresponding trouble code is not displayed.

Related information Battery voltage and power supply at the start relays and at the starter motors are present.

– Engine shut-down from high or low idle.

Problem that appears
– Engine restart is impossible (engine rotates but does not start).
on the machine
– No exhaust smoke visible.
Engine shut-down due to:
Possible causes – Lack of fuel in the fuel tank or contamination
– Water separator and/or fuel filter clogged

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON.
Yes Go to next step.
1. Refuel if necessary.
2. Open shut-off cock.
3. Inspect the fuel
1. Check the level in the fuel tank.
tank and the bot-
2. Check if the fuel shut-off cock is open. tom fuel line con- Refer to the
Lack of Diesel fuel Cummins
1 3. Check the fuel solenoid valve 31Q599 for nection for
at the fuel filters Engine
proper function contamination. Manual for
No
(31Q599 must be open at key switch ON). 4. Check 31Q599 for fuel specifi-
Is fuel supply present at the water separator proper function and cations.
and at the fuel filters? repair if necessary.
5. Check the fuel sup-
ply line for free pas-
sage and repair if
necessary.
 Main key switch 20S001 OFF & Maintenance safety switch 50S058 locked.
1. Check the water separator and/or fuel fil- Bleed the fuel pump
ters for contamination. Yes (key switch ON) and
water separator and/or If necessary clean the water separator and/ restart the engine. Refer to the
fuel filter clogged or replace the filter elements. Cummins
2 Check the supply Engine
Lack of Diesel fuel 2. Replace the fuel filter on the engine side. hoses and unions for Manual for
at the fuel pump fuel specifi-
3. Check the fuel shut-off valve/circuit for No free passage and
repair if necessary. cations.
proper function.
Go to next step.
Is fuel present at the fuel pump?
Bring the machine back into the original condition.
Final check 4
Start the machine and verify that the repair was successful.

8 -6 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the engine and related electrical system

View onto the fuel system water separator (SEL002)

[2/2]

Fig. 8-2 View onto the fuel system water separator (SEL002)

(1) Fuel tank (4) Fuel filters

(2) Fuel shut-off solenoid valve (31Q599) (5) Water separator filter

(3) Fuel shut-off solenoid cock

SHOP-40 06279-xD-GB-1 PC3000-6 8 -7

Symptoms of the engine and related electrical system Troubleshooting by Symptoms

SEL003 - Engine speed is hunting during boom-up movement

[1/2]
Trouble code
Trouble Engine speed is hunting during boom-up movement
SEL003
– At low idle the engine speed is irregular.
Contents of trouble – During boom-up movement the engine speed is hunting
– At high idle the engine speed is lower than specified
– First carry out troubleshooting with the Cummins Service and check for inactive / active trouble
codes stored in the error memory (inactive / active trouble codes could disturb the ECM control
Related information during low or high idle.
– Connect the Cummins tester and check with the "Insite" software tool.
Lack of output power due to:
Problem that appears
– Improper machine operation because of engine hunting
on the machine
– Improper function of the pump regulation system
– Active / inactive trouble codes stored in the Quantum ECM memory disturb the RPM control
– Lack of fuel, filter clogged
Possible causes
– Engine speed at high idle is lower than specified
– Incorrect pump regulation setting via Multimonitor

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Connect the Cummins tester and check with the "Insite" software tool.
Active / inactive
1. Check for inactive trouble codes and delete Go to the final step Refer to the
trouble codes stored Cummins
the error memory completely. and then release the
in the Quantum ECM 1 Yes Engine
shovel back to
memory disturb the 2. Then recheck the engine running condition. Manual for
operation.
RPM control fuel specifi-
Is the hunting problem solved? No Go to next step. cations.
 Main key switch 20S001 OFF & Maintenance safety switch 50S058 locked.
The engine is hunting Replace the fuel filter Refer to the
during boom up Check water Separator / fuel filters elements and clean the Cummins
movement 2 Yes Engine
for contamination. water separator hous-
ing as necessary. Manual for
Lack of fuel Is any filter clogged? fuel specifi-
No Go to next step. cations.
 Connect the Cummins tester and check with the "Insite" software tool.
Go to the final step
At High Idle the engine and then release
Yes Refer to the
speed is lower than 1. Check and adjust the specified RPM. the shovel back Cummins
specified 3 to operation. Engine
2. Also refer to the PM-CLINIC sheets.
Wrong RPM adjust- Together with the Manual for
ments Was the RPM adjustment successful? Cummins Service, fuel specifi-
No cations.
check the complete
fuel system.

8 -8 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the engine and related electrical system

SEL003 - Engine speed is hunting during boom-up movement

[2/2]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON
During operation:
Check the adjustment
of the Primary P-factor
on the Multimonitor. Refer to
Incorrect pump Yes the PM-
Check the basic adjustments of the pump Also refer to the
regulation setting 4 CLINIC
controller CR710 on the Multimonitor. SHOP MANUAL, part
via Multimonitor data from
Are the settings correct? 10 STRUCTURE &
Commis-
FUNCTION, chapter 9.
sioning
Correct the settings
No and bring the shovel
back to operation.
Engine speed sensor  Main key switch 20S001 ON
52B064 polluted by 1. Disassemble and clean engine speed sensor 52B064.
magnetized chipping 5 2. Reassemble and adjust the sensor, refer to SHOP MANUAL, part
Sensor delivers faulty 10 STRUCTURE & FUNCTION, chapter 9, section "ENGINE SPEED
signals SENSOR (PICK-UP) ADJUSTMENT".
Bring the machine back into the original condition.
Final check 6
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 -9

Symptoms of the engine and related electrical system Troubleshooting by Symptoms

SEL004 - Engine does not stop

[1/1]
Trouble code
Trouble Engine does not stop
SEL004

Contents of trouble When the engine stop switch 20S005-1 is activated the engine does not stop.

Related information A corresponding trouble message is not displayed.

Problem that appears

It is not possible to stop the running engine.
on the machine
– When the engine stop switch 20S005-1 is pressed the engine stop not activated.
Possible causes
– It is not possible to activate the shut-off solenoid (QSK60, Quantum ECM fuel block).

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON & Engine stop switch 20S005-1 activated
1. Refer to the Wiring Umin 22V
Diagram. Umax 24V
When the engine stop 2. Locate the prob-
switch 20S005 is Check the circuits of 20S005 and the engine lem and repair as
1 Yes
pressed, the engine stop via relay 11K051 for proper function. necessary.
stop is not activated Is any problem present? 3. After that recheck
the system for
proper function.
No Go to next step.
 Main key switch 20S001 ON & Engine stop switch 20S005-1 activated
Repair or replace as
necessary.
Yes After that recheck Cummins
the system for
proper function.
It is not possible to Inform the Cummins Service.
activate the shut-off Using the Cummins
function (QSK38, 2 Connect the Cummins tester to the engine tester, check for other
Quantum ECM fuel ECM and check the system with the "Insite" pending trouble codes
block) software tool. of the engine/fuel
Is the shut-off function defective? system.
No
Continue search for
faults and relating
repairs according to
the Cummins trouble-
shooting guide.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the repair was successful.

8 - 10 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the engine and related electrical system

SEL005 - Engine lacks output (no power)

[1/2]
Trouble code
Trouble Engine lacks output (no power)
SEL005

Contents of trouble Lack of engine output power.

Related information Refer to the following judgment table.

Problem that appears

A sufficient loading or moving is not possible.
on the machine
General causes for lack of output power:
– Insufficient air intake (air filter clogged)
– Insufficient fuel supply (water separator or fuel filter clogged)
Possible causes
– Improper fuel injection condition (Cummins fuel system)
– The used fuel does not meet the specifications (non-specified fuel causes output drops)
– Engine worn out, too much blow-by pressure

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Test conditions according to the kind of inspection, when following the
judgment table information.
1. Inspect the
suspicious system,
unit, or component
Engine lacks output
1 for malfunction and
(no power) Refer to the following judgment table and identify repair or replace as
the appropriate trouble cause(s). necessary.
2. After that recheck
the system for
proper function.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 11

Symptoms of the engine and related electrical system Troubleshooting by Symptoms

SEL005 - Engine lacks output (no power)

[2/2]

Judgment Table for SEL005 Causes

Defective contact of valve and valve seat

Clogged injector, wrong spray pattern
Wrong adjustment of valve clearance
Seized turbocharger, interference
Worn piston ring, cylinder liner
Clogged air cleaner elements

Clogged fuel filters, strainers

Clogged, leaking fuel piping

Legend

Ο : Possible causes (judging from Questions & Check Items)

◙ : Most probable causes (judging from Questions & Check Items)

Overheating
◊ : Possible causes due to length of use (used for a long period)

● : Items to confirm the cause

Confirm the recent repair history

Degree of use of the machine Operated for a long period ◊ ◊ ◊ ◊
Gradually ◙ ◙
Questions

Power was lost

Suddenly Ο Ο Ο Ο Ο
Engine oil must be added more frequently ◙
Replacement of filters has been carried out according to the OPERATION &
◙ ◙
MAINTENANCE MANUAL
Non-specified fuel is being used ◙ ◙
Air cleaner clogging warning is displayed ◙
Black ◙ ◙
Colour of exhaust gas
Blue under light load ◙
Noise of interference is heard from around the turbocharger ◙
Blow-by gas is excessive ◙
Engine pickup is poor and combustion is abnormal ◙ ◙ Ο
Check items

High idle speed without load is normal, but speed suddenly drops when load
◙
is applied
When touching the exhaust manifolds immediately after engine start, the tem-
◙
perature of some cylinders is low
Engine is hunting (rotation is irregular) Ο Ο
Clanging sound is heard from around the cylinder head ◙
Leakage at the fuel piping ◙
Coolant temperature signal is in red range ◙

When inspecting the air filter elements, clogging is found ●

Carry out troubleshooting for
Troubleshooting

When rotating the turbocharger by hand, it is too heavy ●

Measured compression pressure it is too low ● ●
overheating

When inspecting fuel filters & strainers, clogging is found ●

Eng. speed does not change when any cylinder is disengaged ●
When checking valve clearance, it doesn't meet the specification ●
Replace
Replace
Replace
Correct

Correct

Remedy
Adjust
Clean

Clean

8 - 12 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the engine and related electrical system

SEL006 - Exhaust smoke is black

[1/2]
Trouble code
Trouble Exhaust smoke is black
SEL006

Contents of trouble The exhaust smoke is black (incomplete combustion)

Related information Refer to the following judgment table.

Problem that appears – Reduced engine efficiency

on the machine – Poor emission quality
General causes for black exhaust smoke:
– Insufficient air intake
Possible causes
– Improper condition of fuel injection
– Excessive fuel injection

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Test conditions according to the kind of inspection, when following the
judgment table information.
1. Inspect the
suspicious system,
unit, or component
Exhaust smoke is black for malfunction and
(incomplete 1 repair or replace as
Refer to the following judgment table and identify the
combustion) necessary.
appropriate trouble cause(s).
2. After that recheck
the system for
proper function.
3. Go to final step 2.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 13

Symptoms of the engine and related electrical system Troubleshooting by Symptoms

SEL006 - Exhaust smoke is black

[2/2]

Judgment Table for SEL006 Causes

Air leakage between turbocharger & cyl. head

Defective contact of valve and valve seat

Clogged injector, wrong spray pattern

Wrong adjustment of valve clearance

Seized turbocharger, interference

Worn piston ring, cylinder liner

Clogged air cleaner elements

Crushed, clogged muffler

Legend

Ο : Possible causes (judging from Questions & Check Items)

◙ : Most probable causes (judging from Questions & Check Items)

◊ : Possible causes due to length of use (used for a long period)

● : Items to confirm the cause

Confirm the recent repair history

Degree of use of the machine Operated for a long period ◊ ◊ ◊ ◊
Suddenly became black ◙
Colour of exhaust gas Gradually became black ◙ ◙ Ο
Questions

Blue under light load ◙

Engine oil must be added more frequently ◙
Suddenly ◙ Ο Ο
Power was lost
Gradually Ο Ο Ο Ο
Non-specified fuel is being used Ο
Noise of interference is heard from around the turbocharger ◙
Air cleaner clogging warning is displayed ◙
Blow-by gas is excessive ◙
Engine pickup is poor and combustion is abnormal Ο ◙ Ο Ο Ο
Check items

When touching the exhaust manifolds immediately after engine start, the ◙
temperature of some cylinders is low
Clanging sound is heard from around the cylinder head ◙
Exhaust noise is abnormal Ο Ο ◙
Muffler is crushed ◙
Air leakage between turbocharger and cyl. head, loose clamp ◙

When rotating the turbocharger by hand, it is too heavy ●

When inspecting the air filter elements, clogging is found ●
Troubleshooting

Measured compression pressure it is too low ● ●

Eng. speed does not change when any cylinder is disengaged ●
When the "delivery test" is made, wrong injection timing is found
Injection pump test shows, that the injection amount is wrong
When checking valve clearance, it doesn't meet the specification ●
When muffler is removed, exhaust gas colour returns to normal ●
Replace

Replace

Replace

Replace

Replace
Correct
Adjust

Remedy
Clean

8 - 14 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the engine and related electrical system

SEL007 - Oil consumption is excessive

[1/2]
Trouble code
Trouble Oil consumption is excessive
SEL007

Contents of trouble The oil consumption is excessive (or the exhaust smoke is blue)

Related information Refer to the following judgment table.

Problem that appears – Low output power.

on the machine – Risk of engine breakdown.

Possible causes See the following judgment table.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Test conditions according to the kind of inspection, when following the
judgment table information.
1. Inspect the
suspicious system,
unit, or component
The oil consumption is for malfunction and
excessive (or the 1 repair or replace as
Refer to the following judgment table and identify
exhaust smoke is blue) necessary.
the appropriate trouble cause(s).
2. After that recheck
the system for
proper function.
3. Go to final step 2.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 15

Symptoms of the engine and related electrical system Troubleshooting by Symptoms

SEL007 - Oil consumption is excessive

[2/2]

Judgment Table for SEL007 Causes

Turbocharger
Leakage at the oil pan or cylinder head

Worn valve (stem, guide), broken seal

Worn, broken rear seal, Seal surface
Dust sucked in by the intake system
Clogged breather or breather hose
Worn piston ring, cylinder liner

Leakage at the oil drain plug

Worn seal at turbine end

Leakage at the oil piping

Worn seal at blower end

Legend

Leakage at the oil filter

Broken piston ring
Ο : Possible causes (judging from Questions & Check Items)

◙ : Most probable causes (judging from Questions & Check Items)

◊ : Possible causes due to length of use (used for a long period)

● : Items to confirm the cause

Confirm the recent repair history

Degree of use of the machine Operated for a long period ◊ ◊ ◊ ◊
Questions

Oil consumption suddenly increased ◙

Engine oil must be added more frequently ◙
Engine oil becomes contaminated quickly Ο ◙ Ο
Exhaust smoke is blue under light load ◙ ◙
Excessive ◙ ◙ Ο Ο
Amount of blow-by gas
Check items

None ◙
Area around the engine is contaminated with oil ◙ ◙ ◙ ◙
When exhaust pipe is removed, the inside is dirty with oil ◙ Ο
When the turbocharger air supply pipe is removed, the inside is dirty ◙
Clamps of the intake system are loose ◙

Measured compression pressure it is too low ● ●

When the breather element is checked, it is clogged with dirty oil ●
Troubleshooting

External oil leakage at the engine ● ● ● ●

Excessive play of the turbocharger shaft ● ●
Inspect the rear seal directly ●
When the intake manifold is removed, dust is found inside ●
When the intake manifold is removed, the inside is dirty with oil ●
Replace
Replace

Replace
Replace
Correct
Correct
Correct
Correct

Correct
Correct
Correct

Remedy
Clean

8 - 16 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the engine and related electrical system

SEL008 - Oil becomes contaminated quickly

[1/2]
Trouble code
Trouble Oil becomes contaminated quickly
SEL008

Contents of trouble The engine oil becomes contaminated quickly

Related information Refer to the following judgment table.

Problem that appears – Low output power

on the machine – Increased engine wear
– Intake of exhaust gas due to internal wear
– Clogging of lubrication passages
Possible causes – Improper fuel used
– Improper engine oil used
– Operation under excessive load

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Test conditions according to the kind of inspection, when following the
judgment table information.
1. Inspect the
suspicious system,
unit, or component
The engine oil is for malfunction and
1 repair or replace as
contaminated quickly Refer to the following judgment table and identify
the appropriate trouble cause(s). necessary.
2. After that recheck
the system for
proper function.
3. Go to final step 2.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 17

Symptoms of the engine and related electrical system Troubleshooting by Symptoms

SEL008 - Oil becomes contaminated quickly

[2/2]

Judgment Table for SEL008 Causes

Defective seal at turbocharger turbine end

Clogged breather or breather hose

Clogged turbocharger drain pipe

Worn piston ring, cylinder liner

Worn valve, valve guide

Exhaust smoke is black

Legend

Defective safety valve

Ο : Possible causes (judging from Questions & Check Items)

Clogged oil filter

◙ : Most probable causes (judging from Questions & Check Items)

◊ : Possible causes due to length of use (used for a long period)

● : Items to confirm the cause

Confirm the recent repair history

Questions

Degree of use of the machine Operated for a long period ◊ ◊ ◊

Engine oil must be added more frequently ◙
Non-specified engine oil is used O
Blue under light load ◙
Colour of exhaust gas
Black ◙
Check items

Excessive ◙ O O O
Amount of blow-by gas

smoke is black
None ◙
When the filter is inspected, metal particles are found O ◙ O
When exhaust pipe is removed, the inside is dirty with oil ◙
Engine oil temperature rises quickly ◙

Measured compression pressure it is too low ● ●

Follow troubleshooting for: Exhaust

Troubleshooting

When the breather element is checked, hose is broken or it is clogged with dirty oil ●
When the oil filter is inspected, it is found to be clogged ●
Turbocharger drain tube is clogged ●
Excessive play at the turbocharger shaft ●
When the safety valve is inspected, the spring is found to be catching or broken ●
Replace

Replace
Replace

Replace
Replace

Remedy
Clean

Clean

8 - 18 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the engine and related electrical system

SEL009 - Fuel consumption is excessive

[1/2]
Trouble code
Trouble Fuel consumption is excessive
SEL009

Contents of trouble Fuel consumption highly exceeds the standard values

Judgment table of fuel consumption

Fuel Consumption [Liter/Hour]

Fuel density (kg/l) = 0.86
Mining Conditions Max.
Spec. Consumption
Engine easy average heavy
Shovel Engine Fuel Con-
Output
Type Model sumption load load load
SAE 1995 load factor
g/kWh factor factor factor
100%
70% 75% 83%
Related information
SDA12V159E
PC3000-6 940 209 160 171 190 228
(QSK38)

– Engine oil consumption about 0.20% of the fuel consumption

– Engine oil burning consumption by "Centinel System" about 0.25% of the fuel consumption
– Power and consumption rates are up to 3000 m altitude. Higher altitude may need a deration of
engine output and change the consumption figures.
– Basic hydraulic regulation adjustments are successfully done.
Problem that appears – Low output power
on the machine – Engine generates excessive heat
– Fuel leakage (or loss)
– Improper fuel injection condition
– Excessive fuel injection amount
Possible causes – Please also confirm:
– Bucket size (m³)
– Filling factor including density of the material
– Loading condition

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Test conditions according to the kind of inspection, when following the
judgment table information.
1. Inspect the
suspicious system,
Refer to the following judgment table and identify the unit, or component
Fuel consumption appropriate trouble cause(s). for malfunction and
highly exceeds the 1 Please also confirm: repair or replace as
standard values necessary.
– Bucket size (m³)
– Filling factor including density of the material 2. After that recheck
the system for
– Loading condition
proper function.
3. Go to final step 2.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 19

Symptoms of the engine and related electrical system Troubleshooting by Symptoms

SEL009 - Fuel consumption is excessive

[2/2]

Judgment Table for SEL009 Causes

External leakage at fuel piping, fuel filter

Fuel leakage inside the cylinder head
Defective injector holder, spray
Legend

Defective fuel pump

Ο : Possible causes (judging from Questions & Check Items)

◙ : Most probable causes (judging from Questions & Check Items)

◊ : Possible causes due to length of use (used for a long period)

● : Items to confirm the cause

Confirm the recent repair history

Degree of use of the machine Operated for a long period ◊
Questions

More than other machines of same model ◙

Condition of fuel con-
Gradually increased Ο
sumption
Suddenly increased Ο Ο
Black ◙ Ο
Exhaust smoke colour
White Ο
Seal on injection pump has come off ◙
Check items

There is irregular combustion ◙

When touching the exhaust manifolds immediately after engine start, the temperature of some cylin- ◙
ders is low.
External fuel leakage at the engine ◙
Engine oil level rises and smells of Diesel fuel Ο ◙
Engine low idle speed is high Ο
shooting
Trouble-

Remove cylinder head cover and inspect directly ●

Replace
Correct
Correct

Remedy
Adjust

8 - 20 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the engine and related electrical system

SEL010 - Oil is in engine coolant

[1/2]
Trouble code
Trouble Oil is in engine coolant
SEL010

Contents of trouble Oil is in the engine coolant, the coolant spurts out, or the coolant level goes down.

Precondition, first check:

Related information
The engine coolant pump is working properly and it has no internal leak.
– Low output power
Problem that appears
– Engine generates excessive heat
on the machine
– Excessive smoke coming out of the mufflers

Possible causes See the following judgment table.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Test conditions according to the kind of inspection, when following the
judgment table information.
1. Inspect the
suspicious system,
unit, or component
Oil is in the engine
coolant, or the coolant for malfunction and
1 repair or replace as
spurts out, or the cool- Refer to the following judgment table and identify
ant level goes down the appropriate trouble cause(s). necessary.
2. After that recheck
the system for
proper function.
3. Go to final step 2.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 21

Symptoms of the engine and related electrical system Troubleshooting by Symptoms

SEL010 - Oil is in engine coolant

[2/2]

Judgment Table for SEL010 Causes

Broken liner O-ring, holes caused by pitting

Insufficient protrusion of cylinder liner
Broken cylinder head or head gasket

Internal cracks in the cylinder block

Legend

Ο : Possible causes (judging from Questions & Check Items)

◙ : Most probable causes (judging from Questions & Check Items)

◊ : Possible causes due to length of use (used for a long period)

● : Items to confirm the cause

Confirm the recent repair history

Questions

Degree of use of the machine Operated for a long period ◊

Suddenly increased Ο
Oil level
Gradually increased Ο Ο

Hard water is being used as engine coolant Ο

Check items

Engine oil level has risen, oil is cloudy white Ο Ο

Excessive air bubbles inside radiator, coolant sputters out ◙ ◙

Pressure-tightness test of cylinder head shows, there is a leakage ●

Troubleshooting

Remove cylinder head and inspect directly ●

Remove oil pan and inspect directly ● ●

Replace
Replace
Replace
Replace
Remedy

8 - 22 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the engine and related electrical system

SEL011 - Oil level rises

[1/2]
Trouble code
Trouble Oil level rises
SEL011
– The engine oil level rises (coolant or fuel in the oil)
Contents of trouble – The engine oil level rises due to a malfunction of the "Reserve Pump" in the Centinel system
(optional)
If equipped verify the proper function of the "Oil Management Centinel System" and the "Reserve
Related information Pump System" first (refer to the OPERATION & MAINTENANCE MANUAL and to the SHOP MAN-
UAL).
Problem that appears
Oil spills out of the engine breather hoses.
on the machine
– Coolant gets into the engine oil
Possible causes – Fuel gets into the engine oil (oil becomes diluted and smells of Diesel fuel)
– Oil from any other component gets into the engine oil.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Test conditions according to the kind of inspection, when following the
judgment table information.
1. Inspect the
suspicious system,
unit, or component
The engine oil level for malfunction and
1 repair or replace as
rises Refer to the following judgment table and identify
the appropriate trouble cause(s). necessary.
2. After that recheck
the system for
proper function.
3. Go to final step 2.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 23

Symptoms of the engine and related electrical system Troubleshooting by Symptoms

SEL011 - Oil level rises

[2/2]

Judgment Table for SEL011 Causes

Broken cylinder head or head gasket (precombustion

Clogged coolant pump breather hole, defective seal

Defective seal inside the fuel pump (flange type)

Fuel leakage inside the cylinder head cover

Damaged liner O-ring, holes due to pitting

Worn damaged rear seal surface

Cracks inside the cylinder block

Defective injector holder sleeve
Legend

Ο : Possible causes (judging from Questions & Check Items)

◙ : Most probable causes (judging from Questions & Check Items)

◊ : Possible causes due to length of use (used for a long period)

● : Items to confirm the cause

Confirm the recent repair history

Questions

Degree of use of the machine Operated for a long period ◊ ◊ ◊ ◊

When the engine is first started, drops of water come from the muffler ◙
Exhaust smoke is white ◙ Ο Ο
There is oil in the engine coolant Ο Ο Ο Ο
Leave the radiator cap open. When the engine is running without load, an abnormal
Check items

◙ Ο
number of bubbles appears, or coolant sputters out
Coolant pump breather hole is clogged with mud ◙
Coolant pump breather hole is clean, coolant comes out ◙
Engine oil smells of Diesel fuel ◙ ◙
Fuel must be filled up more frequently ◙ ◙

Pressure-tightness test of cylinder head shows, there is a leakage ●

Measured compression pressure it is too low ●
Troubleshooting

Remove coolant pump and inspect directly ●

Remove rear seal and inspect directly ●
Remove cylinder head cover and inspect directly ●
Remove injection pump and inspect directly ●
Remove oil pan and inspect directly ● ●
Replace
Replace
Replace

Replace
Replace
Replace
Correct
Correct

Remedy

8 - 24 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the engine and related electrical system

SEL012 - Coolant temperature becomes too high (overheating)

[1/2]
Trouble code
Trouble Coolant temperature becomes too high (overheating)
SEL012

Contents of trouble The engine coolant temperature becomes too high (overheating)

When the coolant temperature on the K+ monitor is in normal range, start troubleshooting with
Related information
an infrared temperature gun and verify the adequate coolant temperature.
Problem that appears
Engine overheating - risk of a total engine breakdown and damage of internal components.
on the machine
– Insufficient cooling air flow (radiator deformation, damaged fan)
– Clogged coolant radiator (inside or outside)
Possible causes
– Defective coolant circulation system (thermostat)
– Defective fan drive system

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Test conditions according to the kind of inspection, when following the
judgment table information.
1. Inspect the
suspicious system,
unit, or component
The engine coolant for malfunction and
temperature becomes 1 repair or replace as
Refer to the following judgment table and identify
too high (overheating) necessary.
the appropriate trouble cause(s).
2. After that recheck
the system for
proper function.
3. Go to final step 2.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 25

Symptoms of the engine and related electrical system Troubleshooting by Symptoms

SEL012 - Coolant temperature becomes too high (overheating)

[2/2]

Judgment Table for SEL012 Causes

Damaged cylinder liner O-ring, holes due to pitting

External leakage at the coolant piping
Defective thermostat (does not open)
Defective coolant temperature gauge

Broken cylinder head or head gasket

Defective radiator pressure valve
Clogged crushed radiator fins
Legend

Clogged radiator core

Broken coolant pump
Ο : Possible causes (judging from Questions & Check Items)

Low or no fan RPM

◙ : Most probable causes (judging from Questions & Check Items)

◊ : Possible causes due to length of use (used for a long period)

● : Items to confirm the cause

Confirm the recent repair history

Degree of use of the machine Operated for a long period ◊ ◊ ◊ ◊
Questions

Suddenly overheated ◙ Ο
Condition of overheating
Always tends to overheat ◙ ◙ Ο Ο
Rises quickly ◙
Coolant temperature gauge
Does not go down ◙
Fan drive system malfunction or too low fan drive belt tension ◙
Engine coolant flows out of the overflow hose ◙
Check items

Excessive air bubbles inside radiator, coolant spurts back ◙

Engine oil level has risen, oil is cloudy white ◙
Radiator shroud inside of underguard is clogged with dirt or mud ◙
Radiator clogged by dirt ◙
Coolant is leaking due to cracks in hose(s) or loose clamps ◙

When coolant filler port is inspected, the core is found to be clogged ●

When thermostat function is tested, it does not open, even at the cracking ●
temperature
Troubleshooting

When coolant temperature is measured, it is normal ●

When fan drive system is checked drive belt slippage is present ●
When measurement is made with the radiator cap tester, set pressure is found ●
to be low (pressure is not kept)
Measured compression pressure it is too low ●
Remove oil pan and inspect directly ●
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Correct or

Remedy
Correct
Correct

replace

8 - 26 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

8.2 SYMPTOMS OF THE HYDRAULIC SYSTEM

SHY001 - All the work equipment shows lack of power or slow movement
(especially the "boom up" function)
[1/2]
Trouble code All the work equipment shows lack of power or slow movement
Trouble
SHY001 (especially the "boom up" function)
– The work equipment shows lack of power or its movement (particularly the "boom up" function)
Contents of trouble is too slow.
– A corresponding trouble code is NOT displayed.
Before starting any troubleshooting work in detail:
– Verify if relevant trouble codes are displayed on the K+ monitor or the Multimonitor. - and if so,
repair or replace as necessary.
– Recheck yourself all oil levels and functions and inspect for any leakage.
– Ask the operator for conspicuous failure symptoms and for the history.
– Bring the shovel to the operating temperature (hydr. oil cooler fans running).
– Before starting any troubleshooting or adjustment work, check the Cycle Time during
truck loading (Cycle Time 24 ~ 29 seconds).

Related information – Check for noise or abnormal reactions.

– Carry out an engine Power Check to exclude lack of engine power.
If engine power is too low carry out troubleshooting and repair.
– Using a stop watch, test the cycle times of the work equipment / slew system / travel system
(beginning at movement start, measure the time between start stroke and end stroke of the
cylinder).
– Always use the PM-CLINIC sheet for comparing the taken measurements with the default val-
ues.
– When carrying out tests use the recommended adjustment values only.
– Use an infrared temperature gun and verify internal leaks in any part of the hydraulic system.
Problem that appears
The work performance of the shovel is poor and/or too slow.
on the machine
– Wrong adjustment of the pump regulation system
– Wrong hydraulic adjustments (SRV, MRV) or defective valves
Possible causes
– Any hydraulic cylinder defective (internal leak)
– Low engine power output

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Follow the respective requirements of the SHOP MANUAL.
Yes Go to next step.
Readjust the pump regulation system
Adjust the pump
according to the procedures given in the
Wrong adjustment of regulation system
SHOP MANUAL, part 10 STRUCTURE & PM-Clinic
the pump regulation 1 according to PM
FUNCTION, chapter 9.
system CLINIC and as SHOP
Check the basic settings on the Multimonitor. No
described in the MANUAL
Are the settings correct and does the pump SHOP MANUAL, part
regulation system work properly? 10 STRUCTURE &
FUNCTION.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 27

Symptoms of the Hydraulic System Troubleshooting by Symptoms

SHY001 - All the work equipment shows lack of power or slow movement
(especially the "boom up" function)
[2/2]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Hydraulic oil temperature at T3.
Adjust valves as
Wrong hydraulic necessary according
Check the adjustments of the SRV (Secondary PM-Clinic
adjustments to PM CLINIC and
2 Relief Valves) and MRV (Main Relief Valves) as described in the SHOP
(SRV, MRV) Yes
according to SHOP MANUAL, PM CLINIC, SHOP MANUAL. MANUAL
or defective valves
and Hydraulic Schematics.
After adjustment Hydraulic
Is any valve adjustment out of range? recheck the function. Schematic
No Go to next step.
 Engine running at high idle.
Hydraulic oil temperature at T3.
1. If any cylinder leak-
age is found,
replace the defec-
tive hydraulic
After correct adjustment of the pump
cylinder.
regulation system (pump controller basic value Refer to
setting), the work attachment is still too slow, 2. Check the hydr. oil the general
Any hydraulic cylinder especially the "boom up" function. for contamination -
3 working
defective (internal leak) Yes take an oil sample
Using a temperature gun, check the boom procedure
cylinder temperature (refer to section 2.10 on 3. Visually check the in this
page 2-19 in this manual) in order to locate return oil filters for manual.
any internal leakage. contamination.
Could you determine any abnormality? 4. Visually check the
oil cooler screen for
contamination.
No Go to next step.
 Engine running at high idle.
Hydraulic oil temperature at T3.
1. Perform the engine Power Check accord-
ing to the PM-CLINIC sheet.
Even all adjustments are correctly done
and even they correspond to the default – Filter clogging found:
values, the engine stall speed drops below Clean/replace pre- & fuel fil-
the specified speed of the PM-CLINIC ter and check the stall
Power Check. speed according to PM CLINIC
Low engine power
4 Standard
output 2. Check the engine fuel supply system for PM CLINIC.
sufficient fuel delivery capacity. blow-by
– Blow-by pressure out of pressure =
3. Check the blow-by pressure on the range: 14.9 mbar
K+ monitor: Call the Cummins service
REAL TIME MONITOR for a complete engine
 01 Engine 1 check-up.
 Screen 2/5
Is any water separator or fuel filter clogged? Is
the blow-by pressure as specified?
Bring the machine back into the original condition.
Final check 5
Start the machine and verify that the repair was successful.

8 - 28 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

SHY002 - Engine speed sharply drops or engine stalls too much

[1/2]
Trouble code
Trouble Engine speed sharply drops or engine stalls too much
SHY002
– The engine speed drops sharply during movement or the engine stalls too much during com-
Contents of trouble pound movements of the attachment.
– A corresponding trouble code is not displayed.
Before starting any troubleshooting work in detail:
– Ask the operator for conspicuous failure symptoms and for the history.
– Bring the shovel to the operating temperature (hydr. oil cooler fans running).
– Recheck yourself all oil levels and functions and inspect for any leakage.
– Before starting any adjustment work, operate the shovel yourself and test all affected functions.
Related information Check for noise or abnormal reactions.
– Before starting any troubleshooting or adjustment work, check the Cycle Time of the work
equipment during tuck loading (Cycle Time 24 ~ 29 seconds).
– Always use the PM-CLINIC sheet for comparing the taken measurements with the default val-
ues.
– When carrying out tests use the recommended adjustment values only.
Problem that appears
The work performance of the shovel is poor and/or too slow.
on the machine
Possible causes The engine stalls too much due to insufficient fuel supply or engine damage.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Hydraulic oil temperature at T3.
Switch Qmax service
Qmax service switch switch 11S103 into
11S103 is switched into 1 Check the setting of the Qmax service switch. OFF position.
Yes PM CLINIC
ON position
Is the switch in ON position? Bring the shovel back
to operation.
No Go to next step.
 Engine running at high idle.
Hydraulic oil temperature at T3.
1. Carry out an engine Power Check accord- Clean / replace pre- /
ing to PM CLINIC. fuel filter / air filter if
Even all adjustments are correctly done clogged.
Yes PM CLINIC
and even they correspond to the default Then recheck the
The engine stalls
values, the engine stall speed drops below stall speed according
too much due to
2 the stall speed limits. to PM CLINIC data.
insufficient fuel supply
or engine damage 2. Check all air filters for cleanness and check
the cyclone dust streamer for proper func-
tion. Call the Cummins
No service for a complete
3. Check the engine fuel supply system for engine check-up.
sufficient fuel delivery capacity.
Is any pre- / fuel filter / air filter clogged?

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 29

Symptoms of the Hydraulic System Troubleshooting by Symptoms

SHY002 - Engine speed sharply drops or engine stalls too much

[2/2]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
1. Check the bucket
size and weight.
2. Check the density
(specific weight) of
Yes the material and
compare to the
bucket size and the
Wrong adjustment of mounted wear
Check the basic settings on the Multimonitor. PM-Clinic
the pump regulation 3
Are the settings correct and does the pump package on the SHOP
system.
regulation system work properly? bucket (overload). MANUAL
Adjust the pump
regulation system
according to the
procedures given in
No
the SHOP MANUAL,
part 10 STRUCTURE
& FUNCTION,
chapter 9.
Bring the machine back into the original condition.
Final check 4
Start the machine and verify that the repair was successful.

8 - 30 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

SHY003 - No work equipment, travel or slew movement

[1/1]
Trouble code
Trouble No work equipment, travel or slew movement
SHY003
– Work equipment, travel or slew movement is impossible.
Contents of trouble
– A corresponding trouble code is not displayed.
– Even no trouble code is displayed, any movement of the work equipment is impossible.
Related information – Ladder and service arm are in their correct upper position.
– The engine is running at high idle and all safety functions are unlocked.
Problem that appears
No movement is possible.
on the machine
– Lock lever not in down position - check 20S105.
– Enable switch for the service arm switched ON.
Possible causes
– Ladder / service arm up position not recognized
– Fault in pilot control locking circuit - solenoid valve 10Q515 not energized

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Repair or replace as
necessary:
Lock lever not in If switch
Check the function of lock lever 20S105. – lock lever
down position - 1 Yes closed:
check 20S105 Can you identify any problem in the switch – switch 20S105 Uoutput =
system of 20S105? 24V
– wiring
No Go to next step.
 Engine running at high idle.
Check function of the enable switch according Yes Go to next step. OMM
Enable switch for
to OMM, SHOP MANUAL part 10 STRUC- SHOP
the service arm 2
TURE & FUNCTION, chapter 13, or Wiring Repair or replace MANUAL
switched ON No
Diagram. as necessary. Wiring
Is the switch function OK? Diagram
 Engine running at high idle.
Check ladder and service arm for proper func- Bring the shovel back
Yes
tion and verify that the contact switches to operation.
3
55B023 (service arm) and 70B122 (ladder)
are adjusted properly. No Go to next step.
Ladder / service arm Are the movements now possible?
up position not recog-  Engine running at high idle.
nized
Check wiring in the circuits of contact switches Yes Go to next step.
55B023 (service arm) & 70B122 (ladder)
4 including the relays Wiring
11K145 (service arm) & 11K134 (ladder) Repair or replace Diagram
No
according to the Wiring Diagram. as necessary.
Is the wiring and electrical function OK?
Fault in pilot control  Engine running at high idle.
locking circuit - sole-
5 Check wiring and all relevant relays in the pilot control Repair or replace as Wiring
noid valve 10Q515 not
energized locking circuit for proper function. necessary: Diagram

Bring the machine back into the original condition.

Final check 6
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 31

Symptoms of the Hydraulic System Troubleshooting by Symptoms

SHY004 - Work equipment has too much hydraulic drift

[1/1]
Trouble code
Trouble Work equipment has too much hydraulic drift
SHY004

Contents of trouble In the neutral lever position the work equipment has too much visible drift.

First verify and watch the drift behavior.

a) The attachment drifts but it stops before the bucket touches the ground.
Related information Carry out a Cylinder bypass test.
b) The attachment drifts until the bucket touches the ground.
An SRV, check valve, or load holding valve is defective.
Problem that appears – Risk to loose control of the shovel operation.
on the machine – Damage or breakdown is possible due to contacting dump trucks.
– Hydraulic cylinder damaged (internal leak).
Possible causes
– Valve malfunction (SRV - check valve - load holding valve)

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Hydraulic oil temperature at T3.
1. Replace any
defective cylinder
The function of the main blocks is considered by a new one.
to be ok. 2. Bleed the new
Hydraulic cylinder
Carry out a Cylinder bypass test (refer to hydraulic
damaged 1
section 2.10 on page 2-19 in this manual) and Yes cylinder(s).
(internal leak)
check the suspicious cylinders for defective 3. Perform the bypass
internal seals. test again in order
Can you find significant temperature to make sure that
differences during the cylinder bypass test? no other cylinder is
affected.
No Go to next step.
 Engine running at high idle.
Hydraulic oil temperature at T3.
According to the procedures in the SHOP MANUAL part 10 STRUCTURE &
Valve malfunction
FUNCTION, chapter 10, section "CHECKS AND ADJUSTMENTS OF THE
(SRV - check valve - 2
SECONDARY RELIEF VALVES (SRV)": SHOP
load holding valve)
Check the SRV - check valves or load holding valves in the affected hydraulic MANUAL
circuit.
If any trouble is found, repair or replace as necessary.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the repair was successful.

8 - 32 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

SHY005 - Work equipment has big time lag

[1/1]
Trouble code
Trouble Work equipment has big time lag
SHY005
– The work equipment has a big time lag between lever actuation and movement of the attach-
Contents of trouble ment.
– The PM CLINIC procedures are done and all settings are adjusted to the nominal values.
The reaction time of the attachment after lever movement is related to the hydraulic oil viscosity in
Related information
the pilot control circuit.
Problem that appears
Due to a big time lag the machine can not be operated according to proper quality standards.
on the machine
– Air in the pilot control system
Possible causes
– Hydraulic oil is too cold (too high hydraulic oil viscosity)

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Bleed the pilot control system at the Minimess test ports in the control caps of
Air in the pilot control
1 the main control valve block spools (e.g. M47.1, M54.1...).
system
REMARKS: Even when most air is properly removed from the pilot control cir-
cuit by bleeding, some air may still remain in the system for a while.
 Engine running at high idle.
Hydraulic oil temperature at T3.
1. Bring the hydraulic oil on operating temperature before starting to work.
2. Verify the used oil viscosity and correct temperature setting of the converter
Hydraulic oil is too cold modules for the hydr. oil cooler fan control according to Table 8-1:
(too high hydraulic oil 2 Table 8-1
– 11K026 - low fan speed => medium fan speed (T3)
viscosity)
– 11K171 - medium fan speed => maximum fan speed (>T3) SHOP
MANUAL
3. Check the hydraulic adjustment for the fan speed (refer to SHOP MANUAL
part 10 STRUCTURE & FUNCTION, chapter 6, section "CHECKS
AND ADJUSTMENTS OF THE COOLER FAN DRIVE SPEEDS").
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the repair was successful.

Hydraulic oil temperature table - 11K026 and 11K171 adjustment

Shell Tellus Shell Tellus

Arctic Arctic
ISO oil viscosity grade VG 22 VG 32 VG 46 VG 68 VG 100
S4VX32 S4VX32
(new) (stabilized)
11K026 adjust temperature limit value
to switching point (T3) 32°C 41°C 50°C 58°C 67°C 46°C 39°C
medium fan speed
11K171 adjust temperature limit value
to switching point 48°C 59°C 69°C 75°C 75°C 75°C 71°C
maximum fan speed

Table 8-1

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 33

Symptoms of the Hydraulic System Troubleshooting by Symptoms

SHY006 - Machine deviates during travel movement

[1/1]
Trouble code
Trouble Machine deviates during travel movement
SHY006
– During machine traveling the shovel deviates to one side.
Contents of trouble – The machine is traveling only (no other movement is done).
– Precondition: flat ground and same grip on both sides.
– The PM CLINIC procedures were performed successfully.
Related information – The SRV and MRV adjustments meet the nominal values of the PM CLINIC data.
– The left and right track wear measurements are on the same level.
– During machine traveling the shovel deviates to one side.
Problem that appears
on the machine – The operator has to stop the shovel after a couple of meters in order to correct traveling
to straight direction.
– Internal leak in the rotary joint
Possible causes
– Defective hydraulic travel motor

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Hydraulic oil temperature at T3.
1. Disconnect the parking brake solenoid Tempera-
valve 57Q516 in order to close the travel ture during
Replace the rotary
brake. Yes the test not
joint.
higher than
2. Actuate the travel pedals and read the
T3.
pressure at the gauges.
Internal leak in 3. Using an infrared temperature gun, check
1
the rotary joint for temperature increase at the rotary joint
input (A & B section).

If there is an temperature increase while No Go to next step.

the pressure increases, the seals at the
rotary joint are leaking.
Does the temperature increase during this
test?
 Engine running at high idle.
Hydraulic oil temperature at T3.
1. Lift up the right / left track and rotate the
track without load.

Defective hydraulic 2. Using an infrared temperature gun, check SRV

2 the temperature at the leak oil port of the
travel motor If the temperature increases 310 bar
travel motor. quickly replace the travel motor. MRV
315 bar
If the temperature quickly increases over
the normal hydraulic oil temperature (T3),
the travel motor delivers too much leak oil.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the repair was successful.

8 - 34 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

SHY007 - Hydraulic system has lack of power

[1/1]
Trouble code
Trouble Hydraulic system has lack of power
SHY007
– The hydraulic system has a lack of power (75% of rated output).
– The PM CLINIC procedures were performed successfully.
Contents of trouble
– The engine power check is OK.
– Corresponding trouble messages are not displayed
– Verify that the main pumps are not mechanically stuck.
Related information – During pump operation, check the function of the angle indicator at the main pumps.
– Check if the pump controller CR710 is running in the emergency mode.
Problem that appears
The movement (speed) of the attachment and during traveling is too slow.
on the machine
– Defective or worn out main pump.
Possible causes
– Defective or wrong adjusted pump controller CR710

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Hydraulic oil temperature at T3.
1. Verify that the main pumps are not mechanically
stuck.
2. During pump operation, check the function of the
angle indicator at the main pumps.

It is possible to check
Defective or worn out the maximum main SHOP
1
main pump pump flow volume MANUAL
via travel/slew or part 10
via single movement chapter 9
functions.

 Engine running at high idle.

Hydraulic oil temperature at T3.
Defective or wrong Check the basic setting of the pump controller CR710 If a re-calibration of
on the Multimonitor. CR710 is not possible SHOP
adjusted pump 2
perform a RESET of MANUAL
controller CR710 Info CR710 as described in part 10
If any individual movement (single movement) is section 9 Main pumps chapter 9
selected, the main pumps work with maximum flow. and pump regulation.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 35

Symptoms of the Hydraulic System Troubleshooting by Symptoms

SHY008 - Machine does not slew (or slew speed is very low)
[1/2]
Trouble code
Trouble Machine does not slew (or slew speed is very low)
SHY008
– The machine does not slew when the lever is moved (or slew speed is very low).
Contents of trouble – The slew parking brake is released
– All other operating functions are going well.
Related information Slew movement (left or right) is not possible or very slow.
Problem that appears
Slew movement (left or right) not possible.
on the machine
– No pressure increase at the 2-stage valve.
Possible causes – 57Q505 is disconnected / de-energized - slew parking brake is closed.
– Slew motor defective (internal leakage)

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Hydraulic oil temperature at T3.
Slew parking brake switch 22S029 ON.
Attachment in ground position (to prevent slew movement).

Follow the instructions for testing and adjusting Reconnect the pilot
the slew circuit as described in the SHOP pressure hoses to the
MANUAL, part 10 STRUCTURE & FUNC- Yes 2-stage valves and put
TION, chapter 10, section "CHECKS AND the shovel back to
No pressure increase ADJUSTMENTS FOR THE SLEW CIRCUIT". operation.
1
at the 2-stage valve PM CLINIC
For better adjustment of the 2-stage valves
disconnect and plug the pilot lines of the SHOP
2-stage valve. MANUAL
Replace 2-stage valve
1. Adjustment of the 330 bar stage and perform the basic
2. Adjustment of the 150 bar stage adjustments.
No
Could you successfully adjust the 2-stage Check the slew brake
valves? block main piston for
proper function.

 Engine running at high idle.

Hydraulic oil temperature at T3.
Slew parking brake switch 22S029 ON.
Attachment in ground position.
57Q505 is discon- Put the shovel back to
nected / de-energized - Yes
2 operation.
slew parking brake Check 57Q505 for proper function - connect Check the slew gear/ Standard
is closed the wiring. parking brake for Value
Is the circuit of 57Q505 OK? No mechanical damage Table
and repair or replace
as necessary
Bring the machine back into the original condition.
Final check 4
Start the machine and verify that the repair was successful.

8 - 36 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

Slew brake valve block (SHY008)

[2/2]

Fig. 8-3 Slew brake valve block (SHY008)

(1) Pilot pressure piston (5) Jet bore

(2) Intermediate piston (6) Spring of main piston

(3) Spring (7) Jet bore of main piston plug

(4) Valve poppet (8) Main piston

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 37

Symptoms of the Hydraulic System Troubleshooting by Symptoms

SHY009 - Slew acceleration is poor (or slew speed is very low)

[1/2]
Trouble code
Trouble Slew acceleration is poor
SHY009
– The machine slew acceleration is poor (too long acceleration time or too short acceleration
Contents of trouble time).
– All other operating functions are going well.
– For the basic adjustment procedures refer to the SHOP MANUAL, part 10 STRUCTURE &
Related information FUNCTION, chapter 10, section "CHECKS AND ADJUSTMENTS FOR THE SLEW CIRCUIT".
– For the target adjustment values refer to PM-CLINIC sheets.
Problem that appears – The slew acceleration is poor and fast slew & load movement is not possible.
on the machine – Basic adjustment of the double stage valve is not possible (pressure can’t be reached).
– The 2-stage valve is defective or its adjustment is wrong.
– The slew brake valve is defective (internal leak in the anti-cavitation valves).
Possible causes
– The O-ring at the spacer plate is leaking (oil flows from A to B side), no external leak visible.
– Slew motor defective (internal leakage).

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Hydraulic oil temperature at T3.
Slew parking brake switch 22S029 ON.
Attachment in ground position.
Yes Go to final step.
Replace 2-stage valve
and perform the basic
The 2-stage valve Perform the basic adjustments of the slew
adjustments.
is defective or its 1 circuit according to the SHOP MANUAL, part
adjustment is wrong 10 STRUCTURE & FUNCTION, chapter 10, If - after replacement of PM CLINIC
section "CHECKS AND ADJUSTMENTS FOR the 2-stage valve - the
SHOP
THE SLEW CIRCUIT" and PM CLINIC sheets. No slew acceleration is
MANUAL
still poor, replace the
Could you adjust the correct pressure and
complete slew brake
acceleration?
valve block on top of
the slew motors.
Refer to next step.
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
Perform the following steps according to the
Safety Notes in the SHOP MANUAL:
1. Disconnect the high pressure hoses from
the slew brake block. Bring the shovel back
Yes
to operation.
REMARKS: Before mounting the new block in
the next work step, also see step
The slew brake valve is 3 in this troubleshooting chart.
defective (internal leak 2. Replace the complete block with new PM CLINIC
2
in the anti-cavitation 2-stage valve and O-rings. SHOP
valves) MANUAL
3. Then perform the basic adjustments
according to the SHOP MANUAL, part 10
STRUCTURE & FUNCTION, chapter 10,
section "CHECKS AND ADJUSTMENTS No Go to next step
FOR THE SLEW CIRCUIT" and
PM CLINIC sheets.
Could you now adjust the correct slew
acceleration (slew cycle time)?

8 - 38 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

SHY009 - Slew acceleration is poor (or slew speed is very low)

[2/2]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
Yes Go to next step.
Check the spacer plate
for indications of
corrosion or pitting.
If necessary replace
the spacer plate.
Check the O-rings on the spacer plate PM CLINIC
Replace the O-rings
(lower & upper side) of the slew brake block. SHOP
No and mount the slew
Are these O-rings ok? brake valve. MANUAL
Then perform the
basic adjustments
for the slew system
according to
The O-ring at the SHOP MANUAL and
spacer plate is leaking PM CLINIC sheets.
(oil flows from A to B 3
side), no external leak
visible

(1) Slew brake valve

(2) O-ring

(3) Spacer plate

(4) Slew motor

 Engine running at high idle.

Hydraulic oil temperature at T3.
Replace the defective
Yes
slew motor.
1. Go to troubleshoot-
ing chart SME006
Using an infrared temperature gun, check the in the following
temperature at the leak oil port of the travel section "Symp-
motor.
Slew motor defective toms of the
4 If the temperature quickly increases over Mechanical Sys-
(internal leakage)
the normal hydraulic oil temperature (T3), tem".
the slew motor delivers too much leak oil. No
2. Check the slew
Is the temperature at the leak oil port higher motor drive shaft
than the normal hydraulic oil temperature (T3)
input at the slew
(leak oil flow too high)?
gearbox.
3. If any malfunction
is found, repair as
necessary.
Bring the machine back into the original condition.
Final check 5
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 39

Symptoms of the Hydraulic System Troubleshooting by Symptoms

SHY010 - Excessive overrun when stopping slew movement

[1/2]
Trouble code
Trouble Excessive overrun when stopping slew movement
SHY010

Contents of trouble There is an excessive overrun when the slew movement of the superstructure is stopped.

– If during slew movement the control lever is moved into neutral position, the superstructure slew
movement should be stopped within an angle of max. 90°.
Related information
– If the superstructure does not stop within this angle, the superstructure overrun can be consid-
ered as to be excessive.
Problem that appears
The slew deceleration is poor (too long) and a correct positioning of the attachment is not possible.
on the machine
– The 2-stage valve is defective or its adjustment is wrong (setting too low).
– The slew brake valve is defective (internal leak in the anti-cavitation valves).
Possible causes
– The O-ring at the spacer plate is leaking (oil flows from A to B side).
– Slew motor defective (internal leakage).

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle & slew lock switch ON.
Hydraulic oil temperature at T3.
Yes Go to next step.
Replace both 2-stage
valves and perform the
The 2-stage valve basic adjustments.
Perform the basic adjustments of the slew
is defective or its If - after replacement of PM CLINIC
1 circuit according to SHOP MANUAL and
adjustment is wrong the 2-stage valves -
PM CLINIC sheets. SHOP
(setting too low) No the slew deceleration
Could you adjust the correct slew MANUAL
is still poor, replace the
deceleration?
complete slew brake
valve blocks on top of
the slew motors.
Go to next step.
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
1. Perform the following steps according to
the Safety Notes in the SHOP MANUAL.
2. Disconnect the high pressure hoses from
the slew brake block. Bring the shovel back
Yes
to operation.
3. Replace the complete block with new
The slew brake valve is 2-stage valves and O-rings.
defective (internal leak 4. Then perform the basic adjustments PM CLINIC
2
in the anti-cavitation according to SHOP MANUAL SHOP
valves) MANUAL
and PM CLINIC.
Could you now adjust the correct slew
deceleration?
No Go to next step

8 - 40 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

SHY010 - Excessive overrun when stopping slew movement

[2/2]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
Yes Go to next step.
Check the spacer plate
for indications of
corrosion or pitting.
If necessary replace
the spacer plate.
Check the O-rings on the spacer plate PM CLINIC
Replace the O-rings
(lower & upper side) of the slew brake block. SHOP
No and mount the slew
Are these O-rings ok? brake valve. MANUAL
Then perform the
basic adjustments
for the slew system
according to
The O-ring at the SHOP MANUAL and
spacer plate is leaking PM CLINIC sheets.
(oil flows from A to B 3
side), no external leak
visible

(1) Slew brake valve

(2) O-ring

(3) Spacer plate

(4) Slew motor

 Engine running at high idle.

Hydraulic oil temperature at T3.
Replace the defective
Yes
slew motor.
1. Go to troubleshoot-
ing chart SME006
Using an infrared temperature gun, check the in the following
temperature at the leak oil port of the travel section "Symp-
motor.
Slew motor defective toms of the
4 If the temperature quickly increases over Mechanical Sys-
(internal leakage)
the normal hydraulic oil temperature (T3), tem".
the slew motor delivers too much leak oil. No
2. Check the slew
Is the temperature at the leak oil port higher motor drive shaft
than the normal hydraulic oil temperature (T3)
input at the slew
(leak oil flow too high)?
gearbox.
3. If any malfunction
is found, repair as
necessary.
Bring the machine back into the original condition.
Final check 5
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 41

Symptoms of the Hydraulic System Troubleshooting by Symptoms

SHY011 - Floating system without function (FSA only)

[1/2]
Trouble code
Trouble Floating system without function (FSA only)
SHY011
The floating system for the functions Stick In and/or Boom Down is inoperative and/or
Contents of trouble
its deactivation is impossible.
– The floating system is divided in the two functions "Stick In" or "Boom Down".
– The floating valve 132.3 is pilot-controlled by solenoid valve 61K635 (boom).
Related information
– The floating valves 132.1 and 132.2 are pilot-controlled by solenoid valve 61K632 (stick).
– The floating function is active with energized solenoid valve 61K632 / 61K635.
Problem that appears
No floating function for "Stick In" and/or "Boom Down".
on the machine
– Solenoid valve(s) defective or fault in the relevant electrical circuit (disconnection or defective
Possible causes contact in any connector)
– The spools in the floating valves are mechanically stuck.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON.
1. Find out in which circuit the problem occurs
Solenoid valve(s) ("Stick In" or "Boom Down"). Replace or repair
defective or fault in the Yes
2. Check the electrical signal at the relevant as necessary.
relevant electrical cir- solenoid valve.
cuit 1
3. Check pilot pressure at the relevant test Px2 35 bar
(disconnection or port at the floating valve(s).
defective contact in any
connector) Could you identify any problems? No Go to next step.

 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
The attachment must be in down and full reach position.
1. Find out in which circuit the problem occurs
("Stick In" or "Boom Down"). Replace or repair
Yes
REMARKS: It is unlikely that both floating as necessary.
valves of the stick floating func-
The spools in the float- tion are defective.
ing valves are mechan- 2 So the floating function of the
ically stuck stick is not completely inoperative
but is limited to 50% floating Perform the basic
speed. adjustment.
No Refer to PM CLINIC
2. Disassemble the defective floating valve
sheets and to
and check for proper function of the inner SHOP MANUAL.
spool.
Is any floating valve spool defective?
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the repair was successful.

8 - 42 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

Floating system - overview (SHY011)

[2/2]

Fig. 8-1 Floating system - overview (SHY011)

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 43

Symptoms of the Hydraulic System Troubleshooting by Symptoms

SHY012 - Abnormal noise coming from SRV or MRV

[1/1]
Trouble code
Trouble Abnormal noise coming from SRV or MRV
SHY012

Contents of trouble Abnormal noise is coming from the SRV or MRV sections.

– Due to a possible defect of the mechanical inner parts (spring or piston) in the SRV or
Related information MRV sections, an abnormal noise is possible when the valve is activated.
– Also a wrong adjustment of SRV or MRV may cause abnormal noise in the system.
– Abnormal noise in the hydraulic system occurs during operation.
Problem that appears
– Any malfunction of the hydraulic circuit is possible.
on the machine
– Contamination of the hydraulic oil may damage the valves.
– Wrong adjustment or malfunction of SRV or MRV.
Possible causes
– Malfunction of any throttle valve or suction valve at the main blocks or at the manifold.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Hydraulic oil temperature at T3.
1. Perform a sectional troubleshooting (previ- PM CLINIC
ous test with an infrared temp. gun) and Adjust or replace as
Yes SHOP
Wrong adjustment necessary.
check the adjustments of SRV and MRV. MANUAL
or malfunction of 1
SRV or MRV 2. Follow the instructions and specifications in
the SHOP MANUAL and PM CLINIC
sheets. No Go to next step.
Can you find any functional problem of SRV
and/or MRV?
Malfunction of any  Engine running at high idle.
throttle valve or Hydraulic oil temperature at T3.
suction valve at 2 Check the suspicious hydraulic circuit for noise and
the main blocks Replace or repair as
locate the problem (temperature difference) with an
or at the manifold necessary.
infrared temperature gun.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the repair was successful.

8 - 44 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

SHY013 - Track tensioning system without function (or with poor function)
[1/3]
Trouble code
Trouble Track tensioning system without function (or with poor function)
SHY013

Contents of trouble The automatic track tensioning system does not work.

– The automatic track tensioning system works under the following condition:
Engine running and ladder / service arm in up position (pilot control available).
– During a travel distance of approx. 20 m the track tension is built up automatically.
Related information
– When engine stopped, a system pressure of 35 bar is kept up and in combination with an
accumulator safety system (shock absorber) the correct track tension is always present.
– Ball cock valve 89.1 is closed and ball cock valves 89.2/.3 are open.
Problem that appears – If the track tensioning is too low, the wear-out on track pads and sprockets increases.
on the machine – If the track is loose, track-off may occur during travel or any movements.
– No or too low track tensioning pressure.
Possible causes – Accumulators insufficiently charged or defective.
– Defective track tensioning cylinder(s).

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running in high idle - ladder in up position.
Hydraulic oil temperature at T3.
ptensioning =
Test and adjust the track tensioning pressure 35 bar
No or too low track
1 according to the instructions and specifications Bring the machine
tensioning pressure Yes PM CLINIC
in the SHOP MANUAL and PM CLINIC sheets. back to operation.
SHOP
Is adjustment possible and does the track
MANUAL
tensioning system work orderly?
No Go to next step.
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
Test and adjust the charging of the SHOP
accumulators according to the instructions Bring the machine MANUAL
Yes
Accumulators and specifications in the SHOP MANUAL. back to operation.
insufficiently charged 2 Also refer to the latest version of the PARTS & AH03533
or defective SERVICE NEWS No. AH03533.
Is the function "Charging the Accumulators" No Go to next step.
possible and does the track tensioning system
work orderly?

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 45

Symptoms of the Hydraulic System Troubleshooting by Symptoms

SHY013 - Track tensioning system without function (or with poor function)
[2/3]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running in high idle - ladder in up position.
Hydraulic oil temperature at T3.
Flush the pipes and
hoses of the track
tensioning system.
If necessary repair or
Check the track tensioning cylinders for swol-
3 Yes replace the barrels
len partitions.
(check the piston
Do the track tensioning cylinders have any guide rings).
swollen partitions? Alternatively replace
complete track
Defective track tensioning cylinders.
tensioning cylinder(s). No Go to next step.
The tests and adjustments in steps 1 and 2 Yes Replace the seals.
have been completed successfully
(that means a track tensioning pressure of
35 bar is present and the accumulators are
charged orderly).
4 But the track tensioning cylinders can not hold Replace the track
the supplied pressure. No tensioning block no. 90
Disassemble the track tensioning cylinders (car body).
and check the seals at the pistons.
Are the seals in the track tensioning cylinders
defective?
Idler touch the stop end
5 If the idler touch the stop end plates, remove one track pad.
plates.
Bring the machine back into the original condition.
Final check 6
Start the machine and verify that the repair was successful.

8 - 46 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

View onto the elements of the hydraulic track tensioning system (SHY013)
[3/3]

Fig. 8-2 View onto the elements of the hydraulic track tensioning system

For details refer to SHOP MANUAL part 10 STRUCTURE & FUNCTION, chapter 11 "HYDRAULIC TRACK TEN-
SIONING SYSTEM".

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 47

Symptoms of the Hydraulic System Troubleshooting by Symptoms

SHY014 - Ladder does not move, or slow movement

[1/2]
Trouble code
Trouble Ladder does not move, or slow movement
SHY014
The ladder does not move when the function "ladder up" or "ladder down" is requested,
Contents of trouble
or the ladder movement is too slow.
– The electrical function of this circuit is already tested and OK.
Related information – The ladder pressure supply is charged by X4 pressure.
– A 70 bar SRV is mounted in the ladder circuit.
Problem that appears The ladder does not move when the function "ladder up" or "ladder down" is requested,
on the machine or the ladder movement is too slow.
– No or too low X4 pressure.
– Too low SRV pressure, or the valve is defective.
Possible causes – Valve 57Q623a/b or 57Q625 mechanically stuck.
– The ladder cylinder has an internal leakage (piston seal defective).
– The ladder bearing is defective or it is tightened too firmly.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Hydraulic oil temperature at T3.
No or too low Check the X4 pressure according to the Yes Go to next step. pX4= 60bar
1
X4 pressure instructions and specifications in Re-adjust and PM CLINIC
SHOP MANUAL and PM CLINIC sheets. No check for proper SHOP
Is the X4 pressure adjustment correct? ladder function. MANUAL
 Engine running at low idle.
Check the SRV pressure in the ladder circuit Yes Go to next step. 70bar
Too low SRV pressure
2 according to the instructions and specifications PM CLINIC
or the valve is defective
in the SHOP MANUAL and PM CLINIC sheets. Check SRV for proper
No SHOP
function.
Is the SRV pressure adjustment correct? MANUAL
 Main key switch 20S001 OFF & Maintenance safety switch 50S058 locked.
Valve 57Q623a/b or
Check the solenoid valve 57Q623a/b or Yes Go to next step.
57Q625 is 3
57Q625 for proper condition and function.
mechanically stuck Replace valve
No
Is the function OK? 57Q623a/b or 57Q625.
 Engine running at high idle.
Hydraulic oil temperature at T3.
1. Activate the function "ladder up" or "ladder Repair or replace the
Yes
down" until the cylinder end position is ladder cylinder.
The ladder cylinder has reached.
an internal leakage 4 2. Using an infrared temperature gun mea-
(piston seal defective) sure the temperature difference between
the cylinder rod and the cylinder bottom No Go to next step.
side.
Do you measure a temperature difference of
more than 15°C?

8 - 48 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

SHY014 - Ladder does not move, or slow movement

[2/2]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
Inspect:
Is the standard ladder
1. Check the ladder bearings and assem- frame used (standard
bling for proper condition and for the hand- weight & size)?
tight tightened torque for the ladder bear- Yes Is the ladder or the
The ladder bearing ings. ladder support ASSEMBLY
is defective or it is 5 There must not be any friction between lad- defective or damaged MANUAL
tightened too firmly der and platform. by an accident?
SHOP
2. Also refer to the ASSEMBLY MANUAL and Replace or repair as MANUAL
SHOP MANUAL. necessary.
Repair or replace the
Are the bearings in good condition
bearings as necessary
and is the tightening torque correct?
No and/or correct the
tightening torque
(hand-tight).
Bring the machine back into the original condition.
Final check 6
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 49

Symptoms of the Hydraulic System Troubleshooting by Symptoms

SHY015 - Refilling arm does not move, or slow movement

[1/2]
Trouble code
Trouble Refilling arm does not move, or slow movement
SHY015

Contents of trouble The refilling arm does not move or its movement is too slow.

– The electrical function of this circuit is already tested and OK.

– The refilling arm enable switch is activated.
Related information
– The refilling arm pressure supply is charged by X2 pressure.
– The refilling arm circuit has no SRV.
Problem that appears
The refilling arm does not move, or its movement is too slow.
on the machine
– No or too low X2 pressure.
– Valve 57Q624a/b or 57Q624c is mechanically stuck.
Possible causes
– The refilling arm cylinder has an internal leakage (piston seal defective).
– The refilling arm connection (pin and bushing) is defective.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Hydraulic oil temperature at T3.
Check the X2 pressure according to the Yes Go to next step.
instructions and specifications in the pX2=35 bar
No or too low
1 SHOP MANUAL part 10 STRUCTURE &
X2 pressure Re-adjust and verify PM CLINIC
FUNCTION, chapter 7, section "PILOT PRES-
SURE SUPPLY AND ADJUSTMENTS" and No that the refilling arm
is operated orderly. SHOP
PM-CLINIC sheets.
MANUAL
Is the X2 pressure adjustment correct?
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
Valve 57Q624a/b or Disassemble the solenoid valve 57Q624a/b or Yes Go to next step.
57Q642c is mechani- 2 57Q624c and check the inner spool part for
Replace valve
cally stuck proper condition and function.
No 57Q624a/b or
Is the inner spool insert OK? 57Q624c.
 Engine running at high idle.
Hydraulic oil temperature at T3.
Activate the function "refilling arm up" or Repair or replace the
Yes
The refilling arm "refilling arm down" until the cylinder end refilling arm cylinder.
cylinder has an position is reached, and measure the
3
internal leakage temperature difference between the cylinder
(piston seal defective) rod and the cylinder bottom side with an
infrared temperature gun. No Go to next step.
Is the temperature difference in the piston area
higher than 15°C?

8 - 50 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

SHY015 - Refilling arm does not move, or slow movement

[2/2]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF & Maintenance safety switch 50S058 locked.
Inspect:
Is the standard refilling
arm used (standard
weight & size)?
The refilling arm 1. Check the refilling arm for proper function.
Yes Is the refilling arm or
connection 2. Disconnect the hydraulic cylinder and its support defective
4 SHOP
(pin and bushing) check the free movement of the refilling or damaged by an
is defective MANUAL
arm. accident?
Is the refilling arm movement OK? Replace or repair
as necessary.
Repair or replace the
No refilling arm or the pin/
bushing as necessary.
Bring the machine back into the original condition.
Final check 5
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 51

Symptoms of the Hydraulic System Troubleshooting by Symptoms

SHY016 - Refilling arm is sagging when engine is not running

[1/1]
Trouble code
Trouble Refilling arm is sagging when engine is not running
SHY016

Contents of trouble The refilling arm is slowly sagging when engine is not running.

– Solenoid valve 57Q624c secures the refilling arm in upper position when not energized.
Related information
– The electrical function of this circuit is already tested and OK.
Problem that appears
The refilling arm is slowly sagging when engine is not running.
on the machine
Possible causes Solenoid valve 57Q624c has internal leakage

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
Refilling arm park valve
Disassemble the solenoid valve 57Q642c and check the inner spool part for
57Q624c has internal 1
proper condition and function.
leakage
Repair or replace the solenoid valve as necessary.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the repair was successful.

8 - 52 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

SHY017 - The hydr. driven grease pump does not move

[1/2]
Trouble code
Trouble The hydr. driven grease pump does not move
SHY017

Contents of trouble An hydraulic driven grease pump does not start or move correctly.

– The electrical function of this circuit is already tested and OK.

– The hydraulic driven grease pump pressure supply is charged by X4 pressure.

Related information – The hydraulic oil flow and pressure at the hydraulic driven grease pumps is reduced
(16-19 double strokes/min & 50 bar)
– Also refer to the information and specifications in the SHOP MANUAL part 10 STRUCTURE &
FUNCTION, chapter 17.
Problem that appears – A lubrication system is inoperative because the pump does not work.
on the machine – No relevant trouble code is displayed on the K+ monitor.
– No or too low X4 pressure.
– No or insufficient performance of the relief valve on the grease pump.
– No or insufficient performance of the "Q" volume reducing valve on the grease pump.
Possible causes – Internal leakage or damage at the grease pump.
– Wrong grease pressure adjustment (grease pressure too high).
– The vent valve (62Q507, 62Q509) causes a mechanical jam
(grease pump overload).

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Hydraulic oil temperature at T3.
No or too low Check the X4 pressure according to the Yes Go to next step. pX4 = 60bar
1
X4 pressure instructions and specifications in the Readjust and verify PM CLINIC
SHOP MANUAL and PM CLINIC sheets. No that the grease pump SHOP
Is the X4 pressure adjustment correct? operation is orderly. MANUAL
 Engine running at high idle.
Hydraulic oil temperature at T3.
No or insufficient
Check the pressure of the grease pump vent Yes Go to next step. pmax:
performance of the
2 valve according to the instructions and 45+5 bar
vent valve on the Readjust and verify
specifications in the SHOP MANUAL. bench tested
grease pump
Is the pressure adjustment of the grease pump No that the grease pump SHOP
operation is orderly. MANUAL
relief valve correct?
 Engine running at high idle.
Hydraulic oil temperature at T3.
No or insufficient
Yes Go to next step. 16-19
performance of the Check the volume adjustment of the grease
double-
"Q" volume reducing 3 pump volume reducing valve according to
strokes per
valve on the grease the instructions and specifications in the Readjust and verify
minute
pump SHOP MANUAL. No that the grease pump
operation is orderly. SHOP
Is the volume adjustment correct?
MANUAL
 Engine running at high idle.
Hydraulic oil temperature at T3.
Internal leakage Check the adjustment and operation of the Yes Go to next step.
or damage at the 4 grease pump according to the instructions and
grease pump specifications in the SHOP MANUAL. Repair or replace SHOP
No the grease pump MANUAL
Is the grease pump adjustment and operation
as necessary.
correct?

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 53

Symptoms of the Hydraulic System Troubleshooting by Symptoms

SHY017 - The hydraulic driven grease pump does not move

[2/2]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Wrong grease Hydraulic oil temperature at T3.
pressure adjustment Check the grease pressure adjustment Yes Go to next step. PGrease max
5
(grease pressure according to the instructions and specifications 180±5 bar
too high) in the SHOP MANUAL. Readjust or replace
No SHOP
Is the grease pressure correct? the end of line switch.
MANUAL
The vent valve  Engine running at high idle.
(62Q507, 62Q509) Hydraulic oil temperature at T3.
causes a mechanical 6 Test the vent valve operation according to Repair or replace the vent
jam (grease pump SHOP
the instructions and specifications in the valves and test & adjust the
overload) MANUAL
SHOP MANUAL. grease system if necessary.
Bring the machine back into the original condition.
Final check 7
Start the machine and verify that the repair was successful.

8 - 54 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

SHY018 - Abnormal track chain movement during digging

[1/1]
Trouble code
Trouble Abnormal track chain movement during digging
SHY018
– Abnormal track chain movement in reverse direction during bucket filling - FSA.
Contents of trouble
– Abnormal track chain movement in forward direction during bucket filling - BHA.
– During bucket filling movement with FSA the track chain(s) make(s) a self-movement in
reverse direction. That means, the forward loading force will be eliminated by a self-reversing
movement of the track system.
Related information
– During bucket filling movement with BHA the track chain(s) make(s) a self-movement in forward
direction. That means the reverse loading force will be eliminated by a self-forwarding
movement of the track system.
Problem that appears
Insufficient digging or loading performance.
on the machine

Possible causes Internal leakage at the rotary joint.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Hydraulic oil temperature at T3.
Test and adjust the SRV pressure according to the instructions and
specifications in the SHOP MANUAL part 10 STRUCTURE & FUNCTION, chap-
ter 10, section "CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT"
and PM CLINIC sheets.
→ Measure the SRV pressure at the travel system with connected
travel main lines.
Perform the following work steps:
REMARKS: Test the travel system during loading.
pSRV-travel
Internal leakage 1. Connect test gauges to the test ports M 31.1/.2/.3/.4 310±5.0 bar
1
at the rotary joint 2. Disconnect the parking brake solenoid valve 57Q516 in order to close the PM CLINIC
travel brake.
SHOP
3. Actuate the travel pedals (for single travel movement) of each side sepa- MANUAL
rately and read the pressure at the gauges.
Only the operated channel should build up pressure.
4. If the pressure is not OK replace or re-seal the rotary joint.
5. Test and adjust the MRVs of the travel system on the main blocks I & III.
6. Also refer to troubleshooting chart SHY006.
After adjustment/repair/replacement verify that chain movement is no longer
abnormal.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 55

Symptoms of the Hydraulic System Troubleshooting by Symptoms

SHY019 - Slew parking brake without function

[1/1]
Trouble code
Trouble Slew parking brake without function
SHY019
– The slew parking brake is inoperative (the superstructure moves) although the slew parking
brake switch 20S029 is switched ON.
Contents of trouble
– The X2 pressure circuit is already tested and OK (pX2 = 35 bar at valve 57Q505).
– The electrical circuit is already tested and OK.
– The slew parking brake is a disc brake mounted on the top of the slew gearbox.
– The "Siebenhaar" slew gearbox has an external slew brake housing with a separate oil filling.
– The "L&S" slew gearbox has an integrated slew brake system which is lubricated by the
gearbox oil.
Related information
– According to the safety regulations both slew parking brake is working as a spring loaded, pres-
sure released system. That means the pilot pressure opens the slew parking brake. Without
pilot pressure the springs close the slew parking brake.

Precondition: Air is properly removed from the system by bleeding.

Problem that appears
The slew parking brake is inoperative.
on the machine
– The pilot pressure in the slew parking brake circuit is not released.
Possible causes
– The brake discs are burnt and/or the piston seals are defective.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
The pilot pressure Check if solenoid valve 57Q505 is mechani- Replace solenoid valve
Yes 0 bar
in the slew parking cally stuck. 57Q505.
1
brake circuit is not The pilot pressure in the slew parking brake
released line is not released to the hydraulic oil tank. No Go to next step.
Is the spool of the solenoid valve stuck?
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.

Check for leaks or

Perform the following steps: mixed-up connections 45bar
1. Disconnect the pilot pressure supply hoses Yes in the pilot supply lines kept up for
for the slew parking brakes from the slew for the slew parking 15 minutes
gearboxes. brake system.
2. Install a manual hydraulic pump with
The brake discs are 60 bar manometer in order to test the slew Refer to the instructions in the
burnt and the piston 2 SHOP MANUAL part 50 DISAS-
parking brake piston seals.
seals are defective SEMBLY & ASSEMBLY.
3. Using the manual pump increase
the pressure up to 45 bar. 1. Repair or replace the slew
parking brake.
4. The built-up pressure must be kept up No
for 15 minutes. 2. Bleed the air from the pilot line
to the slew parking brake
Can you build-up 45 bar and is the pressure housing.
kept up for 15 minutes?
3. Finally check the slew parking
brake for proper operation.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the repair was successful.

8 - 56 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Hydraulic System

SHY020 - Travel parking brake without function

[1/1]
Trouble code
Trouble Travel parking brake without function
SHY020
– The travel parking brake is inoperative.
Contents of trouble – The X2 pressure circuit is already tested and OK (pX2 = 35 bar at solenoid valve 57Q516).
– The electrical circuit is already tested and OK.
– The travel parking brake is a disc brake, mounted between both travel motors and the
travel gearboxes (type L&S: wet brakes / type Zollern: dry brakes.
– According to the safety regulations both travel parking brakes are working as a spring loaded,
Related information
pressure released system. That means the pilot pressure opens the travel parking brakes. With-
out pilot pressure the springs close the travel parking brakes.
Precondition: Air is properly removed from the system by bleeding.
Problem that appears There is no automatic travel parking brake function when the ladder is down or the engine
on the machine is stopped.
– The pilot pressure in the travel parking brake circuit is not released.
Possible causes – The X2 pressure adjustment is too low or the X2 pressure valve is defective.
– The brake discs are burnt and/or the piston seals are defective.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
The pilot pressure in Solenoid valve 57Q516 is mechanically stuck. Replace solenoid valve
Yes 0 bar
the travel parking brake 1 The pilot pressure in the travel parking brake 57Q516.
circuit is not released line is not released to the hydraulic oil tank.
No Go to next step.
Is the piston of the solenoid valve stuck?
 Engine running at high idle.
Hydraulic oil temperature at T3.
The X2 pressure
Check and adjust the X2 pressure according to Yes Go to next step. pX2 = 35 bar
adjustment is too low
2 the instructions and specifications in the
or the X2 pressure PM CLINIC
SHOP MANUAL and PM CLINIC sheets.
valve is defective Replace the X2
Is it possible to adjust the X2 pressure as No SHOP
pressure valve.
specified? MANUAL

 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
Perform the following steps: Check for leaks or
mixed-up connections 45bar,
1. Disconnect the pilot pressure supply hoses
Yes in the pilot supply lines kept up for
from the travel parking brake housings.
for the travel parking 15 minutes
2. Install a manual hydraulic pump with brake system.
60 bar manometer in order to test the travel Refer to the instructions in the
The brake discs are parking brake piston seals SHOP MANUAL part 50 DISAS-
burnt and/or the piston 3 (perform the test for both travel brake SEMBLY & ASSEMBLY.
seals are defective housings). 1. Repair or replace the travel
3. Using the manual pump increase the parking brake.
pressure up to 45 bar. No
2. Bleed the air from the pilot line
4. The built-up pressure must be kept up for to the travel parking brake
15 minutes. housing.
Can you build-up 45 bar and is the pressure 3. Finally check the slew parking
kept up for 15 minutes without further action? brake for proper operation.
Bring the machine back into the original condition.
Final check 4
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 57

Symptoms of the Mechanical System Troubleshooting by Symptoms

8.3 SYMPTOMS OF THE MECHANICAL SYSTEM

SME001 - Abnormal noise is made

[1/2]
Trouble code
Trouble Abnormal noise is made
SME001

Contents of trouble Abnormal noise coming from any engine related parts.

Related information First check for proper function and tightening of all related parts.

Problem that appears – Abnormal noise.

on the machine – The noisy component may cause an unexpected breakdown.
– Related parts, components or systems which may cause the noise, because they are loose,
worn, misaligned, or defective:
– Air intake system
– Muffler system
Possible causes – Broken guards
– Broken fire wall
– Lost parts or tools etc.
– Improper alignment between engine and PTO
– Abnormal combustion

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Test conditions according to the kind of inspection, when following the
judgment table information.
Yes Go to final step 2.
1. Refer to the follow-
ing judgment table
and locate the
1. Check all related parts and components for problem.
External noise
(the abnormal noise is proper function.
2. When the cause for
1
not coming from inside 2. Check suspicious screw connections and the noise is deter-
the engine) mountings for proper tightening condition. No mined, perform the
Could you locate and rectify the cause for the appropriate repair
abnormal noise? procedures as
necessary.
3. After the repair is
completed, go to
final step 2.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the repair was successful.

8 - 58 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Mechanical System

SME001 - Abnormal noise is made

[2/2]
Judgment Table for SME001 Causes

Broken dynamic valve syst. (valve, rocker lever etc)

Defect inside muffler (dividing board out of position)

Air leakage between turbocharger & cylinder head
Excessive wear of piston ring, cylinder liner

Wrong adjustment of valve clearance

Deformed fan or defective fan hub
Seized turbocharger, interference

Improper gear train backlash

Legend

Clogged, seized injector

Missing, seized bushing
Ο : Possible causes (judging from Questions & Check Items)

Defective fuel pump

◙ : Most probable causes (judging from Questions & Check Items)

◊ : Possible causes due to length of use (used for a long period)

● : Items to confirm the cause

Confirm the recent repair history

Degree of use of the machine Operated for a long period ◊
Questions

Gradually occurred Ο Ο
Condition of abnormal noise
Suddenly occurred Ο Ο Ο
Non-specified fuel is being used Ο Ο
Engine oil must be added more frequently ◙
Blue under light load ◙
Colour of exhaust gas
Black ◙ Ο Ο
Metal particles are found in the oil filter ◙ ◙
Blow-by gas is excessive ◙
Check items

Noise of interference is heard from around the turbocharger ◙

Engine pickup is poor and combustion is abnormal ◙
When touching the exhaust manifolds immediately after engine start, the ◙ Ο
temperature of some cylinders is low
Abnormal noise is loud when accelerating the engine Ο Ο Ο Ο Ο
Clanging sound is heard from around the cylinder head ◙ ◙
Air leakage between turbocharger & cylinder head, loose clamp ◙
Vibrating noise is heard from around the muffler ◙

Measured compression pressure it is too low ●

When rotating the turbocharger by hand, it is too rough-running ●
Troubleshooting

Remove the gear cover and inspect directly ● ●

Eng. speed does not change when any cylinder is disengaged ●
Fan is deformed or the fan hub is defective ●
When checking valve clearance, it doesn't meet the specification ●
Remove the cylinder head cover and inspect directly ●
When the muffler is removed, abnormal noise disappears ●
Replace
Replace
Replace
Replace

Replace

Replace
Replace
Replace
Correct
Correct

Correct

Remedy

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 59

Symptoms of the Mechanical System Troubleshooting by Symptoms

SME002 - Abnormal noise around the PTO / hydraulic pumps

[1/2]
Trouble code
Trouble Abnormal noise around the PTO / hydraulic pumps
SME002

Contents of trouble Abnormal or excessive noise coming from the PTO or from the hydraulic pumps.

– At first check all oil levels and oil qualities (PTO - pump bearing housings).
Related information – Refer to the OPERATION & MAINTENANCE MANUAL for detailed information on the correct
oil specifications and oil qualities.
Problem that appears – Abnormal noise.
on the machine – The noisy component may cause an unexpected breakdown.
– No oil or the oil level is too low in the PTO
– No oil or the oil level is too low in the pump bearing housing
Possible causes
– Main pump defective (internal mechanical damage)
– Air entering the hydraulic system or air bubbles inside the hydraulic suction lines

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
Between
Yes Go to next step.
MIN & MAX
Check the oil level in the PTO housing using
No oil or the oil level Refill specified oil up
1 the dipstick. For details refer to the OMM.
is too low in the PTO to the specified level
Is the oil level correct between the MIN and
No and recheck if the OMM
MAX marks?
abnormal noise
disappeared.
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
Yes Go to next step. Oil specifi-
cation and
Check the oil level and the oil quality in the
refill level
pump bearing housing of the PTO gearbox.
No oil or the oil level reference:
For details refer to the OPERATION & MAIN- Refill specified oil up
is too low in the pump 2 to the specified level - OMM
TENANCE MANUAL and to the PARTS &
bearing housing No and recheck if the
SERVICE NEWS AH07515 (latest version). - P&S
abnormal noise NEWS
Is the oil level correct and does the oil quality
disappeared. AH07515
meet the specification?
(latest
version)
 Engine running at high idle.
Hydraulic oil temperature at T3.
Move the attachment in working condition.
Double-check the
suspicious main pump
1. Check for abnormal noise coming from for excessive noise Vibration
Main pump defective around or directly from the main pumps. generation. measure-
Yes
(internal mechanical 3 ment com-
2. Using a vibration analyzer, take measure- If it is confirmed, parison
damage)
ments at all 3 main pumps and compare replace the noisy
the measurement results. main pump.
All main pumps
Does any main pump show excessive noise
generate too much
generation? No noise simultaneously.
Got to next step.

8 - 60 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Mechanical System

SME002 - Abnormal noise around the PTO / hydraulic pumps

[2/2]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Hydraulic oil temperature at T3.
Move the attachment in working condition.
If you locate air
bubbles in the
hydraulic system Standard
refer to the latest condition:
version of PARTS & There is no
1. Check the sight glass at the hydraulic tank SERVICE NEWS air in the
for air bubbles. Yes hydraulic
Air entering the 2. Also check the suction lines and clamps of – AH01513 & oil tank
hydraulic system or and in the
4 sealed connections for air leakage. – AH00504 &
air bubbles inside the suction
hydraulic suction lines NOTE! Suction lines always must be – 21.531
lines.
mounted with silicon applied
for bleeding the
to the pipes and they must
hydraulic cylinders.
be fixed with double-clamps!
Check the lifetime of
Could you locate air in the hydraulic tank or the PTO and the main
air bubbles in the suction lines? pumps.
No The abnormal noise
may be caused by
normal wear due to
component aging.
Bring the machine back into the original condition.
Final check 5
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 61

Symptoms of the Mechanical System Troubleshooting by Symptoms

SME003 - Vibration is excessive (engine mountings)

[1/2]
Trouble code
Trouble Vibration is excessive (engine mountings)
SME003

Contents of trouble Abnormal or excessive vibration coming from the engine or related parts.

– At first check all related parts for proper function and tightening.
Related information – Measure the alignment/incline of the engine & PTO mountings (horizontal & vertical).
Support tolerance: ±2 mm
Problem that appears – Abnormal vibration and the risk that a breakdown may occur.
on the machine – The noisy component may cause an unexpected breakdown.
– Defective parts  mounting supports of engine and PTO.
– Improper alignment  mixed mounting of old (worn and/or defective) and new mounting sup-
Possible causes ports.
– Defective front damper.
– Defective rear damper (coupling to PTO).

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Test conditions according to the kind of inspection, when following the
judgment table information.
– Defective parts Yes Go to final step 2.
 mounting supports of engine and PTO. 1. Refer to the follow-
– Improper alignment ing judgment table
 mixed mounting of old (worn and/or and locate the
defective) and new mounting supports. problem.
Abnormal or excessive
– Defective front damper. 2. When the cause for
vibration coming from
1 the noise is deter-
the engine or related – Defective rear damper (coupling to PTO).
parts mined, perform the
1. Check all related parts and components of No
appropriate repair
the above items for proper function and procedures as
condition. necessary.
2. Check suspicious screw connections and 3. After the repair is
mountings for proper tightening. completed, go to
Could you locate and rectify the cause for final step 2.
the abnormal vibration?
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the repair was successful.

8 - 62 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Mechanical System

SME003 - Vibration is excessive (engine mountings)

[2/2]
Judgment Table for SME003 Causes

Defective dynamic valve syst. (valve, rocker lever etc)

Loose engine mounting bolts, broken cushion
Broken part inside output shaft (damper)
Worn connecting rod, main bearing

Improper gear train backlash

Legend

Worn balancer, cam bushing

Ο : Possible causes (judging from Questions & Check Items)

◙ : Most probable causes (judging from Questions & Check Items)

◊ : Possible causes due to length of use (used for a long period)

● : Items to confirm the cause

Confirm the recent repair history

Degree of use of the machine Operated for a long period ◊ ◊ ◊
Questions

Increased suddenly Ο Ο
Condition of vibration
Increased gradually Ο Ο Ο
Non-specified oil is being used Ο Ο
Metal particles are found in the oil filter ◙ ◙
Metal particles are found when oil is drained ◙ ◙
Check items

Oil pressure is low at low idle Ο Ο

Vibrations occurs at mid-range speed (poor combustion) Ο Ο
Vibrations follows the engine speed (poor combustion) Ο Ο Ο
Exhaust smoke is black (poor combustion) ◙

Inspect directly for loose engine mounting bolts, broken cushion ●

shooting
Trouble-

Check all engine supports for proper alignment/incline ●

Inspect output shaft damper (coupling) ●
Inspect front engine damper ●
Replace
Replace
Replace

Replace
Replace
Adjust

Remedy

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 63

Symptoms of the Mechanical System Troubleshooting by Symptoms

SME004 - Vibration is excessive (engine torsion)

[1/1]
Trouble code
Trouble Vibration is excessive (engine torsion)
SME004

Contents of trouble Vibration is excessive (abnormal vibration at the front engine damper or at the coupling).

In order to eliminate abnormal vibration and torque of the engine, the following components are
mounted:
– A damper at the engine front side  double-mass vibration damper
– A damper at the engine rear side  coupling
Related information
The front damper (cooler side) is mounted on the crankshaft.
For inspection and references refer to the Cummins Troubleshooting & Repair Manual for the
QSK38 Engine (SDA12V159E).
The rear damper in the form of a coupling is flange connected to the engine flywheel.
For further information refer to the Cummins engine documentation.
Problem that appears
Vibration is excessive (abnormal vibration at the front engine damper or at the coupling).
on the machine
– Front double-mass vibration damper defective.
Possible causes
– Rear coupling defective.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
Replace the damper.
Front double-mass Check the front damper according to the Cummins
Also check the rear
vibration damper 1 specifications given in the Cummins Yes specifica-
coupling for wear
defective Service Manual. tion
(step 2).
Is the damper defective?
No Go to next step.
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
Replace the coupling.
Also check the front
SHOP
Yes double-mass vibration
MANUAL
Rear coupling Check the rear coupling for wear and proper damper on the
2
defective function. crankshaft (step 1).
Is the coupling defective? Inform the Cummins
Service and measure
No
the blow-by pressure
of the engine.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the repair was successful.

8 - 64 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Mechanical System

SME005 - There is a big shock when stopping slew movement

[1/1]
Trouble code
Trouble There is a big shock when stopping slew movement.
SME005
A big shock occurs when stopping the slew movement with the slew foot brake
Contents of trouble
or by the counter slew function.

Related information A big shock occurs when the superstructure changes its slew direction.

Problem that appears

Excessive wear and in consequence further damage can arise.
on the machine
– Wear in vertical & horizontal direction at the boom foot bushings and pins.
Possible causes
– Excessive wear at the slew ring bearing (causing heavy backlash).

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Hydraulic oil temperature at T3.
1. Replace pins
and bushings at
the connection
Boom foot
between boom
bushings &
and superstructure. pins: max.
2. After replacement clearance
Wear in vertical & measure the axial 2.5mm
horizontal direction
1 Move the attachment smoothly and check for clearance at the
at the boom foot Yes Axial play
excessive wear at the boom foot bushings. connection
bushings and pins between
Is the movement at the bushings too large? between boom and
boom and
super-structure. super-
3. If the axial play is structure:
still out of range max.
repair with the clearance
welding and lathe 2.5mm
tool.
No Go to next step.
 Engine running at high idle.
Hydraulic oil temperature at T3.
P&S
Replace the slew ring. NEWS
Yes Check the slew AH02513
gearbox pinions. (latest
1. Move the superstructure smoothly and release)
Excessive wear at the check for excessive wear and movement of Check the teeth
slew ring (causing 2 the slew ring and backlash. around the slew ring.
heavy backlash)
2. Also refer to the latest release of Also check the grease
PARTS & SERVICE NEWS AH02513. dummy wheels for the
No slew ring teeth
Is the wear out of range?
(tightening).
Go to SME006 and
refer to its trouble-
shooting procedures.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 65

Symptoms of the Mechanical System Troubleshooting by Symptoms

SME006 - There is a big abnormal noise when moving/stopping slew

movement
[1/2]
Trouble code
Trouble There is a big abnormal noise when moving/stopping slew movement
SME006
– A big abnormal noise occurs when moving/stopping slew movement.
Contents of trouble
– The abnormal noise may also exist permanently during slew movement.
– First check all oil levels at the slew gearboxes.
– Verify the oil level and the used oil viscosity in the slew gearboxes (CLP 220 only).
– Verify the oil level and the used oil viscosity in the slew parking brake housing (SAE 10 /
Related information
HLP 32).
– Verify the oil level and the used oil viscosity in the motor adapter housing (SAE 10 / HLP 32).
– Also refer to the OPERATION & MAINTENANCE MANUAL and to the SHOP MANUAL.
Problem that appears
Abnormal noise and in consequence a damage can arise.
on the machine
– Slew gearbox - internal damage.
– Faulty bottom bearing of the slew gearbox pinion (external grease lubrication).
Possible causes – Slew parking brake - internal damage (discs are welded together).
– Damaged mechanical connection between the hydraulic slew motor and the slew gearbox
(motor adapter housing, excessive wear at the connection).

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle & smooth slew movement of superstructure.
Hydraulic oil temperature at T3.
1. Check for proper tightening of the slew
gearboxes, and retighten if necessary. Replace the defective Refer to the
Slew gearbox - Yes
1 slew gearbox. Tightening
internal damage 2. During slew movement, check and listen
Chart in the
for noise at the respective gearbox. SHOP
Can you identify any abnormal noise coming No Go to next step. MANUAL
from the slew gearbox?
 Engine running at high idle & smooth slew movement of superstructure.
Hydraulic oil temperature at T3.
1. During slewing check the movement of the SHOP
slew gearbox pinion. MANUAL,
Replace the defective Component
2. During slewing also check and listen for Yes
slew gearbox. structure
Faulty bottom bearing noise at the lower side of the respective and grease
of the slew gearbox slew gearbox.
2 system
pinion (external grease
lubrication) 3. Check the grease supply and grease
amount (injector adjustment) at the pinion
bearing.
No Go to next step.
Can you identify any abnormal noise or
abnormal movement of the slew gearbox
pinion?

8 - 66 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Mechanical System

SME006 - There is a big abnormal noise when moving/stopping slew

movement
[2/2]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle & smooth slew movement of superstructure.
Hydraulic oil temperature at T3.
Although the slew
parking brake is
closed, the super-
structure moves and
causes noise or shock
during starting or
stopping the slew
movement.
1. Check the slew parking brake for proper
Slew parking brake
condition (parking brake open/closed). 1. Inspect and replace
internal damage
3 the defective slew SHOP
(discs are welded 2. Carefully move the control lever to start Yes
parking brakes as MANUAL
together) slew movement.
necessary.
Can you identify any abnormal noise or
2. Also check for
abnormal slew movement?
contamination of
the gearbox oil.
3. Drain contaminated
oil and refill fresh
specified gearbox
oil.
No Go to next step.
 Engine running at high idle & smooth slew movement of superstructure.
Hydraulic oil temperature at T3.
1. Disconnect the
hydraulic slew
motor from the
slew gearbox and
check the connec-
tion between both
Yes components.
Check the slew movement for proper
Damaged mechanical condition: 2. If the connection is
connection between
– starting slew damaged, replace
the hydraulic slew
the slew gearbox
motor and the slew – stopping slew PM-Clinic
4 and the hydraulic
gearbox
– counter slew motor. SHOP
(motor adapter
housing, excessive – foot brake actuation Check the hydraulic MANUAL
wear at the connection) slew adjustment
– acceleration of slew speed
(2-stage valve)
Can you identify any abnormal noise, or abnor-
For more information
mal slew movement, or abnormal vibration?
and specifications refer
No to the SHOP MANUAL
and to the PM CLINIC
sheet.
Also see the trouble-
shooting charts of
SHY008...SHY010.
Bring the machine back into the original condition.
Final check 5
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 67

Symptoms of the Mechanical System Troubleshooting by Symptoms

SME007 - Fan blades make abnormal noise

[1/1]
Trouble code
Trouble Fan blades make abnormal noise
SME007
– Abnormal noise occurs when the hydraulic oil cooler fans or radiator fans are starting or stop-
Contents of trouble ping.
– The abnormal noise may also exist permanently when the fans are running continuously.
– Check the fan mounting at the fan motor for horizontal & vertical movement.
Related information
– Check the fan blades for cracks.
Problem that appears
Abnormal noise and in consequence any cooler damage may occur.
on the machine
Possible causes Fan blades are loose or broken.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
Check the lifetime of
the concerned fan(s):
– Radiator fan:
15,000 hrs. No hori-
zontal &
Yes – Hydr. oil cooler
Manually check the fan blades and the axial fan
fan blade connections (rivets). fans: 20,000 hrs. movement
Fan blades are loose
1
or broken REMARKS: Turn the fan hand and check If the lifetime is
each blade. exceeded replace the
fan(s).
Is any fan blade loose or cracked?
Check the hydraulic
cooler fan drive for
overspeed. RPM max
No
1250±50
Adjust the specified
speed if necessary.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the repair was successful.

8 - 68 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Mechanical System

SME008 - Abnormal noise coming from a travel gearbox

[1/2]
Trouble code
Trouble Abnormal noise coming from a travel gearbox
SME008
– Abnormal noise occurs when the shovel starts or stops travelling.
Contents of trouble
– The abnormal noise may also exist permanently while the shovel is travelling.
– First check the oil levels at both travel gearboxes.
– Verify the oil level and the used oil viscosity in the travel gearboxes (CLP 220 only).
Related information – Make sure that the vent valves at the end of the breather hoses are clean (inside car body).
– Drain the oil of the travel gearboxes and check for particles, chippings, or pieces due to wear.
– Also refer to the OPERATION & MAINTENANCE MANUAL and to the SHOP MANUAL.
Problem that appears
Abnormal noise and in consequence a capital damage can arise.
on the machine
– Gearbox broken - internal parts defective (short-term failure).
– A wrong oil viscosity is used - any planetary gear teeth and/or bearing defective
Possible causes (long-term failure).
– Hydraulic travel motor connection defective (no oil in the motor adapter housing).
– Travel parking brake disks defective (welded together)

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle.
Hydraulic oil temperature at T3.
1. Refer to the SHOP
MANUAL & PM
CLINIC sheets and
carry out the basic
Gearbox broken - 1. Take the track off the ground.
adjustment of the PM-Clinic
internal parts defective 1 2. During rotation check each side for abnor- Yes travel system. SHOP
(short-term failure) mal noise or shocks.
2. If the noise contin- MANUAL
Can you identify any abnormal noise or shock ues after the basic
during track rotation? adjustment,
replace the respec-
tive travel gearbox.
No Go to next step.
 Engine running at high idle.
Hydraulic oil temperature at T3.
1. Refer to the SHOP
MANUAL & PM
CLINIC sheets and
A wrong oil viscosity carry out the basic
is used - any planetary 1. Take the track off the ground. OMM
adjustment of the
gear teeth and/or 2 2. During rotation check each side for abnor- PM-Clinic
Yes travel system.
bearing defective mal noise or shocks. SHOP
2. If the noise contin-
(long-term failure) Can you identify any abnormal noise or shock MANUAL
ues after the basic
during track rotation? adjustment,
replace the respec-
tive travel gearbox.
No Go to next step.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 69

Symptoms of the Mechanical System Troubleshooting by Symptoms

SME008- Abnormal noise coming from a travel gearbox

[2/2]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
Replace the respec-
tive travel motor and
Yes replace the planetary
Disconnect the concerning travel motor from
Hydraulic travel motor gear pinion at the
the adapter housing and check the connection
connection defective gearbox.
3 at the motor and inside the motor adapter
(no oil in the motor housing for any damage. Check the travel
adapter housing) motor(s) for internal
Can you identify any damage (because of
and external leakage
missing oil)? No
and replace if
necessary.
Also refer to SHY006.
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
1. Replace the travel
parking brakes
(both sides) and
bleed the pilot
brake system prop-
erly.
2. Also check the oil
Yes
level (L&S only) in
the travel brake
housing.
1. Disconnect the respective travel motor Note!
Travel parking brake and the travel parking brake. Zollern parking brakes
disks defective 4
2. Check and inspect the parking brake disks. have dry brake disks.
(welded together)
Do not fill oil in!
Is any damage visible (disks defective or
welded together)? 1. Remove the cover
from the planetary
housing (travel
gearbox) and
inspect the plane-
No tary gears.
2. Also inspect the
drive shaft.
3. If any damage is
found repair as
necessary.
Bring the machine back into the original condition.
Final check 5
Start the machine and verify that the repair was successful.

8 - 70 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Mechanical System

SME009 - Abnormal noise coming from the work equipment (lack of grease)
[1/2]
Trouble code
Trouble Abnormal noise coming from the work equipment (lack of grease)
SME009
– - Abnormal noise occurs when the attachment is moving.
Contents of trouble – - The abnormal noise occurs due to lack of grease at the pins and the bushings of the
work equipment (CLS).
– - First check the grease level at the CLS grease barrel.
- Verify that the barrel contains grease of the specified quality and viscosity.
- Verify that all injectors are in good condition and properly adjusted.
Related information
- Verify that the pause time setting (11K103) is correct.
- Also refer to the OPERATION & MAINTENANCE MANUAL / SHOP MANUAL / ASSEMBLY
MANUAL.
Problem that appears
Abnormal noise and in consequence a capital damage of the pins and bushings can arise.
on the machine
– A wrong grease quality is used.
– Lack of grease by restricted or blocked grease line between injector and bearing.
Possible causes – Contaminated grease is used.
– Daily fault messages of the CLS system occur.
Download the history data via KOMTRAX Plus and verify the system status.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF.
Yes Go to next step.
1. Replace wrong
grease by speci-
fied grease and
replace the
Recheck the grease quality and specification defective pins and
under consideration of the KMG recommenda- bushings on the P&S
A wrong grease quality tions in the OPERATION & MAINTENANCE attachment side. NEWS
1
is used MANUAL and PARTS & SERVICE NEWS AH02535
AH02535, latest release. No 2. Check all grease latest
injectors for proper release
Does the used grease correspond to the KMG
recommendations? function.
3. Pre-lubricate all
pins and bushings
through the injec-
tors until the new
grease flows out.
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
1. Check the relevant
grease injectors for
proper function.
Check all bearing/pin connections at the
Lack of grease by 2. Check the lubrica-
attachment.
restricted or blocked tion line between
2 There must always a small amount of Yes
grease line between injector and bear-
fresh grease be visible.
injector and bearing. ing for clogging or
Is there any bearing/pin connection without damage.
visible fresh grease?
3. Repair or replace
as necessary.
No Go to next step.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 71

Symptoms of the Mechanical System Troubleshooting by Symptoms

SME009 - Abnormal noise coming from the work equipment (lack of grease)
[2/2]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF.
1. Replace the con-
taminated grease
by specified
grease.
2. Clean or replace
the barrel as nec-
essary.

– Pins & bushings & injectors are worn out 3. Replace the defec-
due to contaminated grease in the barrel. tive pins and bush- Fresh
Contaminated grease grease at
ings on the
is used – No or not enough grease causes early every
3 Yes attachment side.
(grease barrel refilling wear and noise at the pins and bushings of bearing at
without refilling filter) the attachment. 4. Check all grease the attach-
injectors for proper ment.
Are pins and bushings worn out due to missing function and
grease and defective injectors?
replace
if necessary.
5. Pre-lubricate all
pins and bushings
through the injec-
tors until the new
grease flows out.
No Go to next step.
 Main key switch 20S001 ON.
For repair main key switch OFF & maintenance safety switch locked
1. Repair or replace any defective parts of
CLS as necessary.
Daily fault messages of
the CLS system occur 2. Replace the defective pins and bushings
Download the history data via KOMTRAX Plus on the attachment side (standardization
Download the history 4 and check the system status.
data via KOMTRAX of overriding importance).
Plus and verify the Check the history data for repeated
3. Check all grease injectors for proper
system status "bucket cut-off" messages due to
missing grease. function.
4. Pre-lubricate all pins and
bushings through the injectors until the
new grease flows out.
Bring the machine back into the original condition.
Final check 5
Start the machine and verify that the repair was successful.

8 - 72 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Mechanical System

SME010 - Abnormal idler movement

[1/1]
Trouble code
Trouble Abnormal idler movement
SME010

Contents of trouble Abnormal idler movement occurs at the supports.

– First check the idler axle and bushings for wear.

– Verify that the specified oil quality and viscosity is used inside the idler (CLP 220 / HD 220 for
Related information arctic temperatures).
– Verify that the track tensioning system is working properly.
– Also refer to the OPERATION & MAINTENANCE MANUAL and to the SHOP MANUAL.
Problem that appears Abnormal idler movement and in consequence a capital damage of axle, bushings, or sliding
on the machine blocks can arise.
– Leak at the lifetime seals (axle & bushing worn out).
Possible causes
– Idler sliding blocks are below the wear limit.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
1. Open the track chain and remove the idler. Replace the complete
Leak at the lifetime Yes idler including new
2. Disassemble the sliding blocks of the idler
seals (axle & bushing 1 sliding blocks.
worn out) and check the lifetime seals and the wear
of axle and bushings.
No Go to next step.
Are axle and bushings worn out?
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked.
1. If excessive wear is found, replace the
Idler sliding blocks are idler sliding blocks.
2 Check for excessive wear between the idler
below the wear limit 2. Also check the lifetime of the idler, and if
sliding blocks and the track frame.
the lifetime is exceeded, replace the idler
sliding blocks.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 73

Symptoms of the Mechanical System Troubleshooting by Symptoms

SME011 - Leak at the PTO shaft seal

[1/2]
Trouble code
Trouble Leak at the PTO shaft seal
SME011

Contents of trouble Leak at the PTO shaft seal (after changing the oil viscosity).

Hypoid oil
ISO oil viscosity grade HLP T32 CLP 150
75W-140
11K182 adjust temperature limit value to
15°C 48°C 54°C
switching point (TG1)
Related information 11K143 adjust temperature limit value to
60°C 95°C 95°C
switching point (TG2)

Standard oil specification  CLP 150

REMARKS: In some areas it is possible to change over to Hypoid Oil 75W-140.
Before changing the oil type contact KMG.
Problem that appears
Leak at the PTO shaft seal.
on the machine
– The bearing of the drive shaft is defective (too much movement), check the PTO lifetime.
Possible causes – The shaft seal is burnt due to use of a wrong oil viscosity.
– Faulty coupling mounting or coupling defective (misalignment).

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked
 Coupling disassembled.
The bearing of the Movement
drive shaft is defective Check the input shaft bearing of the max.
1 Replace or repair as
(too much movement), PTO gearbox. Yes 1.2mm
necessary.
check the PTO lifetime Do you measure abnormal bearing movement horizontal
(horizontal & vertical)? & vertical
No Go to next step.
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked
1. Check the PTO
lifetime and replace
Clean up the PTO drive shaft area and check
the PTO if
for any leakage.
necessary.
Remarks: Yes
The shaft seal is burnt 2. Remanufacture the Standard
In some areas the oil viscosity recommended
due to use of a wrong 2 by KMG is not available. old PTO according oil specifi-
oil viscosity If a wrong oil viscosity was used, the seal ring to the Reman cation:
on the drive shaft may be burnt and causing a Guideline. CLP 150
leakage. Replace / reseal /
Was oil type CLP 150 used in the PTO remanufacture the
on your shovel? No PTO, and from now on
use the correct oil
specification CLP 150.

8 - 74 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of the Mechanical System

SME011 - Leak at the PTO shaft seal

[2/2]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF & maintenance safety switch 50S058 locked
 Coupling disconnected.
Replace the coupling
Yes and observe the
correct alignment.
Due to a long term
PTO overheating
Coupling mounting (permanently over
or coupling defective 3 Check the coupling lifetime and 85C°) the seal ring on Also refer
(misalignment) check the coupling for any defect the input shaft may be to SHOP
Is any problem present? hardened and brittle. MANUAL
No
Check the PTO cooling
system - verify that the
PTO temperature does
not exceed 65C°
during normal
operation.
Bring the machine back into the original condition.
Final check 4
Start the machine and verify that the repair was successful.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 75

Symptoms of Additional Systems Troubleshooting by Symptoms

8.4 SYMPTOMS OF ADDITIONAL SYSTEMS

SAD001 - Air conditioner for the cabin does not work
[1/2]
Trouble code
Trouble Air conditioner for the cabin does not work
SAD001

Contents of trouble The A/C system doesn't work properly or it shuts off.

For maintenance hints and the filling procedure also refer to PARTS & SERVICE NEWS AH05537,
Related information
latest release.
Problem that appears – A/C does not work and overheating in the operator's cab is possible.
on the machine – Operator’s health status may become critical (due to excessive heat in the operator's cab).
– Wrong or no maintenance of the A/C system.
Possible causes – Any electrical problem causes disconnection or short circuit in the wiring or any component
of the A/C system.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle & A/C switched ON.
An electrical problem
Yes may be present,
go to next step.
Wrong or no
Check the A/C maintenance history using the Refer to
maintenance of 1
A/C test tools. Using the A/C test P&S
the A/C system
Was the maintenance done as scheduled? tools, perform the NEWS
No
scheduled A/C AH05537
maintenance. latest
release
 Engine running at high idle & A/C switched ON.
– Check the A/C
WARNING system together
AIR CONDITIONING REFRIGERANT IS HARMFUL! with an A/C spe-
If air conditioner refrigerant gets into your eyes, it cialist and repair
may cause blindness. If it touches your skin, it may as necessary.
cause frostbite. Never touch refrigerant. – Refer to the A/C
manual and follow
In compliance with the regulations: the given proce-
dures. P&S
When working at the A/C circuit or when handling
Any electrical problem refrigerant R134a always observe the safety hints – Refer to the Wiring NEWS
causes disconnection given in the A/C manual and in the data sheet of Diagram and check AH05537
the refrigerant manufacturer. latest
or short circuit in the 2 the main fuse box
Work on the air conditioning system may only be release
wiring or any compo- and the relays in
nent of the A/C system carried out by persons having special knowledge the A/C unit. A/C
and experience in these systems. Manual
Always wear Safety Glasses and Safety Gloves when – Check the wiring
working on the A/C circuit. for disconnection or Wiring
Diagrams
short circuit.
1. Using the A/C test tools perform a standard check
of the A/C system. Locate the problem
and repair as
2. Check for trouble codes displayed at the A/C
necessary.
control unit 22S026a
(for details refer to the A/C manual).
3. Refer to the Wiring Diagram and check
for electrical problems.
Could you identify any problem?
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the repair was successful.

8 - 76 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of Additional Systems

View onto the A/C unit (SAD001)

[2/2]

Fig. 8-3 View onto the A/C unit (SAD001)

(1) A/C switch box (2) Fuse box (3) Relays

(4) A/C control unit (5) A/C unit

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 77

Symptoms of Additional Systems Troubleshooting by Symptoms

SAD002 - Air conditioner compressor clutch is burnt

[1/2]
Trouble code
Trouble Air conditioner compressor clutch is burnt
SAD002
– The A/C compressor clutch is burnt and inoperative.
Contents of trouble
– The A/C system does not work.
– For maintenance hints and the filling procedure also refer to the latest release of
PARTS & SERVICE NEWS AH05537.
Related information
– For repair hints concerning the clutch pulley also refer to the latest release of
PARTS & SERVICE NEWS AH05542 & AH06516 & AH06531.
– A/C does not work and excessive heat in the operator's cab is possible.
Problem that appears
– Frequent breakdowns of the A/C system may happen.
on the machine
– Shovel breakdown may happen (due to excessive heat in the operator's cab).
– Wrong or no maintenance of the A/C system.
Possible causes – A wrong refilling procedure has been performed.
– Wrong installation or alignment of the A/C compressor support.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle & A/C switched ON.
Yes Go to next step.
Wrong or no P&S
maintenance of 1 Check the maintenance history. Using the A/C test
NEWS
the A/C system tools, perform the
Was the maintenance done as scheduled? No AH05537
scheduled checking
latest
procedure.
release
A wrong refilling  Engine running at high idle & A/C switched ON.
procedure has
P&S
been performed WARNING NEWS
AIR CONDITIONING REFRIGERANT IS Yes Go to next step. AH05537
HARMFUL! latest
In compliance with release
the regulations: If air conditioner refrigerant gets into your
eyes, it may cause blindness. If it touches
When working at the your skin, it may cause frostbite. Never Repair and replace defective parts
A/C circuit or when as necessary.
touch refrigerant.
handling refrigerant
R134a always observe
Details for repair or replacement
the safety hints given in 1. Using the A/C test tools perform a
the A/C manual and in standard check of the A/C system. 1. Is the specified amount of the
the data sheet of the 2 specified compressor oil filled
refrigerant manufac- 2. Follow the appropriate filling procedure and
in?
turer. consider the filling capacity in the cooling
circuit. Make sure that the pressure safety No compressor oil or the wrong
Work on the air No
valve at the compressor is open before fill- amount of it causes early
conditioning system
ing the A/C circuit! defects of the A/C compressor.
may only be carried out
by persons having 3. Is the specified amount of the specified 2. Is the specified amount of refrig-
special knowledge compressor oil filled in? erant R134a filled in?
and experience in
4. Is the specified amount of refrigerant Too much R134a (only refilled
these systems.
R134a filled in? over the system pressure)
Always wear Safety causes an early defect of the
Glasses and Safety 5. Has the system been evacuated and is it
free of moisture? A/C compressor shaft seal or
Gloves when working
a burnt clutch.
on the A/C circuit. 6. Is the A/C system dry and clean?

8 - 78 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of Additional Systems

SAD002 - Air conditioner compressor clutch is burnt

[2/2]
Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF.
- Check the A/C compressor support for A/C
correct mounting, proper alignment, Manual
and secure tightening. Refer to the A/C P&S
Wrong installation or
Yes Manual and follow the NEWS
alignment of the A/C 3 - Check the drive belts for wear and correct
maintenance hints. AH05537
compressor support tension.
latest
- Check for the correct V-belt running direction release
between the pulleys.
Adjust, repair, or
Are the above items ok? No
replace as necessary.
Bring the machine back into the original condition.
Final check 4
Start the machine and verify that the repair was successful.

View onto the A/C compressor and its mounting (SAD002)

Fig. 8-4 View onto the A/C compressor and its mounting (SAD002)

(1) A/C compressor (3) Mounting bracket

(2) Belt running direction (4) Mounting bolt

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 79

Symptoms of Additional Systems Troubleshooting by Symptoms

SAD003 - Air conditioning system defective (pipes and hoses full of

moisture)
[1/2]
Trouble code
Trouble Air conditioning system defective (pipes and hoses full of moisture)
SAD003
– The A/C system does not work or causes frequent breakdowns.
Contents of trouble
– Insufficient cooling capacity.
– For maintenance hints and the filling procedure also refer to the latest release of
PARTS & SERVICE NEWS AH05537.
Related information
– For repair hints concerning the clutch pulley also refer to the latest release of
PARTS & SERVICE NEWS AH05542 & AH06516 & AH06531.
– A/C does not work and excessive heat in the operator's cab is possible.
Problem that appears
– Frequent breakdowns of the A/C system may happen.
on the machine
– Shovel breakdown may happen (due to excessive heat in the operator's cab).
– Wrong or no maintenance of the A/C system.
Possible causes – Maintenance or repair is impossible because of too much moisture in the pipes and hoses of the
A/C system.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Engine running at high idle & A/C switched ON.
Yes Go to next step.
Wrong or no P&S
maintenance of the 1 Check the maintenance history. Using the A/C test
NEWS
A/C system tools, perform the
Was the maintenance done as scheduled? No AH05537
scheduled checking
latest
procedure.
release

WARNING
AIR CONDITIONING REFRIGERANT IS HARMFUL!
If air conditioner refrigerant gets into your eyes, it may cause blindness. If
it touches your skin, it may cause frostbite. Never touch refrigerant.

In compliance with the regulations:

When working at the A/C circuit or when handling refrigerant R134a always
observe the safety hints given in the A/C manual and in the data sheet of the
refrigerant manufacturer. A/C
Maintenance or repair Work on the air conditioning system may only be carried out by persons having Manual
is impossible because special knowledge and experience in this system. P&S
of too much moisture in 2 Always wear Safety Glasses and Safety Gloves when working on the A/C circuit. NEWS
the pipes and hoses of AH05537
the A/C system 1. Disassemble the A/C system and check all parts for moisture. latest
If hoses and pipes are full of moisture, this is an indication that no release
or not enough maintenance of the A/C system has been done.
2. Replace any defective or contaminated parts.
Assemble and evacuate the system.
3. Refill the specified amount of the specified compressor oil and
the specified volume of the R134a refrigerant.
4. Carry out the regular maintenance as described in the
PARTS & SERVICE NEWS and use the appropriate tools
for testing and refilling the A/C system.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the repair was successful.

8 - 80 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by Symptoms Symptoms of Additional Systems

View onto an A/C filling and service station

[2/2]

Fig. 8-5 View onto an A/C filling and service station (P/N 232 324 40)

For details refer to the Tools and Accessories catalogue, part number 232 324 40.

SHOP-40 06279-xD-GB-1 PC3000-6 8 - 81

Symptoms of Additional Systems Troubleshooting by Symptoms

Please continue reading on the next page.

8 - 82 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by pump controller trouble codes (Multi Monitor)

9 TROUBLESHOOTING BY
PUMP CONTROLLER
TROUBLE CODES
(MULTI MONITOR)

SHOP-40 06279-xD-GB-1 PC3000-6 9 -1

 Troubleshooting by pump controller trouble codes (Multi Monitor)

DXAAKA - Solenoid-1(Pump-1) open circuit

DXABKA - Solenoid-2(Pump-2) open circuit
DXACKA - Solenoid-3(Pump-3) open circuit
DXADKA - Solenoid-4(Pump-4) open circuit
DXAEKA - Solenoid-5(Pump-5) open circuit
DXAFKA - Solenoid-6(Pump-6) open circuit
[1/2]
Trouble code
Trouble Solenoid-[x](Pump-[x]) open circuit [x = 1...6]
DXA(A...F)KA
Disconnection in the wiring between pump controller and EPC valve.
Overview: pump controller outputs, EPC, and pumps:
Pump controller (10K032)
Main pump Single pump Controller output Solenoid ground EPC
1f CN3.6 57K658f
Contents of trouble 1 CN3.3
1r CN3.16 57K658r
2f CN3.28 57K660f
2 CN3.13
2r CN3.36 57K660r
3f CN3.5 57K661f
3 CN3.23
3r CN3.15 57K661r

Failure detection criteria:

– Controller supply voltage≥ 18 V available
Related information
– Controller output > 0.2 A
– EPC return current < 0.1 A
– Multimonitor displays trouble code DXA(A...F)KA in the Service Menu, 02 Abnormality Record.
Action of controller – Buzzer: intermittent sound
– After fault correction the system immediately returns to standard control.
Problem that appears – The concerned swash plate(s) can’t be controlled (Qmin).
on the machine – Hydraulic performance is poor.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF.
Refer to the Wiring Diagram. Yes Go to next step.
1. Disconnect connector from pump control-
Harness problem or ler, e.g. connector CN3 with pin 6 for pump
connector disconnec- 1 Locate the problem in Rwire
1. the faulty circuit and
tion No max.1Ω
2. Check all relevant cable segments for con- repair or replace as
tinuity, e.g. from CN3.6 to CN3.3 (GND). necessary.
Is continuity of the relevant wiring circuit OK?
 Main key switch 20S001 OFF.
EPC solenoid valve If Rsolenoid is in the
defective 2 Disconnect connector from EPC valve and range of MΩ, replace Rsolenoid
(internal disconnection) measure resistance of EPC valve. the defective EPC 9.7±0.5Ω
solenoid valve.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

9 -2 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by pump controller trouble codes (Multi Monitor)

Wiring Diagram - EPC valve control (pump controller)

[2/2]

Fig. 9-6 Wiring Diagram - EPC valve control (pump controller)

SHOP-40 06279-xD-GB-1 PC3000-6 9 -3

 Troubleshooting by pump controller trouble codes (Multi Monitor)

DXAAKB - Solenoid-1(Pump-1) short circuit

DXABKB - Solenoid-2(Pump-2) short circuit
DXACKB - Solenoid-3(Pump-3) short circuit
DXADKB - Solenoid-4(Pump-4) short circuit
DXAEKB - Solenoid-5(Pump-5) short circuit
DXAFKB - Solenoid-6(Pump-6) short circuit
[1/2]
Trouble code
Trouble Solenoid-[x](Pump-[x]) short circuit [x = 1...6]
DXA(A...F)KB
Short circuit in the wiring between pump controller output and EPC valve
a) Current leading wire short to GND
b) EPC valve internal short circuit
Overview: pump controller outputs, EPC, and pumps:
Pump controller (10K032)
Main pump Single pump Controller output Solenoid ground EPC
Contents of trouble 1f CN3.6 57K658f
1 CN3.3
1r CN3.16 57K658r
2f CN3.28 57K660f
2 CN3.13
2r CN3.36 57K660r
3f CN3.5 57K661f
3 CN3.23
3r CN3.15 57K661r

Failure detection criteria:

Related information – Controller supply voltage≥ 18 V available
– EPC return current > 1.4 A during 0.1 s
– Multimonitor displays trouble code DXA(A...F)KB in the Service Menu, 02 Abnormality Record.
Action of controller – Buzzer: intermittent sound
– After fault correction the system immediately returns to standard control.
Problem that appears – The concerned swash plate(s) can’t be controlled (Qmin).
on the machine – Hydraulic performance is poor.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF.
EPC solenoid valve 1. Disconnect connector from EPC valve. Yes Go to next step.
defective 1 Rsolenoid
(internal short circuit) 2. Measure resistance of EPC valve. Replace the defective
No 9.7±0.5Ω
Is EPC valve resistance OK? EPC solenoid valve.
 Main key switch 20S001 OFF.
Refer to the Wiring Diagram.
Short circuit in wiring 1. Disconnect connector from pump control- If Rwire is in the range of ∞Ω,
or connector of EPC 2 ler, e.g. connector CN3 with pin 6 for pump repair or replace the defective Rwire
solenoid valve 1. wire segment or connector as max.1Ω
2. Check all relevant cable segments for con- necessary.
tinuity, e.g. from CN3.6 to CN3.3 (GND)
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

9 -4 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by pump controller trouble codes (Multi Monitor)

Wiring Diagram - EPC valve control (pump controller)

[2/2]

Fig. 9-7 Wiring Diagram - EPC valve control (pump controller)

SHOP-40 06279-xD-GB-1 PC3000-6 9 -5

 Troubleshooting by pump controller trouble codes (Multi Monitor)

DHPEMA - Pump-1/2 pressure sensor abnormality

DHPGMA - Pump-3/4 pressure sensor abnormality
DHPJMA - Pump-5/6 pressure sensor abnormality
[1/2]
Trouble code DHPEMA - Pump-1/2 pressure sensor abnormality
DHPEMA, DHPGMA Trouble DHPGMA - Pump-3/4 pressure sensor abnormality
DHPJMA DHPJMA - Pump-5/6 pressure sensor abnormality
– Electric power for pump pressure sensors is supplied by the pump controller (5V / 8mA max.)
– Analog ground for pump pressure sensors is also supplied by the pump controller.
Contents of trouble
– Pressure sensors have a signal range of 0.5 ~ 4.5 V for 0 ~ 500 bar.
– Pump control fails if a wrong pressure signal is generated or if the pressure signal is missing.
– Failure detection criteria:
Sensor signal voltage > 4.5V or sensor signal voltage < 0.3V for 1s
– If one ore more pressure transducers fail to work, the relating tandem pump displacement
is kept in Qmin.
– Without pressure signal the cut-off function is not available.
Pressure sensor allocation:
Related information
Main Pressure Input at
pump transducer pump controller
1 61B158a CN1.9
2 61B158b CN1.3
3 61B158c CN1.20

– Use the REAL TIME MONITOR for verification (03 Hydraulic., screen 1/3) to verify sensor.
– Multimonitor displays trouble code DHP(E/G/J)MA in the Service Menu, 02 Abnormality Record.
Action of controller – Buzzer: intermittent sound
– After fault correction the system immediately returns to standard control.
Problem that appears
Hydraulic performance is bad.
on the machine

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON.
1. Measure voltage between sensor terminal Yes Go to next step. Usupply 5V
B and GND (chassis).
1 Locate the problem in
1. Measure Voltage between sensor terminal in the wiring and repair
Connector or wiring B and A (analog GND). No as necessary.
defective in the 5V
Are 5V supply voltage present? Go to step 4.
circuit or in the
analog GND circuit  Main key switch 20S001 OFF.
Yes Go to next step. Rmax 1Ω
Check wiring between sensor terminal C and
2 Locate the problem in
the relevant for continuity.
No in the wiring and repair
Is continuity present?
as necessary.
 Engine running at high idle.
Defective pressure Check the input signal of the relevant pressure Yes Go to next step. 0.0 bar
sensor sensor on the K+ display. if no hydr.
61B158a REAL TIME MONITOR function is
3
61B158b  03 Hydraulic. Replace the relevant activated
61B158c  Screen 1/3 No
pressure sensor.
(internal malfunction) Does the REAL TIME MONITOR show the
correct value according to the PM-Clinic?

9 -6 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by pump controller trouble codes (Multi Monitor)

DHPEMA - Pump-1/2 pressure sensor abnormality

DHPGMA - Pump-3/4 pressure sensor abnormality
DHPJMA - Pump-5/6 pressure sensor abnormality
[2/2]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON
1. Check the controller output at connector/terminal – If any problem is
CN1.21 (GND) and CN1.22 (5V). found in the wiring:
2. Check wiring & terminals from the pump controller Repair or replace
back to the connection terminals at the X2 board. the wiring between
5V output voltage or pump controller
analog GND from
4 and X2 board as
pump controller is
necessary.
missing
– If there is no out-
put at CN1.21 and/
or CN1.22,
replace the pump
controller.
Bring the machine back into the original condition.
Final check 5
Start the machine and verify that the trouble code does not arise again.

Wiring Diagram - PWR & GND supply for pressure sensors (pumps 1...3)

Fig. 9-8 Wiring Diagram - PWR & GND supply for pressure sensors (pumps 1...3)

SHOP-40 06279-xD-GB-1 PC3000-6 9 -7

 Troubleshooting by pump controller trouble codes (Multi Monitor)

DLE2MA - Engine speed sensor abnormality

[1/2]
Trouble code
Trouble Engine speed sensor abnormality
DLE6MA
If the engine speed signal is missing, the pump control system can not regulate to stall speed.
– Check the KOMTRAX Plus monitor
– Is any trouble code displayed which indicates problems with the engine RPM?
Contents of trouble
– If any relevant trouble code is displayed follow its troubleshooting procedure first.
– Check the REAL TIME MONITOR 01 Engine 1, screen 1 of 5
– Is the correct engine speed displayed for 52B064?
The signal to the pump controller is interrupted between connector 51X111 terminals 25 & 26
Related information
and pump controller connector CN2 terminals 39 & 40.
– Multimonitor displays trouble code DLE2MA in the Service Menu, 02 Abnormality Record.
Controller / Monitoring – If the engine RPM signal is missing, the pump controller gives a fixed total torque for all main
pumps at 4000 Nm.
Action of controller Buzzer: intermittent sound
– Loading / normal machine operation is not possible.
Problem that appears
– Hydraulic performance is bad.
on the machine
– After fault correction the system immediately returns to standard control.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF.
Refer to the Wiring Diagram.
Wiring disconnection or Take 2 measurements for continuity:
short circuit between
52B064 pin 1 or 2 and a) Signal line
Refer to the Wiring
pump controller Controller input wiring between CN2.39
Diagram.
10K032 input CN2.39 1 and pin 1 of engine speed sensor including
Locate the problem in Rmax 1Ω
or CN2.40 connectors.
the faulty circuit and
(including connectors b) GND line repair or replace as
and terminals) Controller input wiring between CN2.40 necessary.
and pin 2 of engine speed sensor including
connectors.
 Main key switch 20S001 OFF.
1. Disconnect the connector from engine Replace the defective engine
Engine speed sensor
2 speed sensor. speed sensor 52B064. Rmax
52B064 defective
2. Measure the resistance between pins After repair check the system 850±50Ω
1 & 2. for proper function.
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

9 -8 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by pump controller trouble codes (Multi Monitor)

Wiring Diagram - engine RPM signal (52B064) to pump controller

[2/2]

Fig. 9-9 Wiring Diagram - engine RPM signal (52B064) to pump controller

SHOP-40 06279-xD-GB-1 PC3000-6 9 -9

 Troubleshooting by pump controller trouble codes (Multi Monitor)

DA25KP - 5V sensor1 power abnormality

[1/3]
Trouble code
Trouble 5V sensor1 power abnormality
DA25KP
Short circuit detected in the 5V supply line for the adjustment potentiometers and
pressure transducers.
Contents of trouble Cause for the short circuit can be:
– 5V line contacts GND
– Defective component (internal short circuit)
– Multimonitor displays trouble code DA25KP in the Service Menu, 02 Abnormality Record.
Related information – The displacement of main pumps* is kept in Qmin
– Pump 1...3 regulation is not possible.
Action of controller Buzzer: continuous sound
– Loading / normal machine operation is not possible.
Problem that appears
– Hydraulic performance is bad.
on the machine
– After fault correction reset by key switch OFF–ON.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON.
1. Disconnect one after the other: Replace the defective
• all 3 potentiometers Yes component and check
• all 3 pressure transducers for proper function.
2. After disconnection of each component,
check on the Multimonitor if the red "E"
in the fault message disappears.

Defective component
(internal short circuit)
Potentiometers:
11R096
11R097
1
11R098
Pressure transducers: No Go to next step.
61B158a
61B158b
61B158c
E displayed  Fault present
E removed  Fault no longer present

If the E disappears after disconnection of

one of the components, the disconnected
component is probably defective.
Does the E disappear from the Multimonitor
when one of the components is disconnected?

9 - 10 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by pump controller trouble codes (Multi Monitor)

DA25KP - 5V sensor1 power abnormality

[2/3]

Nominal
Possible cause Step Test condition & Inspection Procedure
value
Short circuit in the  Main key switch 20S001 OFF
wiring between pump 1. Refer to the Wiring Diagram Fig. 9-10.
controller connector
CN1.22 (5V) and 2. Disconnect connector CN1 from the pump control-
the potentiometers & ler.
pressure transducers. 3. Starting at CN1 terminal 22, check all wiring seg-
Potentiometers: ments one after the other, between CR710 and all
2 connected potentiometers & pressure transducers, Replace the defective wire segment
11R096
11R097 for continuity. or the defective connector/terminal.
11R098 4. If 5V line OK, check the GND wiring between
Pressure transducers: CR710 and components in the same way.
61B158a
61B158b
61B158c
Bring the machine back into the original condition.
Final check 3
Start the machine and verify that the trouble code does not arise again.

SHOP-40 06279-xD-GB-1 PC3000-6 9 - 11

 Troubleshooting by pump controller trouble codes (Multi Monitor)

Wiring Diagram - 5V sensor power supply for trouble code DA25KP

[3/3]

Fig. 9-10 Wiring Diagram - 5V sensor power supply for trouble code DA25KP

9 - 12 PC3000-6 SHOP-40 06279-xD-GB-1

Troubleshooting by pump controller trouble codes (Multi Monitor)

DA22KK - Pump Solenoid Power Low Error

[1/1]
Trouble code
Trouble Pump Solenoid Power Low Error
DA22KK

Contents of trouble An external power circuit supplies the EPC solenoid valves via circuit breaker 11F061.

Related information Failure detection criterion: Power supply < 18 V for 5 s

– Multimonitor displays trouble code DA22KK in the Service Menu, 02 Abnormality Record.
Action of controller
– After fault correction the system immediately returns to standard control.
– Pump regulation is not possible.

Problem that appears – The displacement of all main pumps is kept in Qmin.
on the machine – Loading / normal machine operation is not possible.
– Hydraulic performance is bad.
Trouble code Trouble Pump Solenoid Power Low Error

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 ON.
Refer to the Wiring Diagram and measure the Yes Go to next step. Utarget 24V
No power supply
1 input & output voltage of circuit breaker Locate the problem
from 11F061
11F061. No and repair or replace
Are 24 Volt available? as necessary.
 Main key switch 20S001 ON.
Refer to the Wiring Diagram and measure the input
voltage at connector CN3§ terminals 2, 12, 22.

Problem with the Locate the problem

voltage input at the 2 and repair or replace
the defective power Utarget 24V
pump controller
supply circuit or input
as necessary.

Bring the machine back into the original condition.

Final check 3
Start the machine and verify that the trouble code does not arise again.

SHOP-40 06279-xD-GB-1 PC3000-6 9 - 13

 Troubleshooting by pump controller trouble codes (Multi Monitor)

DA29KQ - Model Selection Abnormality

[1/1]
Trouble code
Trouble Model Selection Abnormality
DA29KQ

Contents of trouble Pump controller can not identify a model selection.

– The pump controller is used for all types of mining excavators.

– The pump controller needs the model selection information for identification of the appropriate
Related information software program and the associated shovel.
– The controller terminals CN2.2 and CN2.3 must not have any connection to GND otherwise a
different excavator type than PC3000 is selected at the pump controller.
– If the model selection is missing, the shovel runs in the emergency mode.
Action of controller
– Multimonitor displays trouble code DA29KQ in the Service Menu, 02 Abnormality Record.
– Pump regulation is not possible.

Problem that appears – The displacement of all main pumps is kept in Qmin.
on the machine – Loading / normal machine operation is not possible.
– Hydraulic performance is bad.

Nominal
Possible cause Step Test condition & Inspection Procedure
value
 Main key switch 20S001 OFF.
Pump controller termi-
nal(s) CN2.2 and/or The controller terminals CN2.2 and CN2.3 must not
1 Locate the problem and repair or
CN2.3 connection to have any connection to GND.
replace the defective cable (or con-
GND Check the cable (including connector & terminal)
nector / terminal) as necessary.
between pump controller and GND line.
Bring the machine back into the original condition.
Final check 2
Start the machine and verify that the trouble code does not arise again.

9 - 14 PC3000-6 SHOP-40 06279-xD-GB-1

Appendix

10 APPENDIX

SHOP-40 06279-xD-GB-1 PC3000-6 10 - 1

Comparison of Trouble Codes: VHMS (incl. retrofit kit) vs. KOMTRAX Plus Appendix

10.1 COMPARISON OF TROUBLE CODES:

VHMS (INCL. RETROFIT KIT) VS. KOMTRAX PLUS
Machines delivered with VHMS ex factory or machines upgraded with the VHMS-Retrofit Kit generate trouble
codes which are not displayed at the machine but are transmitted by the ORBCOMM system and also stored in the
service history of the VHMS-controller.

NOTE! This machines use TIER I emission standard and are equipped with ETM text display & pump con-
troller CR700. So this manual is not completely suitable for these machines.
The following tables will only give some hints for troubleshooting the VHMS related machines by
interchange of VHMS trouble codes and K+ trouble codes.

– Analogously follow the troubleshooting procedure of the ETM Message # in the

TROUBLESHOOTING MANUAL of the concerned machine.
– If a corresponding trouble code exists in this manual then analogously follow the troubleshooting procedure of
the K+ code in this manual.

10.1.1 VHMS TROUBLE CODES VS. KOMTRAX PLUS TROUBLE CODES

Explanation of the columns in the following Trouble Code chart

VHMS Code number generated by the VHMS system.

Column 1
Trouble Code

Column 2 Acoustic Signal 1 = an acoustic signal sounds if the relating trouble occurs

Column 3 7 segments LED Short-code of the displayed Trouble Code at the VHMS controller.

Column 4 Subject of trouble Subject of the generated trouble code.

Corresponding Analogously follow the troubleshooting procedure of the correspond-

Column 5
Trouble Code ing trouble code in this manual.

Analogously follow the troubleshooting procedure of the message

Column 6 ETM Message # number in the TROUBLESHOOTING MANUAL of the concerned
machine.

Column 7 Remarks Remarks concerning the VHMS trouble code.

Table of KOMTRAX Plus Trouble Codes:

7 segments LED
Acoustic Signal

ETM Message #

Corre-
VHMS
sponding
Trouble Subject of trouble Remarks
Trouble
Code
Code

DBBQKR M802 KOM-NET/c error DBBQKR - Analogously

Abnormality in VBAT voltage

DBB3KK M905 DBB3KK - Analogously
(VHMS VBAT<10V)

DBB0KK M901 VHMS source voltage Error DBB0KK - Analogously

10 - 2 PC3000-6 SHOP-40 06279-xD-GB-1

Appendix Comparison of Trouble Codes: VHMS (incl. retrofit kit) vs. KOMTRAX Plus

7 segments LED
Acoustic Signal

ETM Message #
Corre-
VHMS
sponding
Trouble Subject of trouble Remarks
Trouble
Code
Code

DBB0KQ MF11 VHMS Connector Mismatch DBB0KQ - Analogously

Wiring diagram of the

DBB5KP M904 VHMS 5V source sys Error - -
concerned machine.
n/a Wiring diagram of the
DHE5KY M331 Blowby Pres. Sensor Failure -
Cummins concerned machine.
n/a Wiring diagram of the
DHE5KB M332 Blowby Pres. Sensor Failure -
Cummins concerned machine.
n/a Wiring diagram of the
F@BBZL 1 M338 High Blowby Pressure -
Cummins concerned machine.
n/a Wiring diagram of the
DGE1KA M241 Eng Oil Temp.Sensor Failure -
Cummins concerned machine.
n/a Wiring diagram of the
DGE1KB M242 Eng Oil Temp.Sensor Failure -
Cummins concerned machine.
n/a Wiring diagram of the
B@BANS 1 M248 Eng Oil Temp. Overheat -
Cummins concerned machine.
n/a
DGE2KA M251 Coolant Temp. Sensor Failure 9 Analogously
Cummins
n/a
DGE2KB M252 Coolant Temp. Sensor Failure 9 Analogously
Cummins
n/a
B@BCNS 1 M258 Eng. Coolant Temp. Overheat 9 Analogously
Cummins

DGH2KA M521 Hyd. Oil Temp. Sensor Failure DGH2KA - Analogously

DGH2KB M522 Hyd. Oil Temp. Sensor Failure DGH2KB - Analogously

J100KA M511 Pilot Press. Sensor Failure J100KA - Analogously

J100KB M512 Pilot Press. Sensor Failure J100KB - Analogously

J100L6 1 M571 Abnomal Pilot Pump press J100L6 - Analogously

DGE5KA M401 Ambient air temp Sensor Failure DGE5KA - Analogously

DGE5KB M402 Ambient air temp Sensor Failure DGE5KB - Analogously

n/a 10 /
DHE4KB M261 Engine Oil Press. Sensor Failure Analogously
Cummins 24
n/a 10 /
DHE4KY M262 Engine Oil Press. Sensor Failure Analogously
Cummins 24
n/a 10 /
B@BAZG 1 M268 Eng. Oil Press. Low Analogously
Cummins 24
n/a
A000N1 1 M201 Engine Over Speed - Cummins via CAN
Cummins

SHOP-40 06279-xD-GB-1 PC3000-6 10 - 3

Comparison of Trouble Codes: VHMS (incl. retrofit kit) vs. KOMTRAX Plus Appendix

7 segments LED
Acoustic Signal

ETM Message #
Corre-
VHMS
sponding
Trouble Subject of trouble Remarks
Trouble
Code
Code

Central lubrication system grease

B@ADPQ M538 G00184 21 Analogously
level too low
Slew gear lubrication system grease
B@AEPQ M539 G00187 22 Analogously
level too low

B@ADMC 1 M537 Central lubrication system Failure G00185 18 Analogously

B@AEMC 1 M537 Slew gear lubrication system Failure G00188 19 Analogously

C641 1 M641 High Exh Temp #1 LB F@DANS - Analogously

C642 1 M642 High Exh Temp #2 LB F@DBNS - Analogously

C643 1 M643 High Exh Temp #3 LB F@DCNS - Analogously

C644 1 M644 High Exh Temp #4 LB F@DDNS - Analogously

C645 1 M645 High Exh Temp #5 LB F@DENS - Analogously

C646 1 M646 High Exh Temp #6 LB F@DFNS - Analogously

C651 1 M651 High Exh Temp #1 RB F@DGNS - Analogously

C652 1 M652 High Exh Temp #2 RB F@DHNS - Analogously

C653 1 M653 High Exh Temp #3 RB F@DJNS - Analogously

C654 1 M654 High Exh Temp #4 RB F@DKNS - Analogously

C655 1 M655 High Exh Temp #5 RB F@DLNS - Analogously

C656 1 M656 High Exh Temp #6 RB F@DMNS - Analogously

C671 M671 Exh Temp Ckt Failed #1 LB DGTAKX - Analogously

C672 M672 Exh Temp Ckt Failed #2 LB DGTBKX - Analogously

C673 M673 Exh Temp Ckt Failed #3 LB DGTCKX - Analogously

C674 M674 Exh Temp Ckt Failed #4 LB DGTDKX - Analogously

C675 M675 Exh Temp Ckt Failed #5 LB DGTEKX - Analogously

C676 M676 Exh Temp Ckt Failed #6 LB DGTFKX - Analogously

C721 M721 Exh Temp Ckt Failed #1 RB DGTGKX - Analogously

C722 M722 Exh Temp Ckt Failed #2 RB DGTHKX - Analogously

C723 M723 Exh Temp Ckt Failed #3 RB DGTJKX - Analogously

10 - 4 PC3000-6 SHOP-40 06279-xD-GB-1

Appendix Comparison of Trouble Codes: VHMS (incl. retrofit kit) vs. KOMTRAX Plus

7 segments LED
Acoustic Signal

ETM Message #
Corre-
VHMS
sponding
Trouble Subject of trouble Remarks
Trouble
Code
Code

C724 M724 Exh Temp Ckt Failed #4 RB DGTKKX - Analogously

C725 M725 Exh Temp Ckt Failed #5 RB DGTLKX - Analogously

C726 M726 Exh Temp Ckt Failed #6 RB DGTMKX - Analogously

Table 10-1 VHMS trouble codes vs. K+ trouble codes

SHOP-40 06279-xD-GB-1 PC3000-6 10 - 5

Comparison of Trouble Codes: VHMS (incl. retrofit kit) vs. KOMTRAX Plus Appendix

10.1.2 PUMP CONTROLLER CR700 VS. PUMP CONTROLLER CR710

TROUBLE CODES
Trouble messages of the pump controller CR700 are only displayed on the Multi Monitor in the cab base.
The trouble causes are analogously the same as for the pump controller CR710.

For further information refer to the SERVICE MANUAL of the concerned machine, section MAIN HYDRAULIC
PUMPS AND PUMP REGULATION.

Explanation of the columns in the following Trouble Code chart

Column 1 Trouble Code Code number shown at the Multi Monitor

Column 2 Display 1 = displayed once

Column 3 Acoustic Signal 1 = an acoustic signal sounds if the relating trouble occurs

The error/message is saved in a History Memory:

1 = Service & Operator History
Column 4 Memory
2 = Service History
3 = Operator History

Column 5 Message Displayed text of the Trouble Code

Analogously follow the troubleshooting procedure of the correspond-

Corresponding
Column 6 ing trouble code in this manual or the troubleshooting procedure in
Trouble Code
the TROUBLESHOOTING MANUAL of the concerned machine.

Corresponding
Column 7 Remarks concerning the trouble code.
Trouble Code

Table of Pump-Controller-Codes on Multi Monitor:

Acoustic Signal

Corre-
Memory
Display

Trouble sponding
Message Remarks
Code Trouble
Code

DXAAKA 1 1 2 P1 EPC Sol. Disc. DXAAKA Analogously

DXAAKB 1 1 2 P1 EPC Sol. S/C DXAAKB Analogously

DXABKA 1 1 2 P2 EPC Sol. Disc. DXABKA Analogously

DXABKB 1 1 2 P2 EPC Sol. S/C DXABKB Analogously

DXACKA 1 1 2 P3 EPC Sol. Disc. DXACKA Analogously

DXACKB 1 1 2 P3 EPC Sol. S/C DXACKB Analogously

DXADKA 1 1 2 P4 EPC Sol. Disc. DXADKA Analogously

DXADKB 1 1 2 P4 EPC Sol. S/C DXADKB Analogously

DXAEKA 1 1 2 P5 EPC Sol. Disc. DXAEKA Analogously

10 - 6 PC3000-6 SHOP-40 06279-xD-GB-1

Appendix Comparison of Trouble Codes: VHMS (incl. retrofit kit) vs. KOMTRAX Plus

Acoustic Signal
Corre-

Memory
Display
Trouble sponding
Message Remarks
Code Trouble
Code

DXAEKB 1 1 2 P5 EPC Sol. S/C DXAEKB Analogously

DXAFKA 1 1 2 P6 EPC Sol. Disc. DXAFKA Analogously

DXAFKB 1 1 2 P6 EPC Sol. S/C DXAFKB Analogously

DHPEMA 1 1 2 P1_2 Press. sensor abnormality DHPEMA Analogously

DHPGMA 1 1 2 P3_4 Press. sensor abnormality DHPGMA Analogously

DHPJMA 1 1 2 P5_6 Press. sensor abnormality DHPJMA Analogously

DLE2MA 1 1 2 Engine speed sensor abnormality DLE2MA Analogously

DA25KP 1 1 2 Sensor power abnormality DA25KP Analogously

Table 10-2 CR700 trouble codes vs. CR710 trouble codes

SHOP-40 06279-xD-GB-1 PC3000-6 10 - 7

Comparison of Trouble Codes: VHMS (incl. retrofit kit) vs. KOMTRAX Plus Appendix

Please continue reading on the next page.

10 - 8 PC3000-6 SHOP-40 06279-xD-GB-1

HYDRAULIC MINING EXCAVATOR

PC3000-6

Machine model Serial numbers

PC3000-6 06279, 06308, 06309, 06310, 06314 and up
with TIER2 & KOMTRAX Plus

50 Disassembly and assembly

Release 1 04/2017

® Copyright 2017 KOMATSU GERMANY GmbH

PC3000-6 1
2 PC3000-6
Table of contents

1 INTRODUCTION........................................................................................ 1-1
1.1 CONTENTS OF THIS BINDER .......................................................................................................... 1-2
1.2 FOREWORD ...................................................................................................................................... 1-2
1.3 RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND
MAINTENANCE OF HYDRAULIC MINING SHOVELS..................................................................... 1-4
1.4 EXPLANATION OF ABBREVIATIONS ............................................................................................. 1-5
1.5 DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL ................................................................... 1-6
1.6 PROCEDURES FOR DISASSEMBLING AND ASSEMBLING IN THIS MANUAL........................... 1-6

2 SAFETY ..................................................................................................... 2-1

2.1 OVERVIEW ........................................................................................................................................ 2-3
2.1.1 METHOD OF USING THIS MANUAL .................................................................................... 2-3
2.2 GENERAL PRECAUTIONS ............................................................................................................... 2-5
2.2.1 GENERAL .............................................................................................................................. 2-5
2.2.2 PERSONAL PROTECTIVE CLOTHING ................................................................................ 2-5
2.2.3 WHEN USING A HAMMER ................................................................................................... 2-6
2.2.4 PROPER TOOLS................................................................................................................... 2-6
2.2.5 PERSONNEL ......................................................................................................................... 2-6
2.2.6 FIRE PREVENTION .............................................................................................................. 2-7
2.2.7 UNAUTHORIZED MODIFICATION ....................................................................................... 2-7
2.3 PRECAUTIONS FOR MAINTENANCE AND REPAIR ...................................................................... 2-8
2.3.1 GENERAL PRECAUTIONS ................................................................................................... 2-8
2.3.2 KEEP WORK PLACE CLEAN AND TIDY.............................................................................. 2-8
2.3.3 PRECAUTIONS WHEN WELDING ....................................................................................... 2-9
2.3.4 PRECAUTION WITH HIGH PRESSURE FLUIDS................................................................. 2-9
2.3.4.1 HANDLING HIGH PRESSURE HOSES AND PIPES ............................................ 2-9
2.3.5 COMPRESSED AIR .............................................................................................................. 2-9
2.3.6 WASTE MATERIALS ........................................................................................................... 2-10

3 SUPERSTRUCTURE................................................................................. 3-1
3.1 SUPERSTRUCTURE OVERVIEW..................................................................................................... 3-2
3.2 MACHINERY HOUSE ........................................................................................................................ 3-4
3.2.1 MACHINERY HOUSE ROOF ................................................................................................ 3-6
3.2.1.1 DISASSEMBLING OF THE COMPLETE ROOF FRAME ...................................... 3-6
3.2.1.2 ASSEMBLING OF THE COMPLETE ROOF FRAME .......................................... 3-11
3.2.1.3 DISASSEMBLING OF SINGLE MACHINERY HOUSE ROOF COVER PLATES 3-15
3.2.1.4 ASSEMBLING OF SINGLE MACHINERY HOUSE ROOF COVER PLATES ..... 3-20
3.2.2 DIESEL ENGINE ................................................................................................................. 3-25
3.2.2.1 DISASSEMBLING OF THE DIESEL ENGINE ..................................................... 3-25
3.2.3 ASSEMBLING OF THE DIESEL ENGINE ........................................................................... 3-31
3.2.3.1 DISASSEMBLING OF THE ALTERNATOR ........................................................ 3-37
3.2.3.2 ASSEMBLING OF THE ALTERNATOR .............................................................. 3-39
3.2.3.3 DISASSEMBLING OF THE STARTER MOTOR ................................................. 3-40
3.2.3.4 ASSEMBLING OF THE STARTER MOTOR. ...................................................... 3-41

SHOP-50 06279-xD-GB-1 PC3000-6 TOC - 1

 3.2.4 BATTERIES ......................................................................................................................... 3-42
3.2.4.1 DISASSEMBLING OF THE BATTERIES............................................................. 3-42
3.2.4.2 ASSEMBLING OF THE BATTERIES................................................................... 3-44
3.2.5 FLEXIBLE COUPLING......................................................................................................... 3-45
3.2.5.1 DISASSEMBLING OF THE GEISLINGER COUPLING ....................................... 3-45
3.2.5.2 ASSEMBLING OF THE GEISLINGER COUPLING ............................................. 3-47
3.2.5.3 DISASSEMBLING OF THE CENTAFLEX COUPLING ASSEMBLY ................... 3-49
3.2.5.4 ASSEMBLING OF THE CENTAFLEX COUPLING ASSEMBLY ......................... 3-52
3.2.5.5 REPLACING THE RUBBER ROLLERS OF THE CENTAFLEX COUPLING ...... 3-54
3.2.6 RADIATOR FAN AND FAN DRIVE ASSEMBLY ................................................................. 3-56
3.2.6.1 DISASSEMBLING OF THE RADIATOR FAN AND THE FAN
DRIVE ASSEMBLY .............................................................................................. 3-57
3.2.6.2 ASSEMBLING OF THE RADIATOR FAN AND THE FAN DRIVE ASSEMBLY... 3-59
3.2.7 RADIATOR ASSEMBLY ...................................................................................................... 3-60
3.2.7.1 DISASSEMBLING OF THE RADIATOR ASSEMBLY.......................................... 3-60
3.2.7.2 ASSEMBLING OF THE RADIATOR ASSEMBLY................................................ 3-63
3.2.8 MAIN PUMPS ASSEMBLIES............................................................................................... 3-66
3.2.8.1 PREPARATORY WORKS FOR MAIN PUMP DISASSEMBLING ....................... 3-67
3.2.8.2 DISASSEMBLING OF MAIN PUMP 1...3 ASSEMBLY ........................................ 3-69
3.2.8.3 ASSEMBLING OF MAIN PUMP 1...3 ASSEMBLY .............................................. 3-72
3.2.9 PUMP DISTRIBUTOR GEAR BOX (PTO)........................................................................... 3-75
3.2.9.1 DISASSEMBLING OF THE PUMP DISTRIBUTOR GEAR BOX (PTO) .............. 3-75
3.2.9.2 ASSEMBLING OF THE PUMP DISTRIBUTOR GEAR BOX (PTO) .................... 3-78
3.2.9.3 DISASSEMBLING OF THE PTO OIL CIRCULATION PUMP.............................. 3-81
3.2.9.4 ASSEMBLING OF THE PTO OIL CIRCULATION PUMP.................................... 3-82
3.3 HYDRAULICS .................................................................................................................................. 3-84
3.3.1 HYDRAULIC OIL COOLER ASSEMBLY ............................................................................. 3-84
3.3.1.1 DISASSEMBLING OF HYDRAULIC COOLER FAN DRIVE PUMP .................... 3-84
3.3.1.2 ASSEMBLING OF HYDRAULIC COOLER FAN DRIVE PUMP .......................... 3-87
3.3.1.3 DISASSEMBLING OF THE HYDRAULIC COOLER FAN ASSEMBLY ............... 3-89
3.3.1.4 ASSEMBLING OF THE HYDRAULIC COOLER FAN ASSEMBLY ..................... 3-91
3.3.1.5 DISASSEMBLING OF HYDRAULIC COOLER FAN AND MOTOR..................... 3-94
3.3.1.6 ASSEMBLING OF HYDRAULIC COOLER FAN AND MOTOR........................... 3-96
3.3.1.7 DISASSEMBLING OF THE HYDRAULIC OIL COOLERS................................... 3-98
3.3.1.8 ASSEMBLING OF THE HYDRAULIC OIL COOLERS....................................... 3-101
3.3.1.9 DISASSEMBLING OF THE HYDRAULIC OIL COOLER ASSEMBLY............... 3-103
3.3.1.10 ASSEMBLING OF THE HYDRAULIC OIL COOLER ASSEMBLY..................... 3-107
3.3.2 PILOT OIL PUMP (GEAR PUMP)...................................................................................... 3-110
3.3.2.1 DISASSEMBLING OF THE PILOT OIL PUMP .................................................. 3-110
3.3.2.2 ASSEMBLING OF THE PILOT OIL PUMP ........................................................ 3-112
3.3.3 MAIN SHUT OFF VALVE................................................................................................... 3-114
3.3.3.1 DISASSEMBLING OF THE MAIN SHUT OFF VALVE ...................................... 3-114
3.3.3.2 ASSEMBLING OF THE MAIN SHUT OFF VALVE ............................................ 3-116
3.3.4 HYDRAULIC OIL TANK ..................................................................................................... 3-117
3.3.4.1 DISASSEMBLING OF THE HYDRAULIC OIL TANK......................................... 3-117
3.3.4.2 ASSEMBLING OF THE HYDRAULIC OIL TANK............................................... 3-123
3.3.5 MAIN CONTROL VALVE BLOCKS ................................................................................... 3-127
3.3.5.1 DISASSEMBLING OF THE MAIN CONTROL VALVE BLOCKS ....................... 3-127
3.3.5.2 ASSEMBLING OF THE MAIN CONTROL VALVE BLOCKS ............................. 3-133
3.3.5.3 DISASSEMBLING OF THE MRV AT THE MAIN CONTROL VALVE BLOCKS 3-138
3.3.5.4 ASSEMBLING OF THE MRV AT THE MAIN CONTROL VALVE BLOCKS ...... 3-139

TOC - 2 PC3000-6 SHOP-50 06279-xD-GB-1

 3.3.5.5 DISASSEMBLING OF SRV ON MAIN CONTROL VALVE BLOCK................... 3-140
3.3.5.6 ASSEMBLING OF SRV ON MAIN CONTROL VALVE BLOCKS ...................... 3-142
3.3.5.7 DISASSEMBLING OF ACV-/SRV-BLOCK ON MAIN CONTROL
VALVE BLOCKS ................................................................................................ 3-144
3.3.5.8 ASSEMBLING OF ACV-/SRV-BLOCK ON MAIN CONTROL VALVE BLOCKS 3-146
3.3.6 DISTRIBUTOR MANIFOLD ............................................................................................... 3-148
3.3.6.1 DISASSEMBLING OF ANTI CAVITATION VALVE BLOCKS AT THE
DISTRIBUTOR MANIFOLD ............................................................................... 3-150
3.3.6.2 ASSEMBLING OF ANTI CAVITATION VALVE BLOCKS AT THE
DISTRIBUTOR MANIFOLD ............................................................................... 3-152
3.3.6.3 DISASSEMBLING OF THROTTLE CHECK VALVES AT THE
DISTRIBUTOR MANIFOLD ............................................................................... 3-154
3.3.6.4 ASSEMBLING OF THROTTLE CHECK VALVES AT THE
DISTRIBUTOR MANIFOLD ............................................................................... 3-156
3.3.6.5 DISASSEMBLING OF THE DIFFUSER BLOCK ON THE
DISTRIBUTOR MANIFOLD (FSA ONLY) .......................................................... 3-158
3.3.6.6 ASSEMBLING OF THE DIFFUSER BLOCK ON THE
DISTRIBUTOR MANIFOLD (FSA ONLY) .......................................................... 3-160
3.3.6.7 DISASSEMBLING OF THE MANIFOLD ............................................................ 3-161
3.3.6.8 ASSEMBLING OF THE MANIFOLD .................................................................. 3-163
3.4 SLEW SYSTEM.............................................................................................................................. 3-165
3.4.1 SLEW GEAR BOX ............................................................................................................. 3-165
3.4.1.1 DISASSEMBLING OF THE SLEW GEAR BOX................................................. 3-166
3.4.1.2 ASSEMBLING OF THE SLEW GEAR BOX....................................................... 3-169
3.4.2 SLEW SERVICE BRAKE VALVE ...................................................................................... 3-172
3.4.2.1 DISASSEMBLING OF THE SLEW SERVICE BRAKE VALVE.......................... 3-172
3.4.2.2 ASSEMBLING OF THE SLEW SERVICE BRAKE VALVE................................ 3-174
3.4.3 SLEW MOTOR .................................................................................................................. 3-176
3.4.3.1 DISASSEMBLING OF THE SLEW MOTOR ...................................................... 3-177
3.4.3.2 ASSEMBLING OF THE SLEW MOTOR ............................................................ 3-180
3.4.4 SLEW PARKING BRAKE .................................................................................................. 3-182
3.4.4.1 DISASSEMBLING THE SLEW PARKING BRAKE (L&S) .................................. 3-183
3.4.4.2 ASSEMBLING THE SLEW PARKING BRAKE (L&S) ........................................ 3-186
3.4.4.3 DISASSEMBLING OF THE SLEW PARKING
BRAKE ASSEMBLY (SIEBENHAAR) ................................................................ 3-189
3.4.4.4 ASSEMBLING OF THE SLEW PARKING
BRAKE ASSEMBLY (SIEBENHAAR) ................................................................ 3-192
3.4.5 SLEW CIRCLE LUBRICATION PINION (DUMMY WHEEL) ............................................. 3-196
3.4.5.1 DISASSEMBLING OF THE SLEW CIRCLE LUBRICATION
PINION ASSEMBLY .......................................................................................... 3-196
3.4.5.2 ASSEMBLING OF THE SLEW CIRCLE LUBRICATION
PINION ASSEMBLY .......................................................................................... 3-197
3.4.6 SLEW CIRCLE................................................................................................................... 3-198
3.4.6.1 DISASSEMBLING OF THE SLEW CIRCLE ...................................................... 3-199
3.4.6.2 ASSEMBLING OF THE SLEW CIRCLE ............................................................ 3-202
3.5 LUBRICATION PUMPS ................................................................................................................. 3-206
3.5.1 DISASSEMBLING OF THE LUBRICATION PUMP ........................................................... 3-206
3.5.2 ASSEMBLING OF THE LUBRICATING PUMP ................................................................. 3-207

SHOP-50 06279-xD-GB-1 PC3000-6 TOC - 3

 3.6 OPERATOR’S CAB ....................................................................................................................... 3-208
3.6.1 DISASSEMBLING OF THE OPERATOR’S CAB............................................................... 3-208
3.6.2 ASSEMBLING OF THE OPERATOR’S CAB..................................................................... 3-213
3.6.3 CAB MOUNTS ................................................................................................................... 3-218
3.6.3.1 DISASSEMBLING OF THE CAB MOUNTS....................................................... 3-218
3.6.3.2 ASSEMBLING OF THE CAB MOUNTS............................................................. 3-220
3.6.4 FRONT WINDOW (WINDSHIELD) .................................................................................... 3-222
3.6.4.1 DISASSEMBLING OF THE FRONT WINDOW.................................................. 3-222
3.6.4.2 ASSEMBLING OF THE FRONT WINDOW........................................................ 3-223
3.6.5 OPERATOR’S SEAT ......................................................................................................... 3-224
3.6.5.1 DISASSEMBLING OF THE OPERATOR’S SEAT ............................................. 3-224
3.6.5.2 ASSEMBLING OF THE OPERATOR’S SEAT ................................................... 3-225
3.7 CAB BASE ..................................................................................................................................... 3-226
3.7.1 DISASSEMBLING OF THE CAB BASE............................................................................. 3-226
3.7.2 ASSEMBLING OF THE CAB BASE................................................................................... 3-228
3.8 ACCESS LADDER ......................................................................................................................... 3-230
3.8.1 DISASSEMBLING OF ACCESS LADDER ........................................................................ 3-231
3.8.2 ASSEMBLING OF ACCESS LADDER .............................................................................. 3-233
3.8.3 DISASSEMBLING OF ACCESS LADDER CYLINDER ..................................................... 3-234
3.8.4 ASSEMBLING OF ACCESS LADDER CYLINDER ........................................................... 3-236
3.9 COUNTERWEIGHT........................................................................................................................ 3-238
3.9.1 DISASSEMBLING OF THE COUNTERWEIGHT .............................................................. 3-239
3.9.2 ASSEMBLING OF THE COUNTERWEIGHT .................................................................... 3-241
3.10 FUEL TANK.................................................................................................................................... 3-244
3.10.1 DISASSEMBLING OF THE FUEL TANK........................................................................... 3-244
3.10.2 ASSEMBLING OF THE FUEL TANK................................................................................. 3-248
3.11 SUPERSTRUCTURE LIFTING ...................................................................................................... 3-252
3.11.1 DISASSEMBLING THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE.............. 3-252
3.11.2 ASSEMBLING THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE.................... 3-256

4 UNDERCARRIAGE.................................................................................... 4-1
4.1 UNDERCARRIAGE OVERVIEW........................................................................................................ 4-2
4.2 TRAVEL SYSTEM.............................................................................................................................. 4-4
4.2.1 CRAWLER TRACK ................................................................................................................ 4-4
4.2.1.1 CHANGING THE CRAWLER TRACK.................................................................... 4-4
4.2.2 SPROCKET ......................................................................................................................... 4-11
4.2.2.1 DISASSEMBLING OF THE SPROCKET ............................................................. 4-11
4.2.2.2 ASSEMBLING OF THE SPROCKET ................................................................... 4-14
4.2.3 GUIDE WHEELS (IDLERS) ................................................................................................. 4-17
4.2.3.1 DISASSEMBLING OF THE GUIDE WHEEL ASSEMBLY ................................... 4-17
4.2.3.2 ASSEMBLING OF THE GUIDE WHEEL ASSEMBLY ......................................... 4-19
4.2.4 TRACK TENSIONING ACCUMULATORS .......................................................................... 4-22
4.2.4.1 DISASSEMBLING OF THE LOW PRESSURE ACCUMULATORS..................... 4-22
4.2.4.2 ASSEMBLING OF THE LOW PRESSURE ACCUMULATORS........................... 4-24
4.2.4.3 DISASSEMBLING OF THE HIGH PRESSURE ACCUMULATORS.................... 4-26
4.2.4.4 ASSEMBLING OF THE HIGH PRESSURE ACCUMULATORS.......................... 4-27
4.2.5 TRACK TENSION VALVE BLOCK ...................................................................................... 4-28
4.2.5.1 DISASSEMBLING OF THE TRACK TENSIONING VALVE BLOCK ................... 4-28
4.2.5.2 ASSEMBLING OF THE TRACK TENSIONING VALVE BLOCK ......................... 4-29

TOC - 4 PC3000-6 SHOP-50 06279-xD-GB-1

 4.2.6 TRACK TENSIONING CYLINDERS .................................................................................... 4-31
4.2.6.1 DISASSEMBLING OF THE TRACK TENSIONING CYLINDERS ....................... 4-31
4.2.6.2 ASSEMBLING OF THE TRACK TENSIONING CYLINDERS ............................. 4-33
4.2.7 SUBSTITUTE THE HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM......... 4-35
4.2.7.1 PRECURSORY WORK........................................................................................ 4-35
4.2.7.2 REPLACE THE HYDRAULIC HOSES INSIDE THE CAR BODY ........................ 4-37
4.2.7.3 REPLACE THE HYDRAULIC HOSE BETWEEN CAR BODY AND
CRAWLER FRAME.............................................................................................. 4-37
4.2.7.4 REPLACE THE HYDRAULIC HOSES INSIDE THE CRAWLER FRAME ........... 4-39
4.2.7.5 SUBSEQUENT WORK ........................................................................................ 4-39
4.2.8 TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE).................................................. 4-40
4.2.8.1 DISASSEMBLING OF THE TRAVEL BRAKE VALVE BLOCK............................ 4-40
4.2.8.2 ASSEMBLING OF THE TRAVEL BRAKE VALVE BLOCK.................................. 4-42
4.2.9 TRAVEL MOTOR................................................................................................................. 4-43
4.2.9.1 DISASSEMBLING OF THE TRAVEL MOTORS .................................................. 4-43
4.2.9.2 ASSEMBLING OF THE TRAVEL MOTORS ........................................................ 4-45
4.2.10 TRAVEL PARKING BRAKE................................................................................................. 4-48
4.2.10.1 DISASSEMBLING OF THE TRAVEL PARKING BRAKE .................................... 4-49
4.2.10.2 ASSEMBLING OF THE TRAVEL PARKING BRAKE .......................................... 4-51
4.2.11 TRAVEL GEAR BOX ........................................................................................................... 4-52
4.2.11.1 DISASSEMBLING OF THE TRAVEL GEAR BOX............................................... 4-53
4.2.11.2 ASSEMBLING OF THE TRAVEL GEAR BOX ..................................................... 4-57
4.2.12 CARRIER ROLLER ............................................................................................................. 4-60
4.2.12.1 DISASSEMBLING OF THE CARRIER ROLLER ASSEMBLY............................. 4-60
4.2.12.2 ASSEMBLING OF THE CARRIER ROLLER ASSEMBLY................................... 4-62
4.2.13 TRACK ROLLER ................................................................................................................. 4-64
4.2.13.1 DISASSEMBLING OF THE TRACK ROLLER ASSEMBLY................................. 4-64
4.2.13.2 ASSEMBLING OF THE TRACK ROLLER ASSEMBLY....................................... 4-66
4.3 CAR BODY....................................................................................................................................... 4-68
4.3.1 DISASSEMBLING OF THE CAR BODY AND THE CRAWLER CARRIERS ...................... 4-68
4.3.2 ASSEMBLING OF THE CAR BODY AND THE CRAWLER CARRIERS ............................ 4-74
4.3.2.1 INSTALL CRAWLER CARRIER MOUNTING BOLTS ......................................... 4-80
4.3.3 ROTARY JOINT................................................................................................................... 4-82
4.3.3.1 DISASSEMBLING OF THE ROTARY JOINT ...................................................... 4-82
4.3.3.2 ASSEMBLING OF THE ROTARY JOINT ............................................................ 4-84

5 ATTACHMENT........................................................................................... 5-1
5.1 REPAIR PROCEDURES.................................................................................................................... 5-2
5.1.1 REPLACEMENT OF BUSHINGS AT THE ATTACHMENT ................................................... 5-2
5.1.1.1 REMOVAL OF THE BUSHINGS............................................................................ 5-2
5.1.1.2 INSTALLATION OF THE BUSHINGS.................................................................... 5-3
5.1.2 GENERAL INSTALLATION INSTRUCTIONS FOR ATTACHMENT PINS............................ 5-4
5.2 BACKHOE.......................................................................................................................................... 5-6
5.2.1 OVERVIEW............................................................................................................................ 5-6
5.2.2 PIN SEALING BUCKET - STEERING ROD - BUCKET LINK ROD....................................... 5-8
5.2.3 BOOM .................................................................................................................................. 5-10
5.2.3.1 DISASSEMBLING OF THE BOOM...................................................................... 5-10
5.2.3.2 ASSEMBLING OF THE BOOM............................................................................ 5-12
5.2.3.3 DISASSEMBLING OF BOOM CYLINDERS ........................................................ 5-15
5.2.3.4 ASSEMBLING OF BOOM CYLINDERS .............................................................. 5-20

SHOP-50 06279-xD-GB-1 PC3000-6 TOC - 5

 5.2.4 STICK ASSEMBLY .............................................................................................................. 5-24
5.2.4.1 DISASSEMBLING OF THE STICK ...................................................................... 5-24
5.2.4.2 ASSEMBLING OF THE STICK ............................................................................ 5-28
5.2.4.3 DISASSEMBLING OF THE STICK CYLINDERS................................................. 5-32
5.2.4.4 ASSEMBLING OF THE STICK CYLINDERS....................................................... 5-37
5.2.5 BUCKET AND STEERING................................................................................................... 5-43
5.2.5.1 DISASSEMBLING OF THE BUCKET .................................................................. 5-43
5.2.5.2 ASSEMBLING OF THE BUCKET ........................................................................ 5-47
5.2.5.3 DISASSEMBLING OF BUCKET CYLINDERS..................................................... 5-50
5.2.5.4 ASSEMBLING OF BUCKET CYLINDERS........................................................... 5-57
5.2.5.5 DISASSEMBLING OF THE BUCKET LINK ROD ................................................ 5-64
5.2.5.6 ASSEMBLING OF THE BUCKET LINK ROD ...................................................... 5-67
5.2.5.7 DISASSEMBLING OF THE STEERING RODS ................................................... 5-70
5.2.5.8 ASSEMBLING OF THE STEERING ROD ........................................................... 5-76
5.2.6 HYDRAULIC HOSES AT THE BACKHOE ATTACHMENT................................................. 5-80
5.2.6.1 REPLACE THE BOOM ARC HOSES .................................................................. 5-80
5.2.6.2 REPLACE THE BOOM CYLINDER HOSES........................................................ 5-84
5.2.6.3 REPLACE THE STICK CYLINDER HOSES ........................................................ 5-88
5.2.6.4 REPLACE THE BUCKET CYLINDER HOSES .................................................... 5-92
5.3 FACE SHOVEL ................................................................................................................................ 5-96
5.3.1 OVERVIEW.......................................................................................................................... 5-96
5.3.2 USING THE CYLINDER MOUNTING DEVICE FOR FRONT SHOVEL
ATTACHMENTS (PN 967 000 40)....................................................................................... 5-98
5.3.2.1 DESIGNATED USAGE ........................................................................................ 5-99
5.3.2.2 NON-DESIGNATED USAGE ............................................................................... 5-99
5.3.3 BOOM ................................................................................................................................ 5-100
5.3.3.1 DISASSEMBLING OF THE BOOM.................................................................... 5-100
5.3.3.2 ASSEMBLING OF THE BOOM.......................................................................... 5-103
5.3.3.3 DISASSEMBLING OF THE BOOM CYLINDERS .............................................. 5-106
5.3.3.4 ASSEMBLING OF THE BOOM CYLINDERS .................................................... 5-111
5.3.4 STICK ASSEMBLY ............................................................................................................ 5-116
5.3.4.1 DISASSEMBLING OF THE STICK .................................................................... 5-116
5.3.4.2 ASSEMBLING OF THE STICK .......................................................................... 5-120
5.3.4.3 DISASSEMBLING OF THE STICK CYLINDERS............................................... 5-124
5.3.4.4 ASSEMBLING OF THE STICK CYLINDERS..................................................... 5-128
5.3.5 BULL CLAM BUCKET........................................................................................................ 5-132
5.3.5.1 DISASSEMBLING OF THE BULL CLAM BUCKET ........................................... 5-132
5.3.5.2 ASSEMBLING OF THE BULL CLAM BUCKET ................................................. 5-136
5.3.5.3 DISASSEMBLING OF THE BUCKET CYLINDERS........................................... 5-140
5.3.5.4 ASSEMBLING OF THE BUCKET CYLINDERS................................................. 5-144
5.3.5.5 DISASSEMBLING OF THE CLAM CYLINDERS ............................................... 5-149
5.3.5.6 ASSEMBLING OF THE CLAM CYLINDERS ..................................................... 5-154
5.3.6 HYDRAULIC HOSES AT THE FACE SHOVEL ATTACHMENT ....................................... 5-160
5.3.6.1 REPLACE THE BOOM ARC HOSES ................................................................ 5-160
5.3.6.2 REPLACE THE BOOM CYLINDER HOSES...................................................... 5-164
5.3.6.3 REPLACE THE STICK ARC HOSES................................................................. 5-168
5.3.6.4 REPLACE THE STICK CYLINDER HOSES ...................................................... 5-176
5.3.6.5 REPLACE THE BUCKET CYLINDER HOSES .................................................. 5-180
5.3.6.6 REPLACE THE CLAM CYLINDER HOSES....................................................... 5-184

TOC - 6 PC3000-6 SHOP-50 06279-xD-GB-1

 5.4 METERING VALVES (GREASE INJECTORS) AT THE ATTACHMENT ..................................... 5-192
5.4.1 DISASSEMBLING OF THE METERING VALVES (GREASE INJECTORS)..................... 5-192
5.4.2 ASSEMBLING OF THE METERING VALVES (GREASE INJECTORS)........................... 5-194
5.5 GROUND ENGAGING TOOLS (GET) ........................................................................................... 5-195
5.5.1 DISASSEMBLING AND ASSEMBLING OF THE GET ...................................................... 5-195
5.6 CYLINDER BYPASS TEST ........................................................................................................... 5-197

6 SERVICE INFORMATION ......................................................................... 6-1

6.1 FLUIDS AND LUBRICANTS.............................................................................................................. 6-2
6.2 LIFTING GEARS ................................................................................................................................ 6-2
6.3 SAFETY HINTS FOR SLING ACCESSORY ..................................................................................... 6-4
6.4 WORK INSTRUCTIONS .................................................................................................................... 6-5
6.4.1 SURFACE COATING WITH INTERZINC 697 ....................................................................... 6-5
6.4.2 HINTS FOR HYDRAULIC HOSE INSTALLATION ................................................................ 6-7
6.4.3 REMOVE / INSTALL THE CRAWLER CARRIER ............................................................... 6-10
6.5 WEIGHT TABLES ............................................................................................................................ 6-11
6.5.1 SUPERSTRUCTURE .......................................................................................................... 6-11
6.5.2 UNDERCARRIAGE ............................................................................................................. 6-13
6.5.3 BACKHOE ATTACHMENT (BHA) ....................................................................................... 6-14
6.5.4 FACE SHOVEL ATTACHMENT (FSA) ................................................................................ 6-15
6.6 TORQUE CHARTS ACCORDING TO KOMATSU COMPANY STANDARD ................................. 6-16
6.6.1 METRIC STANDARD THREAD........................................................................................... 6-16
6.6.2 METRIC FINE THREAD ...................................................................................................... 6-17
6.6.3 CUMMINS MOTOR TORQUES - METRIC.......................................................................... 6-18
6.6.4 CUMMINS MOTOR TORQUES - U.S. CUSTOMARY......................................................... 6-18
6.6.5 SAE-FLANGE CONNECTIONS........................................................................................... 6-19
6.7 BLIND PLUGS ................................................................................................................................. 6-20
6.7.1 DUMMY PLATES FOR SAE–FLANGES ............................................................................. 6-20
6.7.2 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH ........................................... 6-22
6.7.3 PLUGS AND FITTINGS ACCORDING TO DIN 2353.......................................................... 6-23
6.8 CONVERSION TABLE..................................................................................................................... 6-24
6.8.1 METHOD OF USING THE CONVERSATION TABLE......................................................... 6-24
6.8.2 MILLIMETER - INCH & KILOGRAM - POUND .................................................................... 6-25
6.8.3 LITER - U.S. GALLON & LITER - U.K. GALLON................................................................. 6-26
6.8.4 NM- FT.LB ........................................................................................................................... 6-27
6.8.5 BAR - PSI - KPA - MPA ....................................................................................................... 6-28
6.8.6 TEMPERATURE .................................................................................................................. 6-29
6.9 TOOLS ............................................................................................................................................. 6-30
6.9.1 STANDARD TOOL CASE.................................................................................................... 6-30
6.9.2 USED SPECIAL TOOLS (OVERVIEW) ............................................................................... 6-32

7 PARTS & SERVICE NEWS ....................................................................... 7-1

7.1 LIST OF THE PARTS AND SERVICE NEWS ................................................................................... 7-2

SHOP-50 06279-xD-GB-1 PC3000-6 TOC - 7

 Please continue reading on the next page.

TOC - 8 PC3000-6 SHOP-50 06279-xD-GB-1

Introduction

1 INTRODUCTION

SHOP-50 06279-xD-GB-1 PC3000-6 1 -1

Contents of this binder Introduction

1.1 CONTENTS OF THIS BINDER

With this Disassembly & Assembly Manual, KOMATSU provides you with the description of proper removal and
replacement procedures of main components of your hydraulic mining shovel.

The given procedures in this manual are for skilled and special trained personnel only.

1.2 FOREWORD
Observe the instructions in this manual for:

– your Personal SAFETY

– Operating SAFETY, and
– READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.

With this MANUAL KOMATSU provides you with the procedures for the disassembling and assembling of the
major systems of the Hydraulic Excavator PC3000-6.

All necessary procedures for disassembling and assembling are given. Although, depending on modifications dur-
ing production, the described procedures may differ at your machine in some details.

How do you find "your" desired information?

In the TABLE OF CONTENT all the functions and components are shown in their sequence of description.

Periodic preventive inspections and maintenance are the surest means of keeping the machine in proper working
order. Prompt detection and correction of minor irregularities, and immediate replacement of worn out or broken
parts will prevent failures and avoid expenses.

Replace damaged graphics and symbols at the machine.

Observe safety precautions to prevent injury and damage.

If after reading this Disassembly & Assembly Manual you can give us suggestions and comments for improvement
- please do not hesitate to contact us.

Komatsu Germany GmbH

Mining Division

Buscherhofstr. 10
40599 Düsseldorf
GERMANY

1 -2 PC3000-6 SHOP-50 06279-xD-GB-1

Introduction Foreword

Please note:

Personnel entrusted with work on the machine must have read the ASSEMBLY MANUAL, the OPERATION-
LUBRICATION- and MAINTENANCE MANUAL and in particular the section on SAFETY before beginning to work.
Reading the instructions after work has begun, is too late.

Warranty / guarantee

Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturers
guarantee.

If the Shovel is equipped with a fire suppression system, make sure that the system is ready for operation.

In order to keep your Shovel in first-class operating condition use only genuine spare and wear parts.

The use of any part other than the genuine parts releases the KOMATSU GERMANY GmbH from any guarantee.

Service

For all questions related to your Shovel please contact your local Service Center.

In all your written or phoned inquiries please indicate the model and serial number of your Shovel.

SHOP-50 06279-xD-GB-1 PC3000-6 1 -3

Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels Introduction

1.3 RECOMMENDATIONS FOR ENVIRONMENTALLY

FRIENDLY OPERATION AND MAINTENANCE OF
HYDRAULIC MINING SHOVELS
Operation

– Avoid engine idling over long periods. Long periods of idling, more than 10 minutes, will not only waste fuel,
but is also harmful to the engine.
– Avoid operation against the main relief valves of the hydraulic system.
Move control lever to neutral position before the loader attachment stalls due to overload.
– Position trucks in such a way, that loading operation can be carried out in a safe and economic manner.
Avoid swing angles over 90°.

Maintenance and repair

– Preserve our environment. To prevent environmental pollution, pay careful attention to the method of
disposing waste materials.
– Always drain fluids from your machine into containers. Never drain fluids onto the ground or dump it into the
sewage system rivers, the sea, or lakes.
Disposal of harmful material, such as oil, solvent, filters and batteries has to be processed in accordance with envi-
ronmental regulations and laws.

1 -4 PC3000-6 SHOP-50 06279-xD-GB-1

Introduction Explanation of abbreviations

1.4 EXPLANATION OF ABBREVIATIONS

Abbreviation Definition

AC Alternating Current

A/C Air Condition

ACV Anti-Cavitation Valve

API American Petroleum Institute

BHA Backhoe Attachment

°C Degree Celsius

CCW Counterclockwise

CW Clockwise

CLS1 Central Lubrication System - attachment

CLS2 Central Lubrication System - Superstructure

FSA Front Shovel Attachment

GET Ground Engaging Tools

K+ KOMTRAX Plus

LED Light Emitting Diode

L.H. Left Hand

K+ KOMTRAX Plus monitor

MRV Main Relief Valve

PTO Power Take-Off (Pump Distributor Gear)

Qmax Maximum pump delivery = maximum swash plate angle

Qmin Minimum pump delivery = minimum swash plate angle

R.H. Right Hand

RPM Revolutions Per Minute [1/min]

SLS Swing circle pinion Lubrication System

SRV Secondary Relief Valve

Table 1-1 Abbeviations

SHOP-50 06279-xD-GB-1 PC3000-6 1 -5

Diagrams and illustrations in this manual Introduction

1.5 DIAGRAMS AND ILLUSTRATIONS IN THIS

MANUAL
Wiring Diagrams & Hydraulic Diagrams

– During work or troubleshooting always make sure to use your Wiring Diagrams and Hydraulic Diagrams which
are assigned to your machine.
– Due to variable requirements in many respects, the samples of diagrams shown in this manual can not meet
the actual state of each machine in every case.

Illustrations & technical drawings

– The illustrations and technical drawings shown in this manual correspond to state of the technology at the time
of press date.
– Modifications of shown components are possible prior notice.

1.6 PROCEDURES FOR DISASSEMBLING AND

ASSEMBLING IN THIS MANUAL
– The procedures for disassembling and assembling which are given in this manual correspond to state of the
technology at the time of press date.
– Modifications of shown components are possible prior notice.
– Working steps may include steps or procedures that must be carried ot prior to the described steps, i.e. remov-
ing a cover to gain access to the shown component.

1 -6 PC3000-6 SHOP-50 06279-xD-GB-1

Safety

2 SAFETY

IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS

INJURY OR DEATH.
Please read and make sure that you fully understand the precautions described in this section and the
safety labels on the machine. When operating or servicing the machine, always follow these precaution
strictly.

SHOP-50 06279-xD-GB-1 PC3000-6 2 -1

 Safety

Please continue reading on the next page.

2 -2 PC3000-6 SHOP-50 06279-xD-GB-1

Safety Overview

2.1 OVERVIEW

2.1.1 METHOD OF USING THIS MANUAL

Figure references that appear in the operation procedures use the format (4-12, Pos. 4), which means position
number 4 in figure 12 of section 4.

Table references that appear in the operation procedures use the format (Table 4-12), which means Table 12 of
section 4.

Special requirements such as listing of special tools or size or numbers of blind plugs etc. are listed in a table at
the beginning of each operation procedure.
Special tools that appear in the lists are given with part name, part number, and quantity (2 x thread protector, PN
409 329 40).

The following symbols / labels are used in the manual to designate additional information:

Kind and amount of drained fluids

a (e.g. drain oil, 1500 liters).

Lifting weight of an assembly

(e.g. 140 kg).

d Kind and amount of fluids to fill

(e.g. fill oil, 1500 liters).

b Special tightening torques for bolts etc., if not according to the KOMATSU company standard
(e.g. 129 Nm).

General information concerning a section

(e.g. tightening torques according to the KOMATSU company standard).

Special authorized / qualified personnel is required

(e.g. certified electrician).

REMARKS: Designates additional information or hints.

NOTE! Designates general safety relevant information or hints which have no direct reference to an action.

1. 2. 3. Used to designate working steps.

– Used to designate itemization.

↑ /↓ Used in tables to indicate that an entry continues on the previous / next page

SHOP-50 06279-xD-GB-1 PC3000-6 2 -3

Overview Safety

To identify important safety messages in the manual the following signal words are used. This safety messages
have a direct reference to following actions:

DANGER
This signal word indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.

WARNING
This signal word indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.

CAUTION
This signal word indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.

NOTICE
This signal word is used to alert you to information that must be followed to avoid damage to machine
components. This precaution is given where the components may be damaged or the service life reduced
if the precaution is not followed.

2 -4 PC3000-6 SHOP-50 06279-xD-GB-1

Safety General precautions

2.2 GENERAL PRECAUTIONS

2.2.1 GENERAL
NOTE! Country-specific rules and regulations take precedence over all procedures and safety notes in this
manual.

Always follow the precautions below to prepare for action if any

injury or fire should occur, refer to Fig. 2-1.

– Be sure that fire extinguishers have been provided and read

the labels to ensure that you know how to use them in emer-
gencies.
– Carry out periodic inspection and maintenance to ensure that
the fire extinguisher can always be used.
– Provide a first aid kit. Carry out periodic checks and add to
the contents if necessary.

Fig. 2-1

2.2.2 PERSONAL PROTECTIVE CLOTHING

Refer to Fig. 2-2:

– Do not wear loose clothing and accessories. If these catch on

the control levers or moving parts, there is a danger that it
may cause the machine to move unexpectedly.
– Wear safety clothing, goggles, respirator and other safety
devices, whenever working conditions make this necessary.
Observe the local safety rules.
– If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine, so
tie your hair up and be careful not to let it get caught.
– Check that all protective equipment functions properly before
using it. Fig. 2-2

SHOP-50 06279-xD-GB-1 PC3000-6 2 -5

General precautions Safety

2.2.3 WHEN USING A HAMMER

When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury.
Always do as follows.

– If hard metal parts such as pins, bucket teeth, cutting edges,

or bearings are hit with a hammer, there is a hazard that
pieces might be scattered and cause injury. Always wear
safety glasses and gloves (Fig. 2-3).
– When hitting pins or bucket teeth, there is a hazard that bro-
ken pieces might be sent flying and injure people in the sur-
rounding area. Always check that there is no one in the
surrounding area.
– There is a hazard that the pin hit with strong force may fly out
and injure people in the surrounding area.

Fig. 2-3

2.2.4 PROPER TOOLS

Refer to Fig. 2-4:

– Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools
or improper use of the tools could cause serious personal
injury.

Fig. 2-4

2.2.5 PERSONNEL
– Assembly, commissioning and operation, disassembly, service (including maintenance and repair) require
basic mechanical, electrical and hydraulic knowledge, as well as knowledge of the appropriate technical
terms.
In order to ensure safety, these activities may therefore only be carried out by qualified technical personnel or
an instructed person under the direction and supervision of qualified personnel.
– Qualified personnel are those who can recognize possible hazards and institute the appropriate safety mea-
sures due to their professional training, knowledge, and experience, as well as their understanding of the rele-
vant conditions pertaining to the work to be done.
– Qualified personnel must observe the rules relevant to the subject area.

2 -6 PC3000-6 SHOP-50 06279-xD-GB-1

Safety General precautions

2.2.6 FIRE PREVENTION

– Do not bring any flame or fire close to flammable substances such as fuel, oil, antifreeze, or window washer
fluid. There is a danger they may catch fire. To prevent fire, always observe the following:
Refer to Fig. 2-5:

– Do not smoke or use any flame near fuel or other flammable

substances.
– Tighten all fuel and oil caps securely.
– Be careful not to spill flammable substances on overheated
surfaces or on parts of the electrical system.
– After adding fuel or oil, wipe up any spillage.
– Put greasy rags and other flammable materials into a safe
container to maintain safety in the workplace.
– When washing parts with oil, use a non-flammable oil. Do not
use diesel oil or gasoline. There is a danger that they may Fig. 2-5
catch fire.

– Do not weld or use a cutting torch to cut any pipe or tubes that contain flammable liquids.
– Determine well ventilated areas for storing oil and fuel. Keep the oil and fuel in the determined place and do
not allow un authorised persons to enter.
– Before carrying out grinding or welding work on the machine, remove any flammable materials.
– Fire coming from electrical wiring
Short circuits in the electrical system can cause fire. To prevent fire, always observe the following:
– Keep all electrical connections clean and securely tightened.
– Check the wiring for looseness or damage. Tighten any loose connectors or wiring clamps. Repair or
replace any damaged wiring.
– Fire coming from piping
Check that all hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. There is a danger that this
may lead to damage to the hoses and cause high pressure oil to spurt out, leading to fire, personal injury, or
death.

2.2.7 UNAUTHORIZED MODIFICATION

– Komatsu will not be responsible for any injuries, accidents, product failures or other property damage resulting
in modifications made without authorisation from Komatsu.
– Any modifications made without authorisation from Komatsu can create hazards. Before making a modifica-
tion, consult your komatsu distributor.

SHOP-50 06279-xD-GB-1 PC3000-6 2 -7

Precautions for maintenance and repair Safety

2.3 PRECAUTIONS FOR MAINTENANCE AND REPAIR

2.3.1 GENERAL PRECAUTIONS

– Before beginning any work operations set the maintenance
safety switch (Fig. 2-6, Pos. 3) to -0- position to prevent start-
ing of the engines during the work:
Fold up the flap (Fig. 2-6, Pos. 2) and secure this position by
inserting a padlock into the holes (Fig. 2-6, Pos. 4) of the flap
(Fig. 2-6, Pos. 2) and the safety switch (Fig. 2-6,
Pos. 1).
– Ensure that the maintenance area is adequately secured.
– Carry out maintenance and repair work only if the machine
components are positioned on stable and level ground and
has been secured against inadvertent movement and buck-
ling.
– Relieve all pressure in the hydraulic system before servicing Fig. 2-6
the hydraulic system.

– To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes
should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear
and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.
– The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only.
The dogman/rigger giving the instructions must be within sight or sound of the crane operator.
– For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders
and working platforms. Never use machine parts as a climbing aid. Wear a safety harness when carrying out
maintenance work at greater heights.
Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.
– Always tighten any screwed connections that have been loosened during maintenance and repair.
– Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immedi-
ately upon completion of the maintenance and repair work.
– Ensure that all consumable and replaced parts are disposed of safely and with minimum environmental
impact.
– Never allow unauthorized persons access to the machine components during repair and maintenance work.
– For cleaning dirty machine components use only fresh water with a salt content of less than 0.05%.
– DO NOT use steam jet, high pressure cleaning device or strong water jet for cleaning headlights, solenoid
valves, sensors, cable connections and bearings.
– Be sure to reinstall safety devices, guards or shields after repair, adjusting, and/or servicing.

2.3.2 KEEP WORK PLACE CLEAN AND TIDY

– Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other sub-
stances that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out oper-
ations safely.
– Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying
– After servicing, remove oily cloth, inflammable material and all tools from the work place.

2 -8 PC3000-6 SHOP-50 06279-xD-GB-1

Safety Precautions for maintenance and repair

2.3.3 PRECAUTIONS WHEN WELDING

– Welding operations must always be carried out by a qualified welder and in a place equipped with proper
equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any
unqualified personnel to carry out welding.

2.3.4 PRECAUTION WITH HIGH PRESSURE FLUIDS

– If a circuit is under pressure, do not carry out any repair,
inspection, or replacement operation.
– If there is any leakage from the piping or hoses, the surround-
ing area will be wet, so check for cracks in the piping and
hoses and for swelling in the hoses.
– When carrying out inspections, wear full-face protection and
penetration resistant clothing and gloves (leather).
– There is a hazard that high-pressure oil leaking from small
holes may penetrate your skin or cause blindness if it con-
tacts your eyes directly (Fig. 2-7). If you are hit by a jet of
high-pressure oil and suffer injury to your skin or eyes, wash
the place with clean water, and consult a doctor immediately
for medical attention. Fig. 2-7

2.3.4.1 HANDLING HIGH PRESSURE HOSES AND PIPES

– If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are
found, stop operations immediately and replace the hose if any of the following problems are found.
– Damaged or leaking hydraulic fitting.
– Frayed or cut covering or exposed reinforcement wire layer.
– Covering swollen in places.
– Twisted or crushed movable portion.
– Foreign material embedded in covering.

2.3.5 COMPRESSED AIR

– When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves,
and other protective equipment.
– Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying.

SHOP-50 06279-xD-GB-1 PC3000-6 2 -9

Precautions for maintenance and repair Safety

2.3.6 WASTE MATERIALS

– Preserve our environment. To prevent environmental pollu-
tion, pay careful attention to the method of disposing waste
materials.
– Always drain fluids from your machine components into con-
tainers. Never drain fluids onto the ground or dump it into the
sewage system, rivers, the sea or lakes. (Fig. 2-8).
– Dispose of harmful material, such as oil, fuel, coolant, sol-
vent, filters and batteries in accordance with local environ-
mental regulations and laws.

Fig. 2-8

2 - 10 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure

3 SUPERSTRUCTURE

NOTE! In addition to the provisions listed here, full compliance with general safety regulations in chapter
"Safety" is required.

SHOP-50 06279-xD-GB-1 PC3000-6 3 -1

Superstructure overview Superstructure

3.1 SUPERSTRUCTURE OVERVIEW

Fig. 3-1 Superstructure overview

3 -2 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Superstructure overview

Legend for Fig. 3-1:

(1) Operator’s cab (14) Platform with batteries below floor plates

(2) Cab base (15) Distributor manifold

(3) Fuel tank (16) Main control valve blocks

(4) Hydraulically operated access ladder (17) Hydraulic oil cooler assembly

(5) Exhaust muffler (18) Main hydraulic oil tank

(6) Engine air cleaner (19) Slew gear

(7) Counterweight (20) Hydraulic pumps

(8) Engine coolant radiator (21) PTO (pump distributor gear)

(9) Slew circle (22) Flexible coupling

(10) Guide wheel (Idler) (23) Engine oil reserve tank (optional)

(11) Carrier roller (top roller) (24) Diesel engine

(12) Track roller (bottom roller) (25) Lubrication station (CLS)

(13) Sprocket and travel gear (26) Lubrication station (SLS)

SHOP-50 06279-xD-GB-1 PC3000-6 3 -3

Machinery house Superstructure

3.2 MACHINERY HOUSE

Fig. 3-2 Machine house - side and front view

3 -4 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Machinery house

Legend for Fig. 3-2:

A Side view from main control blocks (front) (9) Diesel engine

B Top view (10) Coolant pump

(1) Main hydraulic pumps (3 tandem pumps) (11) Radiator fan

(2) PTO lubrication pump (12) Coolant radiator

(3) Fan pump (13) Expansion tank for radiator

(4) Suction oil reservoir (14) Engine turbo charger

(5) Control oil pump (pilot oil pump) (15) Engine air cleaner

(6) PTO (pump distributor gear) (16) Exhaust muffler

(7) Engine mounts (elastic) (17) Engine oil reserve tank (optional)

(8) Flexible coupling, oil filled

SHOP-50 06279-xD-GB-1 PC3000-6 3 -5

Machinery house Superstructure

3.2.1 MACHINERY HOUSE ROOF

3.2.1.1 DISASSEMBLING OF THE COMPLETE ROOF FRAME

Special tools: n/a

Crane
Additional equipment: Safety harness in conformity with DIN EN 361
Swivel hoist ring: 4 x M 24

Complete roof incl. roof frame: 2500 kg

Dogman/rigger

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

NOTE! Pay attention to the Fire Detection and Suppression System.

Refer to the separate manuals "Fire Detection and Actuating System" and "Fire Suppression Sys-
tem". The wires of the Fire Detection and Suppression System must not be bent excessively or be
damaged to remain functional.
All work on the Fire Detection, Actuation and Suppression System has to be carried out by well
trained specialists having the manufacturer’s certificate for working on such systems. The local rules
and directives regarding the installation procedure of the Fire Detection, Actuation and Suppression
Systems have to be observed.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Disassemble all lamps (Fig. 3-3, Pos. 1) from the outer side
of the roof frame.

Fig. 3-3

3 -6 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Machinery house

5. Disassemble all lamps (Fig. 3-4, Pos. 1) from the inner side of
the roof plates and the roof frame.

6. Disconnect all wires leading through the roof plates.

Fig. 3-4

7. Open the cable brackets (Fig. 3-5, Pos. 1) and clear all wiring
harnesses (Fig. 3-5, Pos. 2) from the roof frame (Fig. 3-5,
Pos. 5).

REMARKS: Clear the wiring harnesses which are mounted at

the roof frame from outside as well.

NOTE! Pay attention to the Fire Detection and Suppression

System.
Refer to the separate manuals "Fire Detection and
Actuating System" and "Fire Suppression System".
The wires of the Fire Detection and Suppression
System must not be bent excessively or be dam-
aged to remain functional.
All work on the Fire Detection, Actuation and Sup- Fig. 3-5
pression System has to be carried out by well
trained specialists having the manufacturer’s certifi-
cate for working on such systems. The local rules
and directives regarding the installation procedure
of the Fire Detection, Actuation and Suppression
Systems have to be observed.

8. Disassemble nuts (Fig. 3-5, Pos. 3) and bolts at the top row of
all wall plates (Fig. 3-5, Pos. 4) to clear the roof frame
(Fig. 3-5, Pos. 5) from the walls of the engine housing.

SHOP-50 06279-xD-GB-1 PC3000-6 3 -7

Machinery house Superstructure

CAUTION
HOT MACHINE PARTS!
Personal injury from hot machine parts.

Do not carry out the following work on a hot engine.

Wait until the temperature of the engine is below 50°C.

9. Directly below the roof cover plate:

Unplug harness connector [52B18] and [52B19] (Fig. 3-6,
Pos. 1) from the sensor (Fig. 3-6, Pos. 2) at the correspond-
ing air intake pipe (Fig. 3-6 Pos. 3).

Fig. 3-6

10. Clear all attached coolant lines from the roof plate.

REMARKS: The upper coolant lines are mounted to the roof

cover plates with retainers (Fig. 3-7, Pos. 2). The
retainers are mounted at fishplates (Fig. 3-7, Pos. 3)
welded to the roof cover plate.

– Remove the bolts (Fig. 3-7, Pos. 1) from the retainer

(Fig. 3-7, Pos. 2) to clear the coolant line.

Fig. 3-7 Coolant line retainers

11. If equipped, disconnect and clear the cold starting aid fluid lines from the roof.

12. Disassemble the heat protection covers (Fig. 3-8, Pos. 1)

covering the exhaust pipes.

Fig. 3-8

3 -8 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Machinery house

WARNING
HOT MACHINE PARTS!
Personal injury from burning at very hot machine parts.

Do not carry out the following work on a hot engine.

Wait until the temperature of the engine is below 50°C.

13. Remove the insulations from the exhaust pipes.

14. Disassemble the clamps (Fig. 3-9, Pos. 1) at the exhaust

pipes and disassemble the flexible pipes (Fig. 3-9, Pos. 2)
Fig. 3-9
from both mufflers.

15. Disassemble the clamps (Fig. 3-9, Pos. 3) of the intake hoses
and disassemble the air intake pipes (Fig. 3-9, Pos. 4) from
the intake manifolds.

16. Insert appropriate swivel hoist rings (M 24) into the threads
(Fig. 3-10, Pos. 1) and attach the roof frame to a crane.

Fig. 3-10

SHOP-50 06279-xD-GB-1 PC3000-6 3 -9

Machinery house Superstructure

17. Disassemble the plates (Fig. 3-11, Pos. 1) to clear the mount-
ing bolts (Fig. 3-11, Pos. 2) of the roof frame.

18. Disassemble the mounting bolts (Fig. 3-11, Pos. 2) of the roof
frame.

Fig. 3-11

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

19. Lift off the complete roof frame using a crane.

3 - 10 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Machinery house

3.2.1.2 ASSEMBLING OF THE COMPLETE ROOF FRAME

Special tools: n/a

Crane
Additional equipment: Safety harness in conformity with DIN EN 361
Swivel hoist ring: 4 x M 24

Complete roof incl. roof frame: 2500 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

REMARKS: Carry out assembling in reverse order of disassembling.

NOTE! Pay attention to the Fire Detection and Suppression System.

Refer to the separate manuals "Fire Detection and Actuating System" and "Fire Suppression Sys-
tem". The wires of the Fire Detection and Suppression System must not be bent excessively or be
damaged to remain functional.
All work on the Fire Detection, Actuation and Suppression System has to be carried out by well
trained specialists having the manufacturer’s certificate for working on such systems. The local rules
and directives regarding the installation procedure of the Fire Detection, Actuation and Suppression
Systems have to be observed.

1. Insert appropriate swivel hoist rings (M 24) into the threads at the roof frame and attach the roof frame to a
crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

2. Lift the complete roof frame into mounting position using a crane.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 11

Machinery house Superstructure

3. Assemble the mounting bolts (Fig. 3-11, Pos. 2) of the roof

frame.

4. Assemble the plates (Fig. 3-11, Pos. 1).

Fig. 3-12

5. Detach the crane and remove the hoist rings from the roof frame.

6. Assemble the air intake pipes (Fig. 3-9, Pos. 4) at the intake
manifolds.

7. Assemble the clamps (Fig. 3-9, Pos. 3) at the air intake pipes.

8. Assemble the exhaust pipes / flexible pipes (Fig. 3-9, Pos. 2)

to the mufflers.

9. Assemble the clamps (Fig. 3-9, Pos. 1) at the pipes.

10. Install the insulations on the exhaust pipes.

Fig. 3-13

3 - 12 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Machinery house

11. Assemble the heat protection covers (Fig. 3-8, Pos. 1) cover-
ing the exhaust pipes.

Fig. 3-14

12. If equipped, re-install the cold starting aid fluid lines at the roof.

13. Retain all attached coolant lines to the roof plate.

REMARKS: The upper coolant lines are mounted to the roof

cover plates with retainers (Fig. 3-7, Pos. 2). The
retainers are mounted at fishplates (Fig. 3-7, Pos. 3)
welded to the roof cover plate.

– Assemble the bolts (Fig. 3-7, Pos. 1) at the retainer

(Fig. 3-7, Pos. 2) to mount the coolant line.

Fig. 3-15 Coolant line retainers

14. Directly below the roof cover plate:

Re-plug harness connector [52B18] and [52B19] (Fig. 3-6,
Pos. 1) at the sensor (Fig. 3-6, Pos. 2) in the corresponding
air intake pipe (Fig. 3-6 Pos. 3).

Fig. 3-16

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 13

Machinery house Superstructure

15. Retain all wiring harnesses (Fig. 3-5, Pos. 2) on the roof
frame (Fig. 3-5, Pos. 5) using the cable brackets (Fig. 3-5,
Pos. 1).

NOTE! Pay attention to the Fire Detection and Suppression

System.
Refer to the separate manuals "Fire Detection and
Actuating System" and "Fire Suppression System".
The wires of the Fire Detection and Suppression
System must not be bent excessively or be dam-
aged to remain functional.
All work on the Fire Detection, Actuation and Sup-
pression System has to be carried out by well
trained specialists having the manufacturer’s certifi-
Fig. 3-17
cate for working on such systems. The local rules
and directives regarding the installation procedure
of the Fire Detection, Actuation and Suppression
Systems have to be observed.

16. Assemble all nuts (Fig. 3-5, Pos. 3) and bolts at the top row of
all wall plates (Fig. 3-5, Pos. 4) to mount the walls of the
engine housing at the roof frame (Fig. 3-5, Pos. 5).

17. Assemble all lamps (Fig. 3-4, Pos. 1) at the inner side of the
roof plates and the roof frame.

18. Reconnect all wires leading through the roof plates.

Fig. 3-18

19. Assemble and reconnect all lamps (Fig. 3-3, Pos. 1) at the
outer side of the roof frame.

Fig. 3-19

3 - 14 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Machinery house

3.2.1.3 DISASSEMBLING OF SINGLE MACHINERY HOUSE ROOF COVER PLATES

Special tools: n/a

Additional equipment: Crane

Safety harness in conformity with DIN EN 361
Swivel hoist rings: 4 x M16

Roof cover plate 1 engine: 162 kg

Roof cover plate 2 engine: 164 kg
Roof cover plate radiator: 119 kg
Roof cover plate PTO: 173 kg

Dogman/rigger

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

NOTE! Pay attention to the Fire Detection and Suppression System.

Refer to the separate manuals "Fire Detection and Actuating System" and "Fire Suppression Sys-
tem". The wires of the Fire Detection and Suppression System must not be bent excessively or be
damaged to remain functional.
All work on the Fire Detection, Actuation and Suppression System has to be carried out by well
trained specialists having the manufacturer’s certificate for working on such systems. The local rules
and directives regarding the installation procedure of the Fire Detection, Actuation and Suppression
Systems have to be observed.

Preparatory work for roof cover plates disassembling

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Disassemble all lamps (Fig. 3-20, Pos. 1) from the inner side
of the concerned roof plate.

5. Disconnect all wires leading through the roof plate.

Fig. 3-20

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 15

Machinery house Superstructure

6. Remove the bolt from the cable bracket (Fig. 3-21, Pos. 1)
and clear all wires from the concerned roof plate.

Fig. 3-21

Fig. 3-22 Roof cover plates overview

3 - 16 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Machinery house

Legend for Fig. 3-22:

(1) Roof cover plate radiator (4) Roof cover plate PTO

(2) Roof cover plate 1 engine (5) Mounting bolts with resilient sleeves

(3) Roof cover plate 2 engine (6) Mounting bolts with lock washers

Disassembling of roof cover plate radiator (Fig. 3-22, Pos. 1) or roof cover plate PTO (Fig. 3-22, Pos. 4)

1. Disassemble all mounting bolts with resilient sleeves (Fig. 3-22, Pos. 5) and all mounting bolts with lock wash-
ers (Fig. 3-22, Pos. 6) from the concerned roof cover plate.

2. Attach the roof cover plate to a crane using swivel hoist rings M16 in the roof cover plate.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

Disassemble the roof cover plate using the crane.

Disassembling of roof cover plates 1/2 engine (Fig. 3-22, Pos. 2 & 3)

1. Disassemble the heat protection covers (Fig. 3-23, Pos. 1)

covering the exhaust pipes.

Fig. 3-23

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 17

Machinery house Superstructure

WARNING
HOT MACHINE PARTS!
Personal injury from burning at very hot machine parts.

Do not carry out the following work on a hot engine.

Wait until the temperature of the engine is below 50°C.

2. Remove the insulations from the exhaust pipes.

3. Disassemble the clamps (Fig. 3-24, Pos. 1) at the exhaust

pipes and disassemble the flexible pipes (Fig. 3-9, Pos. 2)
Fig. 3-24
from both mufflers.

4. Disassemble the clamps (Fig. 3-24, Pos. 3) of the intake

hoses and disassemble the air intake pipes (Fig. 3-24,
Pos. 4) from the intake manifolds.

5. Disassemble the exhaust mufflers from top of the roof cover plate 1 engine.

6. Disassemble the intake air cleaner from top of the roof cover plate 2 engine.

7. If equipped, disconnect and clear the cold starting aid fluid lines from the roof cover plates.

8. Clear all attached coolant lines from the corresponding roof.

REMARKS: The upper coolant lines are mounted to the roof

cover plates with retainers (Fig. 3-25, Pos. 2). The
retainers are mounted at fishplates (Fig. 3-25,
Pos. 3) welded to the roof cover plate.

– Remove the bolts (Fig. 3-25, Pos. 1) from the retainer

(Fig. 3-25, Pos. 2) to clear the coolant line.

Fig. 3-25 Coolant line retainers

REMARKS: Carry out the next three steps for both roof cover plates engine.

9. Disassemble all mounting bolts with resilient sleeves (Fig. 3-22, Pos. 5) and all mounting bolts with lock wash-
ers (Fig. 3-22, Pos. 6) from the roof cover plate radiator (Fig. 3-22, Pos. 1).

10. Attach the roof cover plate to a crane using swivel hoist rings M16 in the roof cover plate.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

11. Disassemble the roof cover plates using the crane.

3 - 18 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Machinery house

Please continue reading on the next page.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 19

Machinery house Superstructure

3.2.1.4 ASSEMBLING OF SINGLE MACHINERY HOUSE ROOF COVER PLATES

Special tools: n/a

Additional equipment: Crane

Safety harness in conformity with DIN EN 361
Swivel hoist rings: 4 x M16

Roof cover plate 1 engine: 162 kg

Roof cover plate 2 engine: 164 kg
Roof cover plate radiator: 119 kg
Roof cover plate PTO: 173 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

Fig. 3-26 Roof cover plates overview

3 - 20 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Machinery house

Legend for Fig. 3-26:

(1) Roof cover plate radiator (4) Roof cover plate PTO

(2) Roof cover plate 1 engine (5) Mounting bolts with resilient sleeves

(3) Roof cover plate 2 engine (6) Mounting bolts with lock washers

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

REMARKS: Carry out assembling in reverse order of disassembling.

Assembling of roof cover plate radiator (Fig. 3-26, Pos. 1) or roof cover plate PTO (Fig. 3-26, Pos. 4)

1. Attach the roof cover plate to a crane using swivel hoist rings M16 in the roof cover plate.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

2. Move the roof cover plate radiator (Fig. 3-26, Pos. 1) into mounting position using the crane.

3. Detach the crane and remove the hoist rings from the cover plate.

CAUTION
TRIPPING HAZARD!
Using bolts with resilient sleeves (Fig. 3-26, Pos. 6) near the walking paths may result in stumbling upon
the resilient sleeves while walking.

Only use bolts with lock washers (Fig. 3-26, Pos. 6) next to the walking paths on top of the roof cover plate
to avoid tripping.

4. Assemble all mounting bolts with resilient sleeves (Fig. 3-26, Pos. 5) and all mounting bolts with lock washers
(Fig. 3-26, Pos. 6).

5. Carry out the subsequent work for roof cover plates assembling.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 21

Machinery house Superstructure

Assembling of roof cover plates 1/2 engine (Fig. 3-26, Pos. 2 & 3)

REMARKS: Carry out the next four steps for both roof cover plates engine.

1. Attach the roof cover plate to a crane using swivel hoist rings M16 in the roof cover plate.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

2. Move the roof cover plate radiator (Fig. 3-26, Pos. 1) into mounting position using the crane.

CAUTION
TRIPPING HAZARD!
Using bolts with resilient sleeves (Fig. 3-26, Pos. 6) near the walking paths may result in stumbling upon
the resilient sleeves while walking.

Only use bolts with lock washers (Fig. 3-26, Pos. 6) next to the walking paths on top of the roof cover plate
to avoid tripping.

3. Assemble all mounting bolts with resilient sleeves (Fig. 3-26, Pos. 5) and all mounting bolts with lock washers
(Fig. 3-26, Pos. 6).

4. Detach the crane and remove the hoist rings from the roof frame.

5. Retain all attached coolant lines to the roof plate.

REMARKS: The upper coolant lines are mounted to the roof

cover plates with retainers (Fig. 3-27, Pos. 2). The
retainers are mounted at fishplates (Fig. 3-27,
Pos. 3) welded to the roof cover plate.

– Assemble the bolts (Fig. 3-27, Pos. 1) at the retainer

(Fig. 3-27, Pos. 2) to mount the coolant line.

Fig. 3-27 Coolant line retainers

6. Assemble the exhaust mufflers from top of the roof cover plate 1 engine.

7. Assemble the intake air cleaner from top of the roof cover plate 2 engine.

8. If equipped, reconnect and retain the cold starting aid fluid lines at the roof cover plates.

3 - 22 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Machinery house

9. Assemble the air intake pipes (Fig. 3-28, Pos. 4) at the intake
manifolds.

10. Assemble the clamps (Fig. 3-28, Pos. 3) at the air intake
pipes.

11. Assemble the exhaust pipes / flexible pipes (Fig. 3-28,

Pos. 2) to the mufflers.

12. Assemble the clamps (Fig. 3-28, Pos. 1) at the pipes.

13. Install the insulations on the exhaust pipes.

Fig. 3-28

14. Assemble the heat protection covers (Fig. 3-29, Pos. 1) cov-
ering the exhaust pipes.

Fig. 3-29

15. Carry out the subsequent work for roof cover plates assembling.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 23

Machinery house Superstructure

Subsequent work for roof cover plates assembling

16. Retain all wiring harnesses (Fig. 3-30, Pos. 2) on the roof
frame (Fig. 3-30, Pos. 5) using the cable brackets (Fig. 3-30,
Pos. 1).

NOTE! Pay attention to the Fire Detection and Suppression

System.
Refer to the separate manuals "Fire Detection and
Actuating System" and "Fire Suppression System".
The wires of the Fire Detection and Suppression
System must not be bent excessively or be dam-
aged to remain functional.
All work on the Fire Detection, Actuation and Sup-
pression System has to be carried out by well
trained specialists having the manufacturer’s certifi-
Fig. 3-30
cate for working on such systems. The local rules
and directives regarding the installation procedure
of the Fire Detection, Actuation and Suppression
Systems have to be observed.

17. Assemble all nuts (Fig. 3-30, Pos. 3) and bolts at the top row
of all wall plates (Fig. 3-30, Pos. 4) to mount the walls of the
engine housing at the roof frame (Fig. 3-30, Pos. 5).

18. Assemble all lamps (Fig. 3-31, Pos. 1) at the inner side of the
roof plates and the roof frame.

19. Reconnect all wires leading through the roof plates.

Fig. 3-31

3 - 24 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Machinery house

3.2.2 DIESEL ENGINE

3.2.2.1 DISASSEMBLING OF THE DIESEL ENGINE

Special tools: n/a

Crane
Additional equipment:
Swivel hoist ring: 4 x M 24

Diesel engine: 7000 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to any location with appropriate ground condition.

3. Isolate the machine according to local regulations.

WARNING
HOT MACHINE PARTS!
Personal injury from hot machine parts.

Do not carry out the following work on a hot engine.

Wait until the temperature of the engine is below 50°C.

a Drain the engine oil from the engine oil pan, approx. 190 liters.
Refer to the to separate ENGINE MAINTENANCE MANUAL.

a Drain the engine oil reserve tank if equipped, approx. 510 liters.
Refer to the OPERATION & MAINTENANCE MANUAL, chapter 3, section "CENTRAL REFILLING
SYSTEM", and the ENGINE OPERATION & MAINTENANCE MANUAL.

a Drain the engine coolant, approx. 360 liters.

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 3, section "CENTRAL REFILLING
SYSTEM", and the ENGINE OPERATION & MAINTENANCE MANUAL.

4. Unplug/disconnect and clear all wire harnesses leading from the engine.

5. Remove the complete roof frame from the engine house, refer to section 3.2.1.1 on page 3-6.

6. Disassemble the radiator fan and the fan drive, refer to section 3.2.6.1 on page 3-57.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 25

Machinery house Superstructure

7. Unplug and clear the harness connectors from the compres-

sor (Fig. 3-32, Pos. 3) of the air conditioning system.

8. Disassemble the compressor of the air conditioning system

with still attached refrigerant hoses (Fig. 3-32, Pos. 1 & 2)
and put it aside.
Clear the refrigerant hoses of the air conditioning from the
engine.

NOTE! Do not disconnect the refrigerant hoses (Fig. 3-32,

Pos. 1 & 2) of the air conditioning from the compres-
sor, because the air conditioning must be serviced
by authorized refrigeration specialists only.
Fig. 3-32

9. Disconnect the hoses (Fig. 3-33, Pos. 2) of the oil manage-

ment system.

REMARKS: When an oil line is disconnected, the oil inside will

flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

10. Disconnect the oil filling hose (Fig. 3-33, Pos. 3) leading from
the engine oil pan to the service arm.

REMARKS: When an oil line is disconnected, the oil inside will

flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation. Fig. 3-33

11. Disconnect and clear all wires (Fig. 3-33, Pos. 1) from the
alternator.

12. Disconnect and clear the coolant hose (Fig. 3-33, Pos. 4) of
the operator’s cab heating from the engine.

13. Disconnect the coolant hoses (Fig. 3-34, Pos. 1) of the heat-
ing of the operator’s cab heating from the back side of the
engine.
Leave the hose fixed to the fire wall (Fig. 3-34, Pos. 2).

Fig. 3-34

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Superstructure Machinery house

Fig. 3-35 Coolant lines leading to the radiator

14. Disconnect the coolant hose (Fig. 3-35, Pos. 1).

15. Disassemble the coolant return hoses (Fig. 3-35, Pos. 2) and the coolant pipes (Fig. 3-35, Pos. 3) leading to
the radiator.

16. Remove two bolts (Fig. 3-35, Pos. 4) and dismantle the coolant pipe (Fig. 3-35, Pos. 5) and the coolant hoses
(Fig. 3-35, Pos. 6).

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 27

Machinery house Superstructure

DANGER
INFLAMMABLE FUEL!
Serious injury, permanent disfigurement and scarring, or
death will result from burns caused by burning fuel.

DO NOT smoke or use an open flame when working at fuel

lines or the cold start system.

17. Disconnect the fuel return hose (Fig. 3-36, Pos. 1) and the
fuel feeding hose (Fig. 3-36, Pos. 2).

REMARKS: When a fuel line is disconnected, the fuel inside will

flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.
Fig. 3-36

18. Disconnect the hoses (Fig. 3-37, Pos. 1) of the cold start sys-
tem from both intake manifolds (Fig. 3-37, Pos. 2).

19. Open all hose clamps (Fig. 3-37, Pos. 3) along the hoses and
clear the hoses from the engine.

Fig. 3-37 Engine top view

20. Disconnect and clear the wire harnesses (Fig. 3-38, Pos. 1 &
2) from the starter motors.

21. Unplug the harnesses connectors (Fig. 3-38, Pos. 3 & 4) and
clear the wire harnesses.

22. Clear and disconnect the hose (Fig. 3-38, Pos. 5) from the
engine if equipped.

Fig. 3-38

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Superstructure Machinery house

23. Unplug the harness connector of the following components and clear the wire harness from the engine:

– Engine speed sensor [52B064] (pick-up) at the PTO/engine mounting flange

– Cylinder temperature sensors [52B243-1...6] & [52B244-1...6] at both sides of the engine
– CAN BUS of the Quantum ECM
– All additional systems which were not disconnected yet
24. Clear all hoses from the engine.

25. Disassemble the coupling assembly from the PTO, refer to

section 3.2.5 on page 3-45.

26. Disassemble all mounting bolts (Fig. 3-39, Pos. 1) attaching

the PTO to the engine flange (Fig. 3-39, Pos. 2).

27. Disassemble the covering (Fig. 3-39, Pos. 3) from the fire
protection wall.

Fig. 3-39

28. Attach the engine to a crane using the four lifting shackles
(Fig. 3-40, arrow) at the engine.

REMARKS: The lifting shackles are located at both cylinder

banks between the valve covers (Fig. 3-40, Pos. 1)
of the cylinders 1-2 and 5-6.

Fig. 3-40

29. Remove eight rear engine mounting bolts (Fig. 3-41, Pos. 1)
at each side.

Fig. 3-41

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Machinery house Superstructure

30. Remove the mounting bolts (Fig. 3-42, Pos. 4 and 3) and
clear the engine torque support (Fig. 3-42, Pos. 2) from the
flexible mounts.

NOTICE
RISK TO RIB OFF HOSES OR HARNESSES!
Hoses or harnesses will be ripped off if the engine is being
removed while still connected.

Before lifting the engine make sure that all hoses and har-
nesses are clear and disconnected from the engine.

Fig. 3-42

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

31. Move the engine including torque support away from the PTO at first and then lift it out of the machinery house
using the crane.

32. Disassemble the bolts (Fig. 3-42, Pos. 1) and remove the engine torque support (Fig. 3-42, Pos. 2) if required.

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Superstructure Machinery house

3.2.3 ASSEMBLING OF THE DIESEL ENGINE

Special tools: n/a

Additional equipment: Crane

Diesel engine: 7000 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: It is recommended to replace all flexible bearings and rubber-bounded metal bars of the flexible
mounts, also at the PTO.
For replacement refer to the PARTS & SERVICE NEWS No. "AH01521".

1. Attach the engine to a crane using the four lifting shackles

(Fig. 3-43, arrow) at the engine.

REMARKS: The lifting shackles are located at both cylinder

banks between the valve covers (Fig. 3-43, Pos. 1)
of the cylinders 1-2 and 5-6.

Fig. 3-43

2. Mount the engine torque support (Fig. 3-44, Pos. 2) to the

engine if required.

b Tightening torque for engine mounting bolts

(Fig. 3-44, Pos. 1) at the torque support: 345 Nm

DANGER Z25737
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine Fig. 3-44
part.

3. Lift and move the engine into its mounting position using the crane.

4. Install the engine torque support (Fig. 3-44, Pos. 2) onto the flexible bearings. Tighten the bolts (Fig. 3-44,
Pos. 3 and 4) hand-tight.

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Machinery house Superstructure

5. Install the bolts (Fig. 3-45, Pos. 1) attaching the PTO to the
engine flange (Fig. 3-45, Pos. 2) and tighten them.

6. Assemble the flexible coupling, refer to section 3.2.5 on

page 3-45.

Fig. 3-45

7. Install eight rear engine mounting bolts (Fig. 3-46, Pos. 1) at

each side and tighten to the specified torque.

b Tightening torque for rear engine mounting

bolts: 400 Nm

8. Detach the crane from the engine.

Fig. 3-46

9. Tighten the mounting bolts (Fig. 3-47, Pos. 3 and 4) at the

engine torque support (Fig. 3-47, Pos. 2) with the specified
torque.

b Tightening torque for engine mounting bolts:

Refer to the PARTS & SERVICE NEWS
No. "AH01521"
Z25737

Fig. 3-47

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Superstructure Machinery house

10. Reconnect and retain the wire harnesses (Fig. 3-48, Pos. 1 &
2) of the starter motors.

11. Re-plug the harnesses connectors (Fig. 3-48, Pos. 3 & 4) and
retain the wire harnesses.

12. Reconnect and retain the hose (Fig. 3-48, Pos. 5) at the
engine if equipped.

Fig. 3-48

DANGER
INFLAMMABLE FUEL!
Serious injury, permanent disfigurement and scarring, or
death will result from burns caused by burning fuel.

DO NOT smoke or use an open flame when working at fuel

lines or the cold start system.

13. Reconnect the fuel return hose (Fig. 3-49, Pos. 1) and the
fuel feeding hose (Fig. 3-49, Pos. 2).

Fig. 3-49

14. Reconnect the hoses (Fig. 3-50, Pos. 1) of the cold start sys-
tem from both intake manifolds (Fig. 3-50, Pos. 2).

15. Mount all hose clamps (Fig. 3-50, Pos. 3) along the hoses
and retain the hoses at the engine.

Fig. 3-50 Engine top view

16. Re-plug the harness connector of the following components and retain the wire harness at the engine:

– Engine speed sensor [52B064] (pick-up) at the PTO/engine mounting flange

– Cylinder temperature sensors [52B243-1...6] & [52B244-1...6] at both sides of the engine
– CAN BUS of the Quantum ECM
– All additional systems which were not connected yet

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 33

Machinery house Superstructure

Fig. 3-51 Coolant lines leading to the radiator

17. Reconnect the coolant hose (Fig. 3-51, Pos. 1).

18. Assemble the coolant return hoses (Fig. 3-51, Pos. 2) and the coolant pipes (Fig. 3-51, Pos. 3) leading to the
radiator.

19. Assemble the coolant hoses (Fig. 3-51, Pos. 6) and connect the coolant pipe (Fig. 3-51, Pos. 5).

20. Assemble two bolts (Fig. 3-51, Pos. 4).

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Superstructure Machinery house

21. Reconnect the coolant hoses (Fig. 3-52, Pos. 1) of the heat-
ing of the operator’s cab heating which is fixed to the fire wall
(Fig. 3-52, Pos. 2).

Fig. 3-52

22. Reconnect the hoses (Fig. 3-53, Pos. 2) of the oil manage-
ment system.

23. Reconnect the oil filling hose (Fig. 3-53, Pos. 3) leading from
the engine oil pan to the service arm.

24. Reconnect and retain all wires (Fig. 3-53, Pos. 1) of the alter-
nator.

25. Reconnect and retain the coolant hose (Fig. 3-53, Pos. 4) of
the operator’s cab heating at the engine.

Fig. 3-53

26. Retain all other cleared hoses at the engine.

27. Re-plug and retain the harness connectors from the compres-
sor (Fig. 3-54, Pos. 3) of the air conditioning system.

28. Disassemble the compressor of the air conditioning system

with still attached refrigerant hoses (Fig. 3-54, Pos. 1 & 2)
and put it aside.
Clear the refrigerant hoses of the air conditioning from the
engine.

NOTE! Do not disconnect the refrigerant hoses (Fig. 3-54,

Pos. 1 & 2) of the air conditioning from the compres-
sor, because the air conditioning must be serviced
by authorized refrigeration specialists only.
Fig. 3-54

29. Re-plug/reconnect and retain all wire harnesses leading from the engine.

30. Assemble the radiator fan and the fan drive, refer to section 3.2.6.2 on page 3-59.

31. Assemble the complete roof frame of the machinery house, refer to section 3.2.1.2 on page 3-11.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 35

Machinery house Superstructure

d Refill the engine coolant, approx. 360 liters.

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 3, section "CENTRAL REFILLING
SYSTEM".

d Refill the engine oil pan with engine oil, approx. 190 liters.
Refer to the OPERATION & MAINTENANCE MANUAL, chapter 3, section "CENTRAL REFILLING
SYSTEM".

d Refill the engine oil reserve tank with engine oil, approx. 510 liters.
Refer to the OPERATION & MAINTENANCE MANUAL, chapter 3, section "CENTRAL REFILLING
SYSTEM".

DANGER
INFLAMMABLE FUEL!
Serious injury, permanent disfigurement and scarring, or death will result from burns caused by burning
fuel.

DO NOT smoke or use an open flame when working at fuel lines.

32. Bleed air from the fuel system, refer to the ENGINE OPERATION & MAINTENANCE MANUAL.

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Superstructure Machinery house

3.2.3.1 DISASSEMBLING OF THE ALTERNATOR

Special tools: n/a

Additional equipment: n/a

Alternator: 39 kg

Second person to remove the alternator

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to any location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Remove both battery main switch keys.

CAUTION
HOT ENGINE!
Burns from hot engine or machine parts may result.

Do not carry out the following work on a hot engine.

Wait until the temperature of the engine is below 50°C.

5. Disconnect and clear the harnesses (Fig. 3-55, Pos. 1) from

the alternator (Fig. 3-55, Pos. 2).

6. Disassemble the alternator belt guard (Fig. 3-55, Pos. 3).

Fig. 3-55

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 37

Machinery house Superstructure

7. Loosen the mounting bolt (Fig. 3-56, Pos. 2).

8. Disassemble the bolt (Fig. 3-56, Pos. 4) at the tensioner

(Fig. 3-56, Pos. 3) to release the drive belt’s tension.

9. Take off the drive belt.

10. Disassemble the mounting bolt (Fig. 3-56, Pos. 2) and the
alternator (Fig. 3-56, Pos. 1).

REMARKS: A second person is required to remove the alterna-

tor.
For further information refer to the ENGINE OPER-
ATION & MAINTENANCE MANUAL.
Fig. 3-56

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Superstructure Machinery house

3.2.3.2 ASSEMBLING OF THE ALTERNATOR

Special tools: n/a

Additional equipment: Belt tension gauge

Alignment chart (steel ruler)

Alternator: 39 kg

Second person to install the alternator

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: A second person is required to remove the alterna-

tor.

1. Assemble the alternator (Fig. 3-57, Pos. 1) with the mounting

bolt (Fig. 3-57, Pos. 2). Do tot tighten the mounting bolt yet.

2. Install the drive belt.

3. Assemble the bolt (Fig. 3-57, Pos. 4) at the tensioner

(Fig. 3-57, Pos. 3) and adjust the drive belt’s tension.

REMARKS: For the correct belt tension and use of the belt ten-
sion gauge, refer to the ENGINE OPERATION &
MAINTENANCE MANUAl and the User Instructions
delivered together with the belt tension gauge. Fig. 3-57

4. Tighten the mounting bolt (Fig. 3-57, Pos. 2).

5. Check the alignment of the pulleys using an alignment chart.

REMARKS: If correction of the pulley alignment is required, refer to the ENGINE OPERATION & MAINTENANCE
MANUAL.

6. Reconnect and retain the harnesses (Fig. 3-58, Pos. 1) at the

alternator (Fig. 3-58, Pos. 2).

7. Assemble the alternator belt guard (Fig. 3-58, Pos. 3).

Fig. 3-58

8. Check charging current of the new alternator on the Komtrax Plus display.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 39

Machinery house Superstructure

3.2.3.3 DISASSEMBLING OF THE STARTER MOTOR

Special tools: n/a

Additional equipment: n/a

Starter motor: 26 kg

Second person to remove the starter motor

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to any location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Remove both battery main switch keys.

CAUTION
HOT ENGINE!
Burns from hot engine or machine parts may result.

Do not carry out the following work on a hot engine.

Wait until the temperature of the engine is below 50°C.

5. Disconnect the positive cable (Fig. 3-59, Pos. 1) from the

starter motor (Fig. 3-59, Pos. 3).

6. Disconnect the positive cable (Fig. 3-59, Pos. 2) and the con-
trol cables from the starter solenoid switch.

7. Disassemble the multi-point mounting bolts (Fig. 3-59,

Pos. 4) and remove the starter motor.

REMARKS: A second person is required to remove the starter

motor.

Fig. 3-59

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Superstructure Machinery house

3.2.3.4 ASSEMBLING OF THE STARTER MOTOR.

Special tools: n/a

Additional equipment: n/a

Starter motor: 26 kg

Second person to install the starter motor

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: Carry out assembling in reverse order of disassembling.

REMARKS: A second person is required to assemble the starter

motor.

1. Move the starter motor (Fig. 3-60, Pos. 3) into mounting posi-
tion and assemble the multi-point mounting bolts (Fig. 3-60,
Pos. 4).

b Tightening torque for starter motor mounting

bolts (multi-point): 195 Nm

2. Reconnect the positive cable (Fig. 3-59, Pos. 1) at the starter

motor.

3. Reconnect the positive cable (Fig. 3-60, Pos. 2) and the con-
trol cables at the starter solenoid switch. Fig. 3-60

4. Insert both battery main switch keys and switch ON.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 41

Machinery house Superstructure

3.2.4 BATTERIES

3.2.4.1 DISASSEMBLING OF THE BATTERIES

Special tools: n/a

Additional equipment: Crane or forklift

Battery: 62 kg

Dogman/rigger
Certified electrician

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

DANGER
EXPLOSIVE HYDROGEN GAS!
Blindness, serious injury, permanent disfigurement, and scarring will result by the explosion caused by
hydrogen gas.

Never allow sparks or open flame near the batteries.

DO NOT smoke or use an open flame when working at the batteries.
DO NOT short circuit or ground any terminals of the batteries.

4. Set main switch key in the operator’s cab to ”0” position and remove the key.

NOTICE
DATA LOSS!
The Komtrax Plus system needs at least 3 minutes for saving data. If batteries are switched OFF before
this time period is over, data will be lost.

After switching OFF the main key switch in the Operator’s cab, wait at least 3 minutes before switching
OFF the battery main switches.

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Superstructure Machinery house

5. Switch off the battery main switches (Fig. 3-61, Pos. 1) and
remove the keys from the battery main switches.

The batteries are located below hinged floor plates in two sepa-
rate boxes.

6. Disassemble floor plate fastening bolts and open the hinged

floor plates (Fig. 3-61, Pos. 2).

REMARKS: Wash the dirt of the floor plates (Fig. 3-61, Pos. 2)
as they can be very heavy.

7. Secure the open floor plates against falling down using the
safety chains provided.

Fig. 3-61

NOTICE
ELECTRICAL SURGE!
Running the engine without the batteries may cause damages to the electrical system because of electri-
cal surge.

Never run the engine with disconnected batteries.

DANGER
HAZARDOUS CURRENT!
Death, serious injury, electrical shock, or burns will result if
the battery cables are disconnected in a false sequence.

Disconnecting the batteries has to be done by a certified

electrician only.
Disconnect the ground cables (-) of both batteries first.

8. Disconnect the cables from the batteries (Fig. 3-62, Pos. 1).
Fig. 3-62
9. Disassemble the angle (Fig. 3-62, Pos. 2) from the batteries.

10. Take the batteries out of the battery boxes.

REMARKS: Check the provided loops and replace them if required. Use the loops to carry the batteries. Do not
drop the battery.

11. Check the wires and repair or replace all broken wires immediately.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 43

Machinery house Superstructure

3.2.4.2 ASSEMBLING OF THE BATTERIES

Special tools: n/a

Additional equipment: Crane or forklift

Battery: 62 kg

Dogman/rigger
Certified electrician

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Put the batteries in the battery boxes.

2. Install the angles (Fig. 3-63, Pos. 2) to secure the batteries.

DANGER
HAZARDOUS CURRENT!
Death, serious injury, electrical shock, or burns will result if
the Battery cables are reconnected in a false sequence.

Reconnecting the batteries has to be done by a certified elec-

trician only.
Connect the positive cables (+) of the batteries first.
Fig. 3-63

3. Reconnect the cables at the batteries (Fig. 3-63, Pos. 1).

REMARKS: All terminals must be clean and securely fastened. Never paint connections.

4. Close the hinged floor plates (Fig. 3-64, Pos. 2) and assem-
ble the floor plate fastening bolts.

5. Insert the keys into the battery main switches (Fig. 3-64,
Pos. 1) and switch ON.

Fig. 3-64

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Superstructure Machinery house

3.2.5 FLEXIBLE COUPLING

The machine may be equipped with either the Geislinger coupling or the CentaFlex coupling.

3.2.5.1 DISASSEMBLING OF THE GEISLINGER COUPLING

Special tools: n/a

Additional equipment: Swivel hoist ring: M16

chain hoist.

Coupling assembly: 165 kg

Dogman/rigger

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to any location with appropriate ground condition.

3. Isolate the machine according to local regulations.

NOTE! Be sure to set the maintenance safety switch 51S058 to "0" position before starting the procedure. In
the "0" position the engines can not be started. Secure this position by inserting a padlock into the
holes of the switch. Up to ten padlocks can be attached to the holes provided.

4. Check if a lifting eye (Fig. 3-65, Pos. 1) is installed at the roof

plate over the coupling. Use the lifting eye to hook a chain
hoist.
If no lifting eye is installed, it has to be welded to the roof
plate.

NOTE! For welding follow the welding precautions given in

the OPERATION & MAINTENANCE MANUAL,
chapter 4, section "WELD REPAIRS" and refer to
the PARTS & SERVICE NEWS No. "AH08507".

Fig. 3-65

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Machinery house Superstructure

5. Disassemble the guard (Fig. 3-66, Pos. 1) of the coupling.

6. Check complete area of coupling and coupling bell for leak-

age or oil contamination. If evidence of oil is found, repair
immediately.

Fig. 3-66

7. Turn the coupling using the barring device (Fig. 3-67, Pos. 1)
to bring the bleeder plug of the coupling in its lowermost
(6 o’clock) position.

REMARKS: To use the barring device, remove the clip and push
the device shaft toward the flywheel. The barring
device must be rotated counter clockwise to turn the
flywheel in the direction of normal rotation.

a Drain the coupling oil, approx 1.45 liters, by remov-

ing the bleeder plug.
Disassemble the dip stick to speed up the flow out.
Catch the oil in an oil pan.

Fig. 3-67 Exemplaric sketch

8. Install a swivel hoist ring M16 at the thread (Fig. 3-68, Pos. 2)
in the engine flange of the coupling (Fig. 3-68, Pos. 1).

9. Attach the swivel hoist ring to a chain hoist.

Fig. 3-68

3 - 46 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Machinery house

10. Disassemble the bolts (Fig. 3-69, Pos. 1 and 2).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

11. Dismantle the coupling assembly (Fig. 3-69, Pos. 3) from the
drive using the chain hoist.

REMARKS: The coupling must be compressed for dismantling.

Fig. 3-69
12. If required:
Disassemble the bolts (Fig. 3-69, Pos. 4) and demount the
spacer (Fig. 3-69, Pos. 5).

3.2.5.2 ASSEMBLING OF THE GEISLINGER COUPLING

Special tools: n/a

Additional equipment: Swivel hoist ring: M16

chain hoist.

Coupling assembly: 165 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Install a swivel hoist ring M16 at the thread (Fig. 3-70, Pos. 2)
in the engine flange of the coupling (Fig. 3-70, Pos. 1).

2. Attach the swivel hoist ring to a chain hoist.

Fig. 3-70

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 47

Machinery house Superstructure

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

3. Move the coupling assembly (Fig. 3-71, Pos. 3) into mounting

position using the chain hoist.

REMARKS: The coupling must be compressed for assembling.

4. If required:
Assemble the spacer (Fig. 3-71, Pos. 5), then assemble the Fig. 3-71
bolts (Fig. 3-71, Pos. 4).

5. Assemble the bolts (Fig. 3-71, Pos. 1 and 2).

d Check the oil level of the new Geislinger coupling

and correct the oil level if required. Refer to the
OPERATION & MAINTENANCE MANUAL, chapter
4, section "FLEXIBLE DRIVE COUPLING - CHECK
OIL LEVEL".

For the proper lubricant, refer to the OPERATION &

MAINTENANCE MANUAL, chapter 4, section "FLU-
IDS AND LUBRICANTS".

REMARKS: To use the barring device (Fig. 3-72, Pos. 1),

remove the clip and push the device shaft toward
the flywheel. The barring device must be rotated
counter clockwise to turn the flywheel in the direc-
tion of normal rotation.

Fig. 3-72 Exemplaric sketch

6. Assemble the guard (Fig. 3-73, Pos. 1) of the coupling.

Fig. 3-73

3 - 48 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Machinery house

3.2.5.3 DISASSEMBLING OF THE CENTAFLEX COUPLING ASSEMBLY

Special tools: n/a

Additional equipment: chain hoist.

Coupling assembly: 80 kg

Dogman/rigger

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to any location with appropriate ground condition.

3. Isolate the machine according to local regulations.

NOTE! Be sure to set the maintenance safety switch 51S058 to "0" position before starting the procedure. In
the "0" position the engines can not be started. Secure this position by inserting a padlock into the
holes of the switch. Up to ten padlocks can be attached to the holes provided.

4. Check if a lifting eye (Fig. 3-74, Pos. 1) is installed at the roof

plate over the coupling. Use the lifting eye to hook a chain
hoist.
If no lifting eye is installed, it has to be welded to the roof
plate.

NOTE! For welding follow the welding precautions given in

the OPERATION & MAINTENANCE MANUAL,
chapter 4, section "WELD REPAIRS" and refer to
the PARTS & SERVICE NEWS No. "AH08507".

Fig. 3-74

5. Disassemble the guard (Fig. 3-75, Pos. 1) of the coupling.

6. Check complete area of coupling and coupling bell for leak-

age or oil contamination. If evidence of oil is found, repair
immediately.

Fig. 3-75

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Machinery house Superstructure

7. Sling the coupling adapter (Fig. 3-76, Pos. 3) and attach a

chain hoist.

8. Disassemble the bolts (Fig. 3-76, Pos. 1) attaching the outer

part (Fig. 3-76, Pos. 4) of the coupling to the engine.

9. Disassemble the bolts (Fig. 3-76, Pos. 2) attaching the

adapter to the PTO.

Fig. 3-76

REMARKS: when disassembling the bolts turn the coupling

using the barring device (Fig. 3-77, Pos. 1).

To use the barring device, remove the clip and push

the device shaft toward the flywheel. The barring
device must be rotated counter clockwise to turn the
flywheel in the direction of normal rotation.

Fig. 3-77 Exemplaric sketch

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REMARKS: The coupling must be telescoped for dismantling.

10. Move the outer part (Fig. 3-78, Pos. 2) of the coupling away
from the engine flywheel.

11. Move the inner part (Fig. 3-78, Pos. 2) of the coupling away
from the engine flywheel.
Use forcing bolts in the forcing threads (Fig. 3-78, Pos. 3).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

Fig. 3-78
12. Dismantle the coupling assembly from the drive using the
chain hoist.

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3.2.5.4 ASSEMBLING OF THE CENTAFLEX COUPLING ASSEMBLY

Special tools: n/a

Additional equipment: Crane

Coupling assembly: 80 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! The coupling is installed in pre-assembled state. Inner and outer elements of the coupling are
aligned to each other (arrows on inner and outer coupling element are in line with each other), so do
not separate the coupling while assembling.

REMARKS: Carry out assembling in reverse order of disassembling.

1. Sling the coupling adapter (Fig. 3-79, Pos. 3) and attach a

chain hoist.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

2. Move the coupling assembly into the drive using the chain
hoist.

3. Bring the outer part (Fig. 3-79, Pos. 4) of the coupling into Fig. 3-79
mounting position at the engine flywheel.

4. Insert the mounting bolts (Fig. 3-79, Pos. 1) and thighten them to the specified torque.

b Tightening torque for mounting bolts (Fig. 3-79, Pos. 1) at the flywheel: 155 Nm

5. Assemble the bolts (Fig. 3-79, Pos. 2) attaching the adapter (Fig. 3-79, Pos. 3) to the PTO.
Thighten the bolts to the specified torque (KOMATSU company standard, refer to section 6.6 on page 6-16).

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REMARKS: when disassembling the bolts turn the coupling

using the barring device (Fig. 3-80, Pos. 1).

To use the barring device, remove the clip and push

the device shaft toward the flywheel. The barring
device must be rotated counter clockwise to turn the
flywheel in the direction of normal rotation.

Fig. 3-80 Exemplaric sketch

6. Assemble the guard (Fig. 3-81, Pos. 1) of the coupling.

Fig. 3-81

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3.2.5.5 REPLACING THE RUBBER ROLLERS OF THE CENTAFLEX COUPLING

REMARKS: When replacing the rubber rollers turn the coupling

using the barring device (Fig. 3-82, Pos. 1).

To use the barring device, remove the clip and push

the device shaft toward the flywheel. The barring
device must be rotated counter clockwise to turn the
flywheel in the direction of normal rotation.

Fig. 3-82 Exemplaric sketch

1. Disassemble the guard (Fig. 3-83, Pos. 1) of the coupling.

2. Check complete area of coupling and coupling bell for leak-

age or oil contamination. If evidence of oil is found, repair
immediately.

Fig. 3-83

3. Disassemble all bolts (Fig. 3-84, Pos. 1) fixing the ring

(Fig. 3-84, Pos. 2).

4. Move the loosened ring away from the rubber rollers

(Fig. 3-84, Pos. 3).

NOTE! The inner and outer elements of the coupling are

aligned to each other (arrows on inner and outer
coupling element are in line with each other), so
replace the rubber rollers on after another.

5. Remove the rubber roller from its bag in the outer coupling
element and replace it by a new one.

REMARKS: For easier assembly wet the roller bags in the outer
coupling element with soap solution (10% liquid
soap and 90% water) or with silicon spray.

6. Repeat the previous step until all rallers are replaced. Fig. 3-84
7. Assemble the ring (Fig. 3-84, Pos. 2)and the bolts (Fig. 3-84,
Pos. 1).

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8. Assemble the guard (Fig. 3-85, Pos. 1) of the coupling.

Fig. 3-85

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3.2.6 RADIATOR FAN AND FAN DRIVE ASSEMBLY

Fig. 3-86 Radiator fan assembly

(1) Bolt (6) Pulley

(2) Locking plate (7) Drive belt

(3) Radiator fan (8) Nut

(4) Bolt (9) Fan drive assembly

(5) Extension (10) Belt tension pulley

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3.2.6.1 DISASSEMBLING OF THE RADIATOR FAN AND THE FAN DRIVE ASSEMBLY

Special tools: n/a

Additional equipment: n/a

Radiator fan: 35 kg

Second person to remove the radiator fan

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to any location with appropriate ground condition.

3. Isolate the machine according to local regulations.

NOTE! Be sure to set the maintenance safety switch 51S058 to "0" position before starting the procedure. In
the "0" position the engines can not be started. Secure this position by inserting a padlock into the
holes of the switch. Up to ten padlocks can be attached to the holes provided.

WARNING
HOT ENGINE!
Burns from hot engine or machine parts may result.

Do not carry out the following work on a hot engine. Wait until the temperature of the engine is below
50°C.

4. Open the fan guard door, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "RADIA-
TOR FAN BELT AND AUTOMATIC BELT TENSIONER-MAINTENANCE CHECK".

Disassembling of the radiator fan:

CAUTION
SHARP BLADE EDGES!
Fan blades could have sharp edges. May result in injury to the hands due to cuts.

Use protective gloves.

5. Remove six mounting bolts (Fig. 3-86, Pos. 1) with the three locking plates (Fig. 3-86, Pos. 2). Discard the
locking plates.

6. Remove the radiator fan (Fig. 3-86, Pos. 3).

REMARKS: A second person is required to remove the radiator fan.

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Disassembling of the fan drive assembly:

7. Disassemble the six attaching bolts (Fig. 3-86, Pos. 4) and remove the extension (Fig. 3-86, Pos. 5).

8. Take the fan drive belt (Fig. 3-86, Pos. 7) from the pulley (Fig. 3-86, Pos. 6), refer to the Engine and Equip-
ment Manual, Volume 2.

9. Disassemble four mounting nuts (Fig. 3-86, Pos. 8) with washers and remove the fan drive assembly
(Fig. 3-86, Pos. 9).

10. Check the drive belt tensioning system.

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "RADIATOR FAN BELT AND
AUTOMATIC BELT TENSIONER-MAINTENANCE CHECK".
If required disassemble the fan belt tensioning system (Fig. 3-86, Pos. 10).

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3.2.6.2 ASSEMBLING OF THE RADIATOR FAN AND THE FAN DRIVE ASSEMBLY

Special tools: Belt tension gauge PN 896 609 40

Additional equipment: n/a

Radiator fan: 35 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

Assembling of the fan drive assembly:

1. If removed: Assemble the fan belt tensioning system (Fig. 3-86, Pos. 10).

2. Install the fan drive assembly (Fig. 3-86, Pos. 9) and assemble four mounting nuts (Fig. 3-86, Pos. 8) with
washers.

3. Apply the fan drive belt (Fig. 3-86, Pos. 7) on the pulley (Fig. 3-86, Pos. 6), refer to the Engine and Equipment
Manual, Volume 2.

4. Check the drive belt tension.

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "RADIATOR FAN BELT AND
AUTOMATIC BELT TENSIONER-MAINTENANCE CHECK".

5. Assemble the extension (Fig. 3-86, Pos. 5) with six attaching bolts (Fig. 3-86, Pos. 4).

Assembling of the radiator fan:

CAUTION
SHARP BLADE EDGES!
Fan blades could have sharp edges. May result in injury to the hands due to cuts.

Use protective gloves.

6. Bring the radiator fan (Fig. 3-86, Pos. 3) into mounting position.

REMARKS: A second person is required to install the radiator fan.

7. Assemble six mounting bolts (Fig. 3-86, Pos. 1) with three new locking plates (Fig. 3-86, Pos. 2).
Lock the bolts using the locking plates.

8. Close the fan guard door, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "RADIA-
TOR FAN BELT AND AUTOMATIC BELT TENSIONER-MAINTENANCE CHECK".

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3.2.7 RADIATOR ASSEMBLY

3.2.7.1 DISASSEMBLING OF THE RADIATOR ASSEMBLY

Special tools: n/a

Additional equipment: Crane

Empty coolant storage tank

Radiator: 748 kg

Dogman/rigger

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to any location with appropriate ground condition.

3. Isolate the machine according to local regulations.

WARNING
HOT COOLANT!
May result in personal injury from hot coolant.

Do not carry out the following work on a hot machine. Wait until the temperature of the coolant is below
50 °C.

a Drain the engine coolant, approx. 360 liters.

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 3, section "CENTRAL REFILLING
SYSTEM" and the ENGINE OPERATION & MAINTENANCE MANUAL.

4. It is recommended to carry out the next two steps for better

access to the cooler:

– Disassemble the rail (Fig. 3-87, Pos. 1).

– Open the radiator sound silencer gate (Fig. 3-87, Pos. 2).

5. Remove the radiator fan, refer to section 3.2.6.1 on

page 3-57.

6. Disassemble the fan cages.

Fig. 3-87

7. Disassemble the roof cover plate radiator from the engine house, refer to section 3.2.1.3 on page 3-15.

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Fig. 3-88 Coolant lines leading to the radiator assembly

8. Open the hose clamps (Fig. 3-88, Pos. 4) and disconnect the coolant hoses (Fig. 3-88, Pos. 2) from the radia-
tor assembly (Fig. 3-88, Pos. 1).

9. Disassemble the coolant hoses (Fig. 3-88, Pos. 3).

10. Disconnect the coolant hoses (Fig. 3-88, Pos. 5) from the radiator assembly.

11. Disconnect the hoses of the central refilling system from the bottom of radiator assembly.

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Machinery house Superstructure

Attachment points at the radiator assembly (Fig. 3-89).

Fig. 3-89

12. Disassemble all mounting bolts (Fig. 3-90, Pos. 5) and con-
nector plates (Fig. 3-90, Pos. 6).

13. Disassemble the cowl (Fig. 3-90, Pos. 7) using the crane.

14. Attach the radiator to the crane at the lifting eyes (see
Fig. 3-89).

15. Disassemble all mounting bolts (Fig. 3-90, Pos. 1) and lock-
ing plates (Fig. 3-90, Pos. 2) attaching the radiator (Fig. 3-90,
Pos. 4) to the mount (Fig. 3-90, Pos. 3).

Fig. 3-90

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down falling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

16. Dismantle the radiator assembly from the machinery house using the crane.

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3.2.7.2 ASSEMBLING OF THE RADIATOR ASSEMBLY

Special tools: n/a

Additional equipment: Crane

Radiator: 748 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Attach the radiator to the crane at the lifting eyes (see Fig. 3-89 on page 3-62).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down falling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

2. Move the radiator assembly into mounting position using the crane.

3. Assemble all mounting bolts (Fig. 3-91, Pos. 1) and locking

plates (Fig. 3-91, Pos. 2) attaching the radiator (Fig. 3-91,
Pos. 4) to the mount (Fig. 3-91, Pos. 3).

4. Detach the crane from the radiator.

5. Move the cowl (Fig. 3-91, Pos. 7) into mounting position using
the crane.

6. Assemble all mounting bolts (Fig. 3-91, Pos. 5) and connec-

tor plates (Fig. 3-91, Pos. 6).

7. Detach the crane from the cowl.

Fig. 3-91

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Machinery house Superstructure

Fig. 3-92 Coolant lines leading to the radiator assembly

8. Assemble the coolant hoses (Fig. 3-92, Pos. 3).

9. Connect the coolant hoses (Fig. 3-92, Pos. 5) to the radiator assembly.

10. Connect the coolant hoses (Fig. 3-92, Pos. 2) to the radiator assembly (Fig. 3-92, Pos. 1) and install the hose
clamps (Fig. 3-92, Pos. 4).

11. Connect the hoses of the central refilling system to the bottom of radiator assembly.

12. Assemble the roof cover plate radiator at the engine house, refer to section 3.2.1.4 on page 3-20.

d Fill up the engine coolant, approx. 360 liters.

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 3, section "CENTRAL REFILLING
SYSTEM" and the ENGINE OPERATION & MAINTENANCE MANUAL.

13. Assemble the radiator fan, refer to section 3.2.6.2 on page 3-59.

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14. Assemble the fan cages.

15. Run engine to circulate the coolant through the system.

16. Check all coolant lines for leaks.

17. Check coolant level and add coolant if required.

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 3, section "CHECKS BEFORE STARTING
THE ENGINE".

18. Close the radiator sound silencer gate (Fig. 3-93, Pos. 2).

19. Assemble the rail (Fig. 3-93, Pos. 1).

Fig. 3-93

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3.2.8 MAIN PUMPS ASSEMBLIES

Fig. 3-94 Main pumps assembly

(1) Main pump 3 (4) PTO (Pump distributor gear box)

(2) Main pump 2 (5) O-ring

(3) Main pump 1

The main pump assemblies are removed only completely and not further disassembled. The main pump assem-
blies must be sent to a certified REMAN-center for remanufacturing or must be completely replaced.

Refer to "10 Structure & function" in the SHOP MANUAL for further information about the main pump assemblies.

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3.2.8.1 PREPARATORY WORKS FOR MAIN PUMP DISASSEMBLING

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Close the hand wheel (Fig. 3-95, Pos. 1) of main shut off
valve between suction oil reservoir and main oil reservoir.

Fig. 3-95

4. Open the cover (Fig. 3-96, Pos. 1) of the return oil filter.

5. Transfuse oil from the suction oil reservoir into the main oil
reservoir, refer to the PARTS & SERVICE NEWS
No. "AH10530".

6. After transfusing is complete close the cover of the return oil

filter.

7. Isolate the machine according to local regulations.

8. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".
Fig. 3-96

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WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

9. Disassemble the return oil hoses (Fig. 3-97, Pos. 1) on the

main pumps to accelerate the draining of oil from the pump.

REMARKS: The following steps indicate the standard procedure

for main pump disassembling. It is also possible to
access the main pump assemblies using a forklift
with elonged forks through the opened PTO sound
silencer gate on the right side of the engine housing.
Carry out the following steps only if you refer to the
standard procedure.

Fig. 3-97

10. Disassemble roof cover plate PTO refer to section 3.2.1.3 on page 3-15.

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3.2.8.2 DISASSEMBLING OF MAIN PUMP 1...3 ASSEMBLY

Special tools: n/a

Additional equipment: Crane

Safety harness in conformity with DIN EN 361
Oil drain pans

Main pump 1 assembly: 475 kg

Main pump 2 assembly: 547 kg
Main pump 3 assembly: 481 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

REMARKS: The following procedure describes the disassembly of main pump 1 assembly only in basic steps.
The disassembling of all main pump assemblies is analogously the same.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Carry out the preparatory work for main pump disassembling, refer to section 3.2.8.1 on page 3-67.

2. Unplug the harness connectors from the servo valves at the main pump assembly.

3. Clear all harnesses by opening cable clamps, disassembling

the retainers (Fig. 3-98, Pos. 1), and removing cable straps
from the main pump assembly.

4. Disassemble all hose brackets (Fig. 3-98, Pos. 2) from the

main pump assembly.

Fig. 3-98

5. Mark all pipes and hoses at main pump assembly.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

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DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening the hydraulic system under pressure will result in
blindness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

6. Disconnect the SAE-pressure hoses on top of the main pump assembly and the SAE-suction hoses at the bot-
tom side of the main pump assembly.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

7. Disconnect and clear all other pressure hoses and leak oil hoses from the assembly.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

8. Insert swivel hoist rings and sling the pump assembly

(Fig. 3-99) at the hoist rings.

Fig. 3-99

9. Remove six mounting bolts (Fig. 3-100, Pos. 1). Then remove
pump assembly by pulling it out of the drive shaft housing
(Fig. 3-100, Pos. 2).

REMARKS: When the pump assembly is removed, oil will flow

out of the drive shaft housing. Catch it in an oil pan.

Fig. 3-100

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DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

10. Lift the main pump assembly out of the machinery house using the crane.

11. Check the O-ring (Fig. 3-94, Pos. 5 on page 3-66) at the pump assembly flange and replace it if required.

12. Recommendation:
Replace the suction oil strainer at the suction oil reservoir and the high pressure filter at the control block.

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3.2.8.3 ASSEMBLING OF MAIN PUMP 1...3 ASSEMBLY

Special tools: n/a

Additional equipment: Crane

Safety harness in conformity with DIN EN 361
Paste Optimol Paste White T, PN 323 444 40

Main pump 1 assembly: 475 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: The following procedure describes the assembly of main pump 1 assembly only in basic steps. The
assembling of all main pump assemblies is analogously the same.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Insert swivel hoist rings (Fig. 3-101) and attach the main
pump assembly to a crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

2. Lift the main pump assembly into the machinery house using
the crane.
Fig. 3-101

3. Apply "Optimol Paste White T" to the main pump’s spline

shaft (Fig. 3-102, Pos. 1) before sliding the spline shaft into
the drive shaft housing.

Fig. 3-102

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REMARKS: Use a new O-Ring at the pump mounting flange.

4. Use new mounting bolts (Fig. 3-103, Pos. 1) of grade 8.8 and
tighten the bolts to the specified tightening torque.

b Tightening torque for mounting bolts: 360 Nm

d Refill oil of the drive shaft housing (Fig. 3-103,

Pos. 2), refer to he OPERATION & MAINTENANCE
MANUAL, chapter 4, section "MAIN HYDRAULIC
PUMPS - CHECK OIL LEVEL IN DRIVE SHAFT
HOUSINGS".

For the proper lubricant, refer to the OPERATION &

MAINTENANCE MANUAL, chapter 4, section "FLU-
IDS AND LUBRICANTS".

Fig. 3-103

5. Connect the SAE-pressure hoses on top of the main pump assembly and the SAE-suction hoses at the bottom
side of the main pump assembly.

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Tightening torques for SAE-flange connections

at oil pumps with aluminium housing: Refer to
the PARTS & SERVICE NEWS No. "AH00521".
Fig. 3-104 Exemplaric sketch

6. Reconnect all other pressure hoses and leak oil hoses from the assembly.

7. Replug the harness connectors from the servo valves at the main pump assembly.

8. Retain all harnesses using cable clamps at the retainers

(Fig. 3-98, Pos. 1)

9. Assemble the hose brackets (Fig. 3-98, Pos. 2) at the main

pump assembly and retain the hydraulic hoses.

Fig. 3-105

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10. Assemble roof cover plate PTO refer to section 3.2.1.4 on page 3-20.

11. After installation of new or repaired main pump assemblies it is necessary to adjust the EPC current of every
single pump of the tandem pumps with individual Sol Min Current and Sol Max Current values belonging to
them.
Refer to SHOP MANUAL part 10 STRUCTURE & FUNCTION chapter 9 and to the Parts & Service News No.
"AH12503" for further information.

12. Open the main shut off valve completely.

13. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

14. Add specified hydraulic oil up to the specified level.

15. Check for leaks and proper operation.

16. Check the hydraulic oil level again and add oil if required.

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3.2.9 PUMP DISTRIBUTOR GEAR BOX (PTO)

3.2.9.1 DISASSEMBLING OF THE PUMP DISTRIBUTOR GEAR BOX (PTO)

Special tools: n/a

Additional equipment: Crane

Appropriate stand for the PTO

PTO: 3400 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Disassemble all main pump assemblies from the PTO, refer to section 3.2.8 on page 3-66.

2. Disassemble the pilot oil pump from the PTO, refer to section 3.3.2.1 on page 3-110.

a Drain oil of the spline shaft housings

Drain the gear oil of the PTO: approx. 87 liters
Refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "PTO (PUMP DISTRIBU-
TOR GEAR) - CHANGE OIL".

3. Disconnect the spray nozzle hose (Fig. 3-106, Pos. 2), the
leak oil hose (Fig. 3-106, Pos. 3) and the cooler bypass hose
(Fig. 3-106, Pos. 4) from the PTO (Fig. 3-106, Pos. 1).

4. Disconnect the suction hose (Fig. 3-106, Pos. 5) of the PTO

lubrication pump from the suction port of the PTO (Fig. 3-106,
Pos. 1).

5. Unplug the harness connectors from the temperature sensors

(Fig. 3-106, Pos. 6) [47B049] and [57B182].

REMARKS: When a line is disconnected PTO gear oil will flow

out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation. Fig. 3-106

6. Remove the bolts (Fig. 3-107, Pos. 1) and clear all retainer
(Fig. 3-107, Pos. 2) with attached hoses and wire harnesses
from the PTO.

Fig. 3-107 Example

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7. Disassemble and remove the fire wall (Fig. 3-108, Pos. 1)

using a crane.

REMARKS: The fire wall is a customized assembly and may

consist of several parts or be a single assembly,
depending on the customer and/or the used fire pro-
tection and suppression system.

Fig. 3-108

8. Disassemble the coupling assembly from the PTO, refer to

section 3.2.5 on page 3-45.

9. Disassemble all mounting bolts (Fig. 3-109, Pos. 1) attaching

the PTO to the engine flange (Fig. 3-109, Pos. 2).

Fig. 3-109

10. Attach the PTO to a crane, using the lifting eyes (Fig. 3-110,
arrow).

Fig. 3-110

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11. Disassemble four bolts (Fig. 3-111, Pos. 1) with resilient

sleeves attaching the PTO to the engine suspensions
(Fig. 3-111, Pos. 2).

Fig. 3-111

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

12. Disassemble the PTO using the crane.

REMARKS: It is recommended to replace all flexible bearings and rubber-bounded metal bars of the flexible
mounts at the engine suspensions. Refer to the PARTS & SERVICE NEWS No. "AH01521".

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3.2.9.2 ASSEMBLING OF THE PUMP DISTRIBUTOR GEAR BOX (PTO)

Special tools: Hydraulic testing kit, PN 232 315 40

Additional equipment: MPG (Multi Purpose Grease)

Crane

Fire wall (3 parts): 89 kg + 2 x 23 kg

PTO: 3400 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: Carry out assembling in reverse order of disassembling.

1. Attach the PTO to a crane, using the lifting eyes (Fig. 3-112,
arrow).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

2. Move the PTO into mounting position using the crane.

Fig. 3-112

3. Install four bolts (Fig. 3-113, Pos. 1) with resilient sleeves

attaching the PTO to the engine suspensions (Fig. 3-113,
Pos. 2).

REMARKS: Use new mounting bolts with grade 10.9.

Apply MPG (or roller bearing grease, or grease from
the CLS system) and tighten the bolts to the speci-
fied tightening torque.

b Tightening torque for the PTO mounting bolts:

1670 Nm

Fig. 3-113

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4. Install all mounting bolts (Fig. 3-114, Pos. 1) attaching the

PTO to the engine flange (Fig. 3-114, Pos. 2).

5. Assemble the coupling assembly from the PTO, refer to

section 3.2.5 on page 3-45.

Fig. 3-114

6. Assemble the fire wall (Fig. 3-115, Pos. 1) using a crane.

REMARKS: The fire wall is a customized assembly and may

consist of several parts or be a single assembly,
depending on the customer and/or the used fire pro-
tection and suppression system.

Fig. 3-115

7. Assemble all retainer (Fig. 3-116, Pos. 2) using the bolts

(Fig. 3-116, Pos. 1) to retain hoses and wire harnesses at the
PTO.

Fig. 3-116 Example

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8. Connect the spray nozzle hose (Fig. 3-117, Pos. 2), the leak
oil hose (Fig. 3-117, Pos. 3) and the cooler bypass hose
(Fig. 3-117, Pos. 4) at the PTO (Fig. 3-117, Pos. 1).

9. Connect the suction hose (Fig. 3-117, Pos. 5) of the PTO

lubrication pump at the suction port of the PTO (Fig. 3-117,
Pos. 1).

10. Re-plug the harness connectors of the temperature sensors

(Fig. 3-117, Pos. 6) [47B049] and [57B182].

Fig. 3-117

d Refill gear oil of the PTO, approx. 120 liters.

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "PTO (PUMP DISTRIBU-
TOR GEAR) - CHANGE OIL".
For the proper lubricant, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"FLUIDS AND LUBRICANTS".

d Backfill the PTO gear oil pump for bleeding.

11. Bleed air from the hydraulic system, refer to OPERATION & MAINTENANCE MANUAL, chapter, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
the PARTS & SERVICE NEWS No. "AH06519".

12. Open the main shut off valve completely.

13. Run machine to warm, test pressure of the circulation pump and adjust if required.
Refer to SHOP MANUAL part 10 STRUCTURE & FUNCTION, chapter 4 for further information.

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3.2.9.3 DISASSEMBLING OF THE PTO OIL CIRCULATION PUMP

Special tools: n/a

Additional equipment: Oil drain pan

PTO oil circulation pump: 11 kg

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Isolate the machine according to local regulations.

2. Disconnect the SAE-flanges of pressure hose and suction hose from the oil circulation pump.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

3. Disassemble two mounting bolts (Fig. 3-118, Pos. 2) and pull

the PTO oil circulation pump (Fig. 3-118, Pos. 3) out of the
main pump 3 assembly.

4. Check the O-ring (Fig. 3-118, Pos. 1) at the pump flange and
replace it if required.

REMARKS: It is recommended to replace the filter of the PTO oil

circulation pump.

Fig. 3-118

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3.2.9.4 ASSEMBLING OF THE PTO OIL CIRCULATION PUMP

Special tools: Hydraulic testing kit, PN 232 315 40

Additional equipment: Paste Optimol Paste White T, PN 323 444 40

PTO oil circulation pump: 11 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Assemble the PTO oil circulation pump (Fig. 3-118, Pos. 3)

with the O-ring (Fig. 3-118, Pos. 1) at the main pump 3
assembly.

REMARKS: Apply paste Optimol Paste White T on the spline

shaft of the pump (Fig. 3-118, Pos. 3).

2. Assemble two mounting bolts (Fig. 3-118, Pos. 2).

Fig. 3-119

3. Install the SAE-pressure hoses on top of the main pump assembly and the SAE-suction hoses at the bottom
side of the main pump assembly and tighten the bolts with the specified torque.

NOTE! Always replace the flat seals at SAE-flange connections when installing used hydraulic lines!
A flat and level sealing surface is essential for proper sealing!

NOTICE
RISK OF PUMP DAMAGE!
The PTO oil circulation pump has an aluminium pump housing so the tightening torque for the mounting
bolts of SAE-flange connection is limited to 8 Nm.

Do not exceed the specified tightening torque when assembling the SAE-hoses.

b Tighten the mounting bolts of SAE-flange connection at the PTO oil circulation pump: 8 Nm

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4. Bleed air from the hydraulic system, refer to OPERATION & MAINTENANCE MANUAL, chapter, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
the PARTS & SERVICE NEWS No. "AH06519".

5. Bleed air from the PTO oil circulation pump by backfilling the pump with PTO gear oil.

6. Fill PTO gear oil up to the specified level.

For the proper lubricant, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "FLUIDS
AND LUBRICANTS".

7. Run machine to warm, test pressure of the PTO oil circulation pump and adjust if required.
Refer to SHOP MANUAL part 10 STRUCTURE & FUNCTION, chapter 4 for further information.

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3.3 HYDRAULICS

3.3.1 HYDRAULIC OIL COOLER ASSEMBLY

3.3.1.1 DISASSEMBLING OF HYDRAULIC COOLER FAN DRIVE PUMP

Special tools: n/a

Additional equipment: Crane

Oil drain pan

Hydraulic cooler fan drive pump: 106 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Open the PTO sound silencer gate on the right side of the engine housing.

4. Close the hand wheel (Fig. 3-120, Pos. 1) of main shut off
valve between suction oil reservoir and main oil reservoir.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.

Fig. 3-120

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5. Open the cover (Fig. 3-121, Pos. 1) of the return oil filter.

6. Transfuse oil from the suction oil reservoir into the main oil
reservoir, refer to the PARTS & SERVICE NEWS
No. "AH10530".

7. After transfusing is complete close the cover of the return oil

filter.

8. Isolate the machine according to local regulations.

9. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".
Fig. 3-121

10. Disconnect the high pressure hose (Fig. 3-122, Pos. 1), the
leak oil hose (Fig. 3-122, Pos. 2), and the SAE-flange of the
suction hose from the pump.

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

Fig. 3-122

11. Attach the pump to a crane at the hoist ring (Fig. 3-123).

NOTE! Do not use rigid lifting eye bolts to disassemble the

pump assembly. Always use appropriate certified
swivel hoist rings instead.

12. Disassemble the four mounting bolts (Fig. 3-123, Pos. 1).
Then pull hydraulic cooler fan drive pump out of the main
pump 2 assembly.

Fig. 3-123

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DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

13. Disassemble the hydraulic cooler fan drive pump through the PTO sound silencer gate using a crane.

14. Check the following parts for damage and wear and replace if
required (Fig. 3-124):

(1) Coupling
(2) Seal
(3) Snap ring
(4) O-ring
(5) Hydraulic cooler fan drive pump

REMARKS: It is recommended to replace the screen filter of the

hydraulic cooler fan drive pump and the high pres-
sure filter.

Fig. 3-124

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3.3.1.2 ASSEMBLING OF HYDRAULIC COOLER FAN DRIVE PUMP

Special tools: Rotational speed infrared probe DS03, PN 793 788 73

Additional equipment: Crane

Paste Optimol Paste White T, PN 323 444 40

Hydraulic cooler fan drive pump: 106 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: Ensure that the mating surfaces are clean and free of paint before assembly.

1. Assemble the following parts in the given order (Fig. 3-125):

(1) Coupling
(2) Seal
(3) Snap ring
(4) O-ring
(5) Hydraulic cooler fan drive pump

NOTE! Always use new flat sealings at the SAE-flange con-

nections.
A flat and level sealing surface is essential for
proper sealing!

REMARKS: Apply paste Optimol Paste White T on the spline

shaft of the pump.

Fig. 3-125

2. Attach the pump to a crane at the hoist ring (Fig. 3-126).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

Fig. 3-126
3. Move the hydraulic cooler fan drive pump into mounting posi-
tion main pump 2 assembly, through the PTO sound silencer
gate using the crane.

4. Assemble the four mounting bolts (Fig. 3-126, Pos. 1).

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5. Connect the high pressure hose (Fig. 3-127, Pos. 1), the leak
oil hose (Fig. 3-127, Pos. 2), and the SAE-flange of the suc-
tion hose from the pump.

Fig. 3-127

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 3-128 Exemplaric sketch

6. Open the main shut off valve completely.

7. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

8. Add specified hydraulic oil up to the specified level.

9. Check and adjust the cooler fan drive if required.

Refer to SHOP MANUAL part 10 STRUCTURE & FUNCTION, chapter 6 for further information.

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3.3.1.3 DISASSEMBLING OF THE HYDRAULIC COOLER FAN ASSEMBLY

Special tools: n/a

Additional equipment: Oil drain pan

Crane

Hydraulic cooler fan assembly: 71.5 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter
3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure may result in
blindness, serious injury, permanent disfigurement, or scaring.

Make sure that the pressure is relieved before any hydraulic lines will be disassembled.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

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5. Disconnect the hydraulic pressure hose (Fig. 3-129, Pos. 1)

and the return hose (Fig. 3-129, Pos. 2).

6. Disconnect the leak oil hose from the hydraulic motor.

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

7. Disassemble the hydraulic pipes (Fig. 3-129, Pos. 3) between

the hydraulic motors and disassemble the piping arch
(Fig. 3-129, Pos. 4) incl. the check valve.

Fig. 3-129

8. Disassemble the upper hydraulic fan guard halve (Fig. 3-130,

Pos. 1) and the lower hydraulic fan guard halve (Fig. 3-130,
Pos. 2).

Fig. 3-130

9. Disassemble the hydraulic cooler fan assembly (Fig. 3-131,

Pos. 1) from the main cooler frame support using a crane.

CAUTION
SHARP BLADE EDGES!
Fan blades could have sharp edges. May result in injury to
the hands due to cuts.

Use protective gloves.

NOTE! Move the assembly carefully in order to avoid dam-

age to the oil cooler or the fan blades. Fig. 3-131

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3.3.1.4 ASSEMBLING OF THE HYDRAULIC COOLER FAN ASSEMBLY

Special tools: Rotational speed infrared probe DS03, PN 793 788 73

Additional equipment: Crane

Hydraulic cooler fan assembly: 71.5 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Assemble the hydraulic cooler fan assembly (Fig. 3-132,

Pos. 1) into the main cooler frame support using a crane.

CAUTION
SHARP BLADE EDGES!
Fan blades could have sharp edges. May result in injury to
the hands due to cuts.

Use protective gloves.

NOTE! Move the assembly carefully in order to avoid dam-

age to the oil cooler or the fan blades. Fig. 3-132

2. Assemble the lower hydraulic fan guard halve (Fig. 3-133,

Pos. 2) and the upper hydraulic fan guard halve (Fig. 3-133,
Pos. 1).

Fig. 3-133

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3. Connect the hydraulic pressure hose (Fig. 3-134, Pos. 1) and

the return hose (Fig. 3-134, Pos. 2).

4. Disconnect the leak oil hose from the hydraulic motor.

5. Assemble the hydraulic pipes (Fig. 3-134, Pos. 3) between

the hydraulic motors.

6. Assemble the piping arch (Fig. 3-134, Pos. 4) incl. the check
valve.

REMARKS: Note the flow direction of the check valve.

Fig. 3-134

7. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4,section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

8. Add specified hydraulic oil up to the specified level.

9. Check and adjust the cooler fan drive if required.

Refer to SHOP MANUAL part 10 STRUCTURE & FUNCTION, chapter 6 for further information.

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Please continue reading on the next page.

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3.3.1.5 DISASSEMBLING OF HYDRAULIC COOLER FAN AND MOTOR

Special tools: n/a

Additional equipment: n/a

Hydraulic motor: 19 kg
Fan motor carrier: 20.5 kg
Fan hub: 13 kg

Fig. 3-135 Hydraulic cooler fan assembly

(1) Bolt (6) Fan hub

(2) Locking plate (7) Bolt

(3) Cooler fan (8) Hydraulic motor

(4) Mounting bolt (9) Fan motor carrier

(5) Thrust block

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CAUTION
SHARP BLADE EDGES!
Fan blades could have sharp edges. May result in injury to the hands due to cuts.

Use protective gloves.

1. Disassemble the hydraulic cooler fan assembly, refer to section 3.3.1.3 on page 3-89.

2. Disassemble the attaching bolts (Fig. 3-135, Pos. 1) with the locking plates (Fig. 3-135, Pos. 2).
Discard the locking plates.

3. Remove the cooler fan (Fig. 3-135, Pos. 3) from the fan hub (Fig. 3-135, Pos. 6).

4. Disassemble the mounting bolt (Fig. 3-135, Pos. 4) with the thrust block (Fig. 3-135, Pos. 5) and take off the
fan hub (Fig. 3-135, Pos. 6) from the hydraulic motor (Fig. 3-135, Pos. 8).

5. Disassemble the four bolts (Fig. 3-135, Pos. 7) and disassemble the hydraulic motor (Fig. 3-135, Pos. 8) from
the fan motor carrier (Fig. 3-135, Pos. 9).

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3.3.1.6 ASSEMBLING OF HYDRAULIC COOLER FAN AND MOTOR

Special tools: n/a

Additional equipment: Paste Optimol Paste White T, PN 323 444 40

Hydraulic motor: 19 kg
Fan motor carrier: 20.5 kg
Fan hub: 13 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: Carry out assembling in reverse order of disassembling.

Fig. 3-136 Hydraulic cooler fan assembly

(1) Bolt (6) Fan hub

(2) Locking plate (7) Bolt

(3) Cooler fan (8) Hydraulic motor

(4) Mounting bolt (9) Fan motor carrier

(5) Thrust block

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1. Install the hydraulic motor (Fig. 3-136, Pos. 8) at the fan motor carrier (Fig. 3-136, Pos. 9) and fix it using four
bolts (Fig. 3-136, Pos. 7).

REMARKS: Use new bolts (Fig. 3-136, Pos. 1 and 7) and locking plates (Fig. 3-136, Pos. 2).

2. Apply paste Optimol Paste White T at the spline shaft of the hydraulic motor.

3. Mount the hub (Fig. 3-136, Pos. 6) onto the spline shaft of the hydraulic motor.

CAUTION
SHARP BLADE EDGES!
Fan blades could have sharp edges. May result in injury to the hands due to cuts.

Use protective gloves.

4. Move the cooler fan (Fig. 3-136, Pos. 3) into mounting position.

5. Assemble the attaching bolts (Fig. 3-136, Pos. 1) with new the locking plates (Fig. 3-136, Pos. 2).

6. Re-install the hydraulic cooler fan assembly, refer to section 3.3.1.4 on page 3-91.

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3.3.1.7 DISASSEMBLING OF THE HYDRAULIC OIL COOLERS

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Crane
Mobile elevator working platform

Hydraulic oil cooler: 240 kg each

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Close the hand wheel (Fig. 3-137, Pos. 1) of main shut off
valve between suction oil reservoir and main oil reservoir.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.

Fig. 3-137

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4. Open the cover (Fig. 3-138, Pos. 1) of the return oil filter.

5. Transfuse oil from the return manifold and the suction oil res-
ervoir into the main oil reservoir, refer to the PARTS & SER-
VICE NEWS No. "AH10530".

6. After transfusing is complete close the cover of the return oil

filter.

7. Isolate the machine according to local regulations.

8. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".
Fig. 3-138

9. Open the hydraulic oil cooler swing out door(s).

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "HYDRAULIC OIL COOLERS -
INSPECT AND CLEAN IF NECESSARY".

10. Disconnect all inlet hoses and outlet hoses from the hydraulic oil cooler and from the PTO gear oil cooler.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

11. Sling oil cooler as shown in Fig. 3-139.

Fig. 3-139

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Hydraulics Superstructure

Fig. 3-140 Disassembling of the oil cooler

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

12. Disassemble bolt (Fig. 3-140, Pos. 2) and resilient sleeve (Fig. 3-140, Pos. 3) and clear the oil cooler
(Fig. 3-140, Pos. 1) from the angle (Fig. 3-140, Pos. 8).

13. Using a crane, take the oil cooler out of the radiator mounting (Fig. 3-140, Pos. 4).

14. Check the buffer element (Fig. 3-140, Pos. 9) and replace it if required.

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3.3.1.8 ASSEMBLING OF THE HYDRAULIC OIL COOLERS

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Crane
Mobile elevator working platform
Glue PN 256 952 40

Hydraulic oil cooler: 240 kg each

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Change the resistor (inlet hoses) and all blind plugs from the old oil cooler to the new oil cooler.

2. Apply glue PN 256 952 40 at the profiled joints (Fig. NOTE!, Pos. 5 to 7) and attach the profiled joints to the oil
cooler:

– (Fig. NOTE!, Pos. 5) 30 x 1600

– (Fig. NOTE!, Pos. 6) 25 x 1600
– (Fig. NOTE!, Pos. 7) 15 x 1600
3. Sling oil cooler as shown in Fig. 3-141.

Fig. 3-141

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

4. Using the crane, move the oil cooler (Fig. 3-140, Pos. 1) into the radiator mounting (Fig. 3-140, Pos. 4).

5. Assemble bolts (Fig. 3-140, Pos. 2) and resilient sleeves (Fig. 3-140, Pos. 3) to retain the oil cooler at the
angle (Fig. 3-140, Pos. 8).

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6. Reconnect the respective inlet and outlet hoses to the hydraulic oil cooler and to the PTO gear oil cooler.

7. Open the main shut off valve completely.

8. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

9. Add specified hydraulic oil up to the specified level.

10. Add PTO gear oil up to the specified level.

For the proper lubricant, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "FLUIDS
AND LUBRICANTS".

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3.3.1.9 DISASSEMBLING OF THE HYDRAULIC OIL COOLER ASSEMBLY

Special tools: Hydraulic torque wrench & aggregate set, PN 232 759 40
46 mm hexagon impact socket wrench (1"), PN 793 788 73

Additional equipment: Safety harness in conformity with EN 361

Crane
Mobile elevator working platform
Oil drain pan
Crane

Hydraulic oil cooler assembly (standard): 2508 kg

Hydraulic oil cooler assembly (55°C): 3353kg
Sound silencer (optional): 1400 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Close the hand wheel (Fig. 3-142, Pos. 1) of main shut off
valve between suction oil reservoir and main oil reservoir.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.

Fig. 3-142

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4. Open the cover (Fig. 3-143, Pos. 1) of the return oil filter.

5. Transfuse oil from the return manifold and the suction oil res-
ervoir into the main oil reservoir, refer to the PARTS & SER-
VICE NEWS No. "AH10530".

6. After transfusing is complete close the cover of the return oil

filter.

7. Isolate the machine according to local regulations.

8. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".
Fig. 3-143

9. Disconnect the harness connectors [51E050...] from the lightning equipment and clear the wiring harness from
hydraulic oil cooler frame (refer to Fig. 3-171 on page 3-120).

10. Disconnect the harness connector of the end-line pressure switch [62B046] and clear the wiring harness from
the hydraulic oil cooler frame (refer to Fig. 3-171 on page 3-120).

11. At the console (Fig. 3-144, Pos. 2):

Disconnect hydraulic inlet hoses (Fig. 3-144, Pos. 1) and
return hoses of the hydraulic cooler fan motors.

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

Fig. 3-144

12. At the console (Fig. 3-145, Pos. 3):

Disconnect the PTO gear oil hoses (Fig. 3-145, Pos. 1 and 2)
leading to the hydraulic coolers.

REMARKS: When a PTO gear oil line is disconnected oil will

flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

Fig. 3-145

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13. Disconnect the hydraulic hoses (Fig. 3-146, Pos. 1 and 2) at

the shown joints (Fig. 3-146, Arrow).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

Fig. 3-146

14. Disconnect the return hoses (Fig. 3-147, Pos. 1).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

Fig. 3-147

15. If equipped:
Disassemble the optional sound silencer (Fig. 3-148, Pos. 1)
using a crane.

16. Insert swivel hoist rings into the threads at the top of the
assembly.

17. Attach the hydraulic oil cooler assembly at the swivel hoists
rings (Fig. 3-148, arrows) to a crane.

Fig. 3-148

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18. Disassemble mounting bolts (Fig. 3-149, Pos. 2) using the

hydraulic torque wrench.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

19. Remove the hydraulic oil cooler assembly (Fig. 3-149, Pos. 1)
from the superstructure using the crane.

20. Rest the hydraulic oil cooler assembly on the ground on an Fig. 3-149
appropriate stand.

Carry out the next steps with the hydraulic oil cooler assembly resting on the ground.

21. Disassemble the hand rails from the hydraulic oil cooler assembly.

22. If required, disassemble the hydraulic oil cooler from the hydraulic oil cooler assembly, refer to section 3.3.1.7
on page 3-98.

23. If required, disassemble the cooler fan assembly from the hydraulic oil cooler assembly, refer to
section 3.3.1.3 on page 3-89.

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3.3.1.10 ASSEMBLING OF THE HYDRAULIC OIL COOLER ASSEMBLY

Special tools: Hydraulic torque wrench & aggregate set, PN 232 759 40
46 mm hexagon impact socket wrench (1"), PN 793 788 73

Additional equipment: Safety harness in conformity with EN 361

Crane
Mobile elevator working platform
MPG (Multi Purpose Grease)

Hydraulic oil cooler assembly (standard): 2508 kg

Hydraulic oil cooler assembly (55°C): 3353kg
Sound silencer (optional): 1400 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

REMARKS: Carry out assembling in reverse order of disassembling.

1. If required, assemble the hydraulic oil cooler from the hydraulic oil cooler assembly, refer to section 3.3.1.8 on
page 3-101.

2. If required, assemble the cooler fan assembly from the hydraulic oil cooler assembly, refer to section 3.3.1.4
on page 3-91.

3. Assemble the hand rails at the hydraulic oil cooler assembly.

NOTE! An optional sound silencer (Fig. 3-150, Pos. 1) must

not be assembled with the hydraulic oil cooler
assembly resting on the ground.
The center of gravity of the hydraulic oil cooler
assembly is changed!

4. Insert swivel hoist rings into the threads at the top of the
assembly.

5. Attach the hydraulic oil cooler assembly at the swivel hoists

rings (Fig. 3-150, arrows) to a crane.

Fig. 3-150

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Hydraulics Superstructure

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

6. Move the hydraulic oil cooler assembly (Fig. 3-151, Pos. 1)

into mounting position using the crane.

7. Assemble new mounting bolts (Fig. 3-151, Pos. 2) of grade

10.9. Apply MPG (or roller bearing grease, or grease from the
CLS system) on heads and threads of the bolts and tighten
the mounting bolts with the specified tightening torque using Fig. 3-151
the hydraulic torque wrench.

b Tightening torque for mounting bolts (Fig. 3-151,

Pos. 2): 1770 Nm.

8. Detach the crane.

9. If equipped:
Assemble the optional sound silencer (see Fig. 3-150, Pos. 1) using the crane.

10. Connect the return hoses (Fig. 3-152, Pos. 1).

Fig. 3-152

11. Connect the hydraulic hoses (Fig. 3-153, Pos. 1 and 2) at the
shown joints (Fig. 3-153, Arrow).

Fig. 3-153

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12. At the console (Fig. 3-154, Pos. 3):

Connect the PTO gear oil hoses (Fig. 3-154, Pos. 1 and 2)
leading to the hydraulic coolers.

Fig. 3-154

13. At the console (Fig. 3-155, Pos. 2):

Disconnect hydraulic inlet hoses (Fig. 3-155, Pos. 1) and
return hoses of the hydraulic cooler fan motors.

Fig. 3-155

14. Reconnect the harness connectors [51E050...] of the lightning equipment and retain the wiring harness at
hydraulic oil cooler frame (refer to Fig. 3-171 on page 3-120).

15. Reconnect the harness connector of the end-line pressure switch [62B046] and retain the wiring harness a the
hydraulic oil cooler frame (refer to Fig. 3-171 on page 3-120).

16. Open the main shut off valve completely.

17. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

18. Add specified hydraulic oil up to the specified level.

19. Add PTO gear oil to the specified level.

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3.3.2 PILOT OIL PUMP (GEAR PUMP)

3.3.2.1 DISASSEMBLING OF THE PILOT OIL PUMP

Special tools: n/a

Additional equipment: Oil drain pan

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Close the hand wheel (Fig. 3-156, Pos. 1) of main shut off
valve between suction oil reservoir and main oil reservoir.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.

Fig. 3-156

2. Open the cover (Fig. 3-157, Pos. 1) of the return oil filter.

3. Transfuse oil from the suction oil reservoir into the main oil
reservoir, refer to the PARTS & SERVICE NEWS
No. "AH10530".

4. After transfusing is complete close the cover of the return oil

filter.

5. Isolate the machine according to local regulations.

6. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".
Fig. 3-157

7. Disconnect the pressure hose and the SAE-flange of the suction hose from the pilot pump.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

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Fig. 3-158 Disassembling of the pilot pump

8. Disassemble four bolts (Fig. 3-158, Pos. 2) and washers (Fig. 3-158, Pos. 3) attaching the pilot oil pump
(Fig. 3-158, Pos. 1) to the PTO (Fig. 3-158, Pos. 4).

9. Disassemble the pilot pump (Fig. 3-158, Pos. 1) by pulling it out of the PTO (Fig. 3-158, Pos. 4).

REMARKS: When the pilot pump is disassembled, oil will flow out of the spline shaft housing.
Catch it in an oil pan.

10. Recommendation:
Replace the suction oil strainer at the suction oil reservoir and the pressure filter (26.1) at the control and filter
plate.

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3.3.2.2 ASSEMBLING OF THE PILOT OIL PUMP

Special tools: Hydraulic testing kit, PN 232 315 40

Additional equipment: Paste Optimol Paste White T, PN 323 444 40

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: Carry out assembling in reverse order of disassembling.

Fig. 3-159 Disassembling of the pilot pump

1. Apply paste Optimol Paste White T on the spline shaft of the pilot oil pump (Fig. 3-158, Pos. 1).

2. Assemble the pilot pump by pulling it out of the PTO (Fig. 3-158, Pos. 4).

3. Assemble four bolts (Fig. 3-158, Pos. 2) and washers (Fig. 3-158, Pos. 3) attaching the pilot oil pump to the
PTO (Fig. 3-158, Pos. 4).

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4. Re-connect the SAE-flanges of the pressure hose and the suction hose at the pilot oil pump.

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 3-160 Exemplaric sketch

d Refill oil at the level plug (Fig. 3-161, Pos. 1) in the

spline shaft housing.
For the proper lubricant, refer to the OPERATION &
MAINTENANCE MANUAL, chapter 4, section "FLU-
IDS AND LUBRICANTS".
Fill up to lower edge of level plug opening.

Fig. 3-161

5. Open the main shut off valve completely.

6. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

7. Check the pilot pressure and adjust if required.

Refer to SHOP MANUAL part 10 STRUCTURE & FUNCTION, chapter 7 for further information.

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3.3.3 MAIN SHUT OFF VALVE

3.3.3.1 DISASSEMBLING OF THE MAIN SHUT OFF VALVE

Special tools: n/a

Additional equipment: Oil tank (3000 liters)

Main shut off valve: 22 kg

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

3. Close the hand wheel (Fig. 3-162, Pos. 1) of main shut off
valve between suction oil reservoir and main oil reservoir.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.

Fig. 3-162

4. Open the cover (Fig. 3-163, Pos. 1) of the return oil filter.

5. Transfuse oil from the return manifold and the suction oil res-
ervoir, refer to the PARTS & SERVICE NEWS
No. "AH10530".

6. After transfusing is complete close the cover of the return oil

filter.

7. Isolate the machine according to local regulations.

8. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".
Fig. 3-163

a Drain hydraulic oil from the hydraulic oil tank, approx. 2900 liters.
Refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "HYDRAULIC SYSTEM,
CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

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9. Disconnect harness connector from the proximity switch at

the main shut off valve. Refer to Fig. 3-171 on page 3-120.

10. Disassemble the bolts (Fig. 3-164, Pos. 1), dismantle the
compensator (Fig. 3-164, Pos. 2), and the main shut off valve
(Fig. 3-164, Pos. 3).

REMARKS: When the main shut off valve (Fig. 3-164, Pos. 3)
and the compensator (Fig. 3-164, Pos. 2) are disas-
sembled some oil inside the piping will flow out.
Catch it in an oil pan.

11. Check the condition of the compensator (Fig. 3-164, Pos. 3)

and replace when necessary.
Fig. 3-164

12. Recommendation:
Replace the screen filter at the suction oil reservoir.

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3.3.3.2 ASSEMBLING OF THE MAIN SHUT OFF VALVE

Special tools: n/a

Additional equipment: n/a

Main shut off valve: 22 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: Carry out assembling in reverse order of disassembling.

1. Assemble the compensator (Fig. 3-165, Pos. 2), and the main
shut off valve (Fig. 3-165, Pos. 3) using the bolts (Fig. 3-165,
Pos. 1).

2. Reconnect harness connector at the proximity switch at the

main shut off valve. Refer to Fig. 3-171 on page 3-120.

Fig. 3-165

d Fill hydraulic oil into the hydraulic oil tank,

approx. 2900 liters.
Refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "HYDRAULIC SYSTEM -
CHANGE OIL, REPLACE STRAINERS AND PULSATION DAMPER".

3. Open the main shut off valve completely.

4. Bleed air from the hydraulic system, refer to OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

5. Add specified hydraulic oil up to the specified level.

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3.3.4 HYDRAULIC OIL TANK

3.3.4.1 DISASSEMBLING OF THE HYDRAULIC OIL TANK

Special tools: Hydraulic torque wrench & aggregate set, PN 232 759 40
46 mm hexagon impact socket wrench (1"), PN 793 788 73

Additional equipment: Safety harness in conformity with EN 361

Crane
Mobile elevator working platform
4 x Swivel hoist ring: M 36

Hydraulic oil tank incl. back pressure valve: 2341 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Relieve the pressure in the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter
3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

4. Isolate the machine according to local regulations.

5. Disassemble the main shut off valve, refer to section 3.3.3.1 on page 3-114.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

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6. Disassemble the transfer pump (Fig. 3-166, Pos. 1) from the

hydraulic oil tank.

7. Loosen the clamps (Fig. 3-166, Pos. 2) to clear all hydraulic

lines from the hydraulic oil tank.

Fig. 3-166

8. Disconnect the hydraulic lines (Fig. 3-167, Pos. 1) leading to

the hydraulic coolers from the hydraulic oil tank.

9. Disconnect the pressure hoses (Fig. 3-167, Pos. 2) from the

back pressure valve.

10. Mark and disconnect all return lines (Fig. 3-167, Pos. 3) from
the hydraulic oil tank.

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

11. Disassemble the clamps (Fig. 3-167, Pos. 4) to clear all pres- Fig. 3-167
sure hoses from the hydraulic oil tank.

12. Disconnect the hydraulic hoses (Fig. 3-168, Pos. 1) from the
hydraulic oil tank.

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

13. Safely fix the control frame (Fig. 3-168, Pos. 2) at the roof
frame (Fig. 3-168, Pos. 3) before the bolts (Fig. 3-168,
Pos. 4) are disassembled. So the control frame (Fig. 3-168,
Pos. 2) is in a fixed position and no damage to the hydraulic
hoses may occur.

14. Disassemble the bolts (Fig. 3-168, Pos. 4) to clear the control Fig. 3-168
frame (Fig. 3-168, Pos. 2) from the hydraulic oil tank.

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15. Disassemble the clamp (Fig. 3-169, Pos. 1) to clear the hose
from the hydraulic oil tank (bottom).

Fig. 3-169

16. Disconnect the hose assembly (Fig. 3-170, Pos. 1) from the
hydraulic oil tank (Fig. 3-170, Pos. 2).

REMARKS: When the hose assembly (Fig. 3-170, Pos. 1) is dis-

assembled oil inside the piping and the hydraulic oil
tank will flow out. Catch it in an oil pan.

Fig. 3-170

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Fig. 3-171 Hydraulic Oil Tank - Location of electrical equipment

17. Disconnect the harness connectors [51E050...] from the lightning equipment and clear the wiring harness from
hydraulic oil cooler frame (see Fig. 3-171).

18. Disconnect the harness connector of the end-line pressure switch [62B046] and clear the wiring harness from
the hydraulic oil cooler frame (see Fig. 3-171).

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19. Disconnect the harness connectors from all sensors [40B0XX] at the hydraulic oil tank (see Fig. 3-171).

20. Clear the wiring harness from the hydraulic oil tank.

21. Disassemble the plates (Fig. 3-172, Pos. 1) at the threads

(Fig. 3-172, Pos. 2).

22. Insert swivel hoist rings (M 36) into the threads (Fig. 3-172,
Pos. 2).

23. Attach the hydraulic oil tank to a crane.

Fig. 3-172

24. Disassemble two mounting bolts (Fig. 3-173, Pos. 1) from

each mount flange (Fig. 3-173, Pos. 3) of the hydraulic oil
tank (Fig. 3-173, Pos. 2) using the hydraulic torque wrench.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

25. Lift the hydraulic oil tank (Fig. 3-173, Pos. 2) off the super-
structure using the crane and place it on the ground.

Fig. 3-173

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Hydraulics Superstructure

Carry out the next steps with the hydraulic oil tank resting on the ground:

26. Disassemble the hand rails from the hydraulic oil tank.

27. Carry out the next four steps as required:

– Disassemble the filters and all other provided parts from

the top of the hydraulic oil tank.
– Disassemble the back pressure valve (Fig. 3-174, Pos. 1)
and discard the gasket (Fig. 3-174, Pos. 2).
– Disassemble all plugs and provided parts (Fig. 3-174,
Pos. 3 to 6) from the hydraulic oil tank.
– Disassemble all sensors and switches [40B0XX] (see
Fig. 3-171 on page 3-120) from the hydraulic oil tank.

Fig. 3-174

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3.3.4.2 ASSEMBLING OF THE HYDRAULIC OIL TANK

Special tools: Hydraulic torque wrench & aggregate set, PN 232 759 40
46 mm hexagon impact socket wrench (1"), PN 793 788 73

Additional equipment: Safety harness in conformity with EN 361

Crane
Mobile elevator working platform
MPG (Multi Purpose grease)
4 x Swivel hoist ring: M 36

Hydraulic oil tank incl. back pressure valve: 2341 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Carry out the next four steps as required (use new gaskets,
and O-rings):

– Assemble the filters and all other provided parts from the
top of the hydraulic oil tank.
– Assemble the back pressure valve (Fig. 3-175, Pos. 1)
with a new gasket (Fig. 3-175, Pos. 2).
– Assemble all plugs and provided parts (Fig. 3-175, Pos. 3
to 6) at the hydraulic oil tank.
– Assemble all sensors and switches [40B0XX] (see
Fig. 3-171 on page 3-120) at the hydraulic oil tank.

Fig. 3-175

2. Assemble the hand rails at the hydraulic oil tank.

3. Insert swivel hoist rings (M 36) into the threads on top of the hydraulic oil tank and attach the hydraulic oil tank
to a crane.

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DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

4. Lift the hydraulic oil tank (Fig. 3-176, Pos. 2) into mounting
position using the crane.

5. Assemble new mounting bolts (Fig. 3-176, Pos. 1) with grade

10.9 at the mounting flanges (Fig. 3-176, Pos. 3) of the
hydraulic oil tank (Fig. 3-176, Pos. 2).
Apply MPG (or roller bearing grease, or grease from the CLS
system) at the bolts and tighten the bolts (Fig. 3-176, Pos. 1)
with the specified torque using the hydraulic torque wrench.

b Tightening torque for mounting bolts:

1770 Nm

Fig. 3-176

6. Detach the crane and remove the swivel hoist rings (M 36)
from the threads (Fig. 3-177, Pos. 2).

7. Assemble the plates (Fig. 3-177, Pos. 1).

Fig. 3-177

8. Reconnect the harness connectors from all sensors [40B0XX] at the hydraulic oil tank and retain the wiring
harness at the hydraulic oil tank (see Fig. 3-171 on page 3-120).

9. Assemble the main shut off valve, refer to section 3.3.3.2 on page 3-116.

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10. Reconnect the hydraulic hoses (Fig. 3-168, Pos. 1) at the

hydraulic oil tank.

11. Unfix the control frame (Fig. 3-168, Pos. 2) from the roof
frame (Fig. 3-168, Pos. 3) and move the control frame into
mounting position at the hydraulic oil tank.

12. Assemble the bolts (Fig. 3-168, Pos. 4) to mount the control
frame (Fig. 3-168, Pos. 2) at the hydraulic oil tank.

Fig. 3-178

13. Reconnect the hose assembly (Fig. 3-179, Pos. 1) at the bot-
tom of hydraulic oil tank (Fig. 3-179, Pos. 2).

Fig. 3-179

14. Assemble the clamp (Fig. 3-180, Pos. 1) to retain the hose at
the hydraulic oil tank (bottom).

Fig. 3-180

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Hydraulics Superstructure

15. Assemble the transfer pump (Fig. 3-181, Pos. 1) at the

hydraulic oil tank.

16. Install the clamps (Fig. 3-181, Pos. 2) to retain all hydraulic
lines at the hydraulic oil tank.

Fig. 3-181

17. Reconnect the hydraulic lines (Fig. 3-182, Pos. 1) leading to

the hydraulic coolers to the hydraulic oil tank.

18. Reconnect the pressure hoses (Fig. 3-182, Pos. 2) to the

back pressure valve.

19. Reconnect all return lines (Fig. 3-182, Pos. 3) to the hydraulic
oil tank.

Fig. 3-182

d Fill hydraulic oil into the hydraulic oil tank,

approx. 2900 liters. Refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION
DAMPER".

20. Open the main shut off valve completely.

21. Bleed air from the hydraulic system, refer to OPERATION & MAINTENANCE MANUAL, chapter 4, section
HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

22. Add specified hydraulic oil up to the specified level.

23. Check and adjust the back pressure if required.

Refer to SHOP MANUAL part 10 STRUCTURE & FUNCTION, chapter 6 for further information.

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3.3.5 MAIN CONTROL VALVE BLOCKS

Refer to SHOP MANUAL part 10 STRUCTURE & FUNCTION, chapter 8 for further information about the main
control valve blocks.

3.3.5.1 DISASSEMBLING OF THE MAIN CONTROL VALVE BLOCKS

Special tools: n/a

Additional equipment: Crane

Oil drain pan

Main control valve block 1 & 2: 400 kg

Main control valve block 3: 310 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Close the hand wheel (Fig. 3-183, Pos. 1) of main shut off
valve between suction oil reservoir and main oil reservoir.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.

Fig. 3-183

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Hydraulics Superstructure

4. Open the cover (Fig. 3-184, Pos. 1) of the return oil filter.

5. Transfuse oil from the return manifold and the suction oil res-
ervoir, refer to the PARTS & SERVICE NEWS
No. "AH10530".

6. After transfusing is complete close the cover of the return oil

filter.

7. Isolate the machine according to local regulations.

8. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".
Fig. 3-184

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

9. Carry out the steps 10 and 11 at FSA-excavators only, if the

main control valve block 3 must be disassembled:

10. Disassemble the pipes (Fig. 3-185, Pos. 3) between the float
control valves and the intermediate blocks (Fig. 3-185,
Pos. 4):

– Inner pipes of the float control valve (Fig. 3-185, Pos. 1)

– Both pipes of the float control valve (Fig. 3-185, Pos. 2)
REMARKS: When a hydraulic line is disconnected hydraulic oil
will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

11. Discard the flat seals (Fig. 3-185, Pos. 5) of the SAE-flanges
connections.

Fig. 3-185

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12. Disconnect all pilot hoses (Fig. 3-186, Pos. 1) from the spool
valves (Fig. 3-186, Pos. 2) at the main control valve block.

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

Fig. 3-186

13. Disconnect all leak oil hoses (Fig. 3-187, Pos. 1) leading to
the SRV-blocks (Fig. 3-187, Pos. 2) from outside.
The leak oil hoses between SRV-blocks at the same main
control valve block can stay connected.

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

Fig. 3-187

14. Disconnect the harness connectors and clear the wiring harness from the main control valve block.

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Hydraulics Superstructure

Fig. 3-188 Pressure lines to manifold and rotary joint, disassembling

15. At control valve block I & II only:

Disconnect the pressure lines (Fig. 3-188, Pos. 1) to the rotary joint.

16. Disconnect all pressure tubes (Fig. 3-188, Pos. 2) leading to the manifold from the main control valve block.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

17. Discard the flat seals (Fig. 3-188, Pos. 4) of the SAE-flange connections.

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Fig. 3-189 Pressure lines and return lines, disassembling

18. Disconnect the return line (Fig. 3-189, Pos. 2) of the concerned main control valve block.

19. Discard the flat seal (Fig. 3-189, Pos. 3) of the SAE-flange connection.

20. Disassemble the pressure filter (Fig. 3-189, Pos. 1).

21. Discard the flat seals (Fig. 3-190, Pos. 1 and 2) at the
SAE-flange connections.

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

22. Insert a swivel hoist rings into the thread of the SAE flange
instead of one bolt when installing the blind plug at main con-
trol valve block I and II.

Fig. 3-190

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Hydraulics Superstructure

23. Attach main control valve block to the crane at the installed
hoist rings.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

24. Disassemble the mounting bolts (Fig. 3-191, Pos. 4 and 5)

and remove the main control valve block (Fig. 3-191, Pos. 1,
2 or 3) from the control valve block carrier (Fig. 3-191, Pos. 6)
using the crane.

Fig. 3-191

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3.3.5.2 ASSEMBLING OF THE MAIN CONTROL VALVE BLOCKS

Special tools: Hydraulic testing kit, PN 232 315 40

Additional equipment: Crane

Main control valve block 1 & 2: 400 kg

Main control valve block 3: 310 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: Ensure that the mating surfaces are clean and free of paint before assembly.

1. Attach main control valve block to the crane at the installed

hoist rings.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

2. Move the main control valve block (Fig. 3-191, Pos. 1, 2 or 3)

into mounting position at the control valve block carrier
(Fig. 3-191, Pos. 6) using the crane.

3. Assemble new mounting bolts (Fig. 3-192, Pos. 4 and 5) and

tighten the bolts to the specified tightening torque.

b Tightening torques for mounting bolts

(Fig. 3-192, Pos. 4 and 5): 179 Nm

NOTE! Make sure to use the specified torque for MRV, refer
to section 3.3.5.4 on page 3-139.

Fig. 3-192

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Hydraulics Superstructure

Fig. 3-193 Pressure lines to manifold and rotary joint, assembling

4. At control valve block I & II only:

Connect the pressure lines (Fig. 3-193, Pos. 1) to the rotary joint.

5. Connect all pressure tubes (Fig. 3-193, Pos. 2) leading to the manifold at the main control valve block.

NOTE! Always replace the flat seals (Fig. 3-193, Pos. 4) at SAE-flange connection.
A flat and level sealing surface is essential for proper sealing!

b Tighten the mounting bolts of SAE-flange connection according to the KOMATSU company
standard "Torques for SAE-flange connections", refer to section 6.6.5 on page 6-19.

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Fig. 3-194 Pressure lines and return lines, assembling

6. Reconnect the return line (Fig. 3-194, Pos. 2) of the main control valve block.

NOTE! Always replace the flat seal (Fig. 3-194, Pos. 3) at SAE-flange connection.
A flat and level sealing surface is essential for proper sealing!

b Tighten the mounting bolts of SAE-flange connection according to the KOMATSU company
standard "Torques for SAE-flange connections", refer to section 6.6.5 on page 6-19.

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Hydraulics Superstructure

7. Assemble the pressure filter (Fig. 3-194, Pos. 1) with a a new filter element at the main control valve block.

NOTE! Always replace the flat seals (Fig. 3-195, Pos. 1 &
2) at SAE-flange connections.
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 3-195

8. Reconnect all pilot hoses (Fig. 3-196, Pos. 1) at the spool

valves (Fig. 3-196, Pos. 2) of the main control valve block.

Fig. 3-196

9. Reconnect all leak oil hoses (Fig. 3-197, Pos. 1) at the SRV-
blocks (Fig. 3-196, Pos. 2).

Fig. 3-197

10. Reconnect the harness connectors and retain the wiring harness at the main control valve block.

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11. FSA-excavators only, if the main control valve block 3 was

disassembled:
Assemble the pipes (Fig. 3-198, Pos. 3) between the float
control valves and the intermediate blocks (Fig. 3-198,
Pos. 4):

– Inner pipes of the float control valve (Fig. 3-198, Pos. 1)

– Both pipes of the float control valve (Fig. 3-198, Pos. 2)
NOTE! Always replace the flat seals (Fig. 3-198, Pos. 5) of
the SAE-flanges connections.

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 3-198

12. Open the main shut off valve completely.

13. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

14. Add specified hydraulic oil up to the specified level.

15. Check pressure of all circuits of the control valve block (use 400 bar gauge).

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3.3.5.3 DISASSEMBLING OF THE MRV AT THE MAIN CONTROL VALVE BLOCKS

Special tools: 36 mm Socket wrench, PN 232 374 40

Additional equipment: n/a

1. Close the hand wheel (Fig. 3-199, Pos. 1) of main shut off
valve between suction oil reservoir and main oil reservoir.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.

Fig. 3-199

2. Open the cover (Fig. 3-200, Pos. 1) of the return oil filter.

3. Transfuse oil from the return manifold and the suction oil res-
ervoir, refer to the PARTS & SERVICE NEWS
No. "AH10530".

4. After transfusing is complete close the cover of the return oil

filter. After transfusing is complete close the cover of the
return oil filter.

5. Isolate the machine according to local regulations.

6. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM". Fig. 3-200

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Disassembling
the MRV under pressure will result in blindness, serious
injury or permanent disfigurement.

Make sure that the pressure is relieved before the MRV is dis-
assembled from the main control valve block.

7. Unscrew the MRV (Fig. 3-201, Pos. 1, 2 or 3) from the main

control valve block.
Fig. 3-201
REMARKS: When the MRV is disassembled, oil will flow out of
the main control valve block. Catch it in an oil pan.

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3.3.5.4 ASSEMBLING OF THE MRV AT THE MAIN CONTROL VALVE BLOCKS

Special tools: 36 mm Socket wrench, PN 232 374 40

Additional equipment: n/a

REMARKS: Fit new O-rings to the MRV.

1. Screw the MRV (Fig. 3-201, Pos. 1, 2 or 3) into the main control valve block and tighten the MRV with the
specified tightening torque.

b Tightening torque for MRV: 300 Nm

2. Open the main shut off valve completely.

3. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

4. Add specified hydraulic oil up to the specified level.

5. Check and adjust the MRV using Multi Monitor.

NOTE! Wear hearing protection when checking relief pressure.

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Hydraulics Superstructure

3.3.5.5 DISASSEMBLING OF SRV ON MAIN CONTROL VALVE BLOCK

Special tools: n/a

Additional equipment: Oil drain pan

REMARKS: Different SRV with different pressures are installed. If removing more than one SRV at the same
time, mark the SRV and the position where it is installed.
Refer to part 10 STRUCTURE & FUNCTION, chapter 8 in the SHOP MANUAL for further information
about the main control valve blocks and their different layouts.

1. Close the hand wheel (Fig. 3-202, Pos. 1) of main shut off
valve between suction oil reservoir and main oil reservoir.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.

Fig. 3-202

2. Open the cover (Fig. 3-203, Pos. 1) of the return oil filter.

3. Transfuse oil from the return manifold and the suction oil res-
ervoir, refer to the PARTS & SERVICE NEWS
No. "AH10530".

4. After transfusing is complete close the cover of the return oil

filter. After transfusing is complete close the cover of the
return oil filter.

5. Isolate the machine according to local regulations.

6. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM". Fig. 3-203

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DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

7. Unscrew the SRV (Fig. 3-204, Pos. 1) from the SRV-block

(Fig. 3-204, Pos. 2).

REMARKS: When the SRV is removed, oil will flow out of the
main valve block. Catch it in an oil pan.

Fig. 3-204

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Hydraulics Superstructure

3.3.5.6 ASSEMBLING OF SRV ON MAIN CONTROL VALVE BLOCKS

Special tools: Hydraulic testing kit, PN 232 315 40

Additional equipment: n/a

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTICE
FAILURE IN PRESSURE CONTROL!
Different SRV with different pressures are installed. An installed SRV with the wrong pressure causes a
failure in the pressure control.

If more than one SRV were removed at the same time, check if their mounting positions were marked dur-
ing disassembling. If the mounting positions were not marked, check the hydraulic diagram of the resp.
machine.
Reinstall the correct SRV into the correct position only.

1. Screw the SRV (Fig. 3-205, Pos. 1) into the SRV-block

(Fig. 3-205, Pos. 2).

b Tightening torque for the built-in SRV: 300 Nm

Fig. 3-205

2. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

3. Add specified hydraulic oil up to the specified level.

4. Check and adjust the SRV.

Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL for further information.

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Please continue reading on the next page.

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3.3.5.7 DISASSEMBLING OF ACV-/SRV-BLOCK ON MAIN CONTROL VALVE

BLOCKS

Special tools: n/a

Additional equipment: Oil drain pan

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

REMARKS: Different SRV with different pressures are installed. If removing more than one SRV at the same
time, mark the SRV and the position where it is installed.
Refer to part 10 STRUCTURE & FUNCTION, chapter 8 in the SHOP MANUAL for further information
about the main control valve blocks and their different layouts.

1. Close the hand wheel (Fig. 3-206, Pos. 1) of main shut off
valve between suction oil reservoir and main oil reservoir.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.

Fig. 3-206

2. Open the cover (Fig. 3-207, Pos. 1) of the return oil filter.

3. Transfuse oil from the return manifold and the suction oil res-
ervoir, refer to the PARTS & SERVICE NEWS
No. "AH10530".

4. After transfusing is complete close the cover of the return oil

filter. After transfusing is complete close the cover of the
return oil filter.

5. Isolate the machine according to local regulations.

6. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM". Fig. 3-207

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DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

ACV-block with attached SRV-block:

7. Disconnect the leak oil hoses (Fig. 3-208, Pos. 1) from the
SRV-block (Fig. 3-208, Pos. 3).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

8. Disassemble four mounting bolts (Fig. 3-208, Pos. 2) and

remove SRV-block together with the ACV block (Fig. 3-208,
Pos. 4).
Cap the openings to avoid contamination.
Fig. 3-208

9. ACV-block without attached SRV-block:

10. Disassemble four mounting bolts (Fig. 3-209, Pos. 1) and

remove ACV-block (Fig. 3-209, Pos. 3) together with the blind
plate (Fig. 3-208, Pos. 2).
Cap the openings to avoid contamination.

Fig. 3-209

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Hydraulics Superstructure

3.3.5.8 ASSEMBLING OF ACV-/SRV-BLOCK ON MAIN CONTROL VALVE BLOCKS

Special tools: n/a

Additional equipment: n/a

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Ensure that the mating surfaces are clean and free of paint before assembly.

REMARKS: Fit new sealing rings.

NOTICE
FAILURE IN PRESSURE CONTROL!
Different SRV with different pressures are installed. An installed SRV with the wrong pressure causes a
failure in the pressure control.

If more than one SRV-block was removed at the same time, check if their mounting positions were marked
during disassembling. If the mounting positions were not marked, check the hydraulic diagram of the
resp. machine.
Reinstall the correct SRV-block into the correct position only.

ACV-block with attached SRV-block:

2. Position the SRV-block together with the ACV block

(Fig. 3-210, Pos. 4) and assemble four mounting bolts
(Fig. 3-210, Pos. 2).

3. Reconnect the leak oil hoses (Fig. 3-210, Pos. 1) at the

SRV-block (Fig. 3-210, Pos. 3).

Fig. 3-210

ACV-block without attached SRV-block:

4. Position the ACV-block (Fig. 3-209, Pos. 3) together with the

blind plate (Fig. 3-208, Pos. 2) and assemble four mounting
bolts (Fig. 3-209, Pos. 1).

Fig. 3-211

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5. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

6. Add specified hydraulic oil up to the specified level.

7. Check and adjust the SRV.

Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL for further information.

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3.3.6 DISTRIBUTOR MANIFOLD

Fig. 3-212 ACV and throttle check valves at the manifold

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Superstructure Hydraulics

Legend for Fig. 3-212:

BHA manifold

(1) ACV (64.1...64.8) (3) SRV with check valve (65.1 & 65.2)

(2) SRV with throttle check valve (63.3...63.10) (4) Check valve (70.1 & 70.2)

FSA manifold

(1) ACV (64.1 to 64.7) (3) SRV with check valve (65.1...65.2)

(2) SRV with throttle check valve (63.1...63.9) (4) SRV (112.1)

The numbers in brackets behind the valve type (ACV/SRV) are component numbers for the hydraulic diagram.
Refer to the hydraulic diagram of the respective machine to identify the individual valves.
Fig. 3-212 shows a standard arrangement of the BHA and FSA manifold.

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Hydraulics Superstructure

3.3.6.1 DISASSEMBLING OF ANTI CAVITATION VALVE BLOCKS AT THE

DISTRIBUTOR MANIFOLD

Special tools: n/a

Additional equipment: Oil drain pan

2 x threaded pin: M16 x 300

Anti cavitation valve block: 10 kg

Second person to hold the valve

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

REMARKS: The disassembling of the anti cavitation valve is exemplarily explained at one nonspecific ACV. The
disassembling of the other ACVs is analogously the same.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

1. Open the cover (Fig. 3-213, Pos. 1) of the return oil filter.

2. Transfuse oil from the return manifold into the main oil reser-
voir, refer to the PARTS & SERVICE NEWS No. "AH10530".

3. After transfusing is complete close the cover of the return oil

filter.

4. Isolate the machine according to local regulations.

5. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

Fig. 3-213

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Superstructure Hydraulics

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

Disassembling of an ACV valve block with attached throttle check valve or diffuser block:

The anti cavitation valve is mounted to the distributor manifold by

means of the mounting bolts of the attached throttle check valve /
diffuser block. Both components are removed one after another
(using appropiate threaded pins to hold the anti cavitation valve in
position).

1. Disconnect the return oil SAE-hose (Fig. 3-214, Pos. 1) from

the bottom side of the anti cavitation valve (Fig. 3-214,
Pos. 3).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

2. Disassemble the throttle check valve (Fig. 3-214, Pos. 2),

refer to section 3.3.6.3 on page 3-154 or the diffuser block,
refer to section 3.3.6.5 on page 3-158 using appropiate
threaded pins then remove the anti cavitation valve Fig. 3-214
(Fig. 3-214, Pos. 3).

Disassembling of an single ACV valve block:

1. Disconnect the return oil SAE-hose from the bottom side of

the anti cavitation valve (refer to Fig. 3-214, Pos. 1).

2. Disconnect the SAE-tube leading to the main control valve

block from the front face of the anti cavitation valve (refer to
Fig. 3-193, Pos. 2 on page 3-134).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

3. Disassemble and replace the upper two mounting bolts

(Fig. 3-215, Pos. 1) by threaded pins M16 x 300.
Fig. 3-215
4. Disassemble the lower two mounting bolts (Fig. 3-215,
Pos. 1) and remove the anti cavitation valve (Fig. 3-215,
Pos. 2) via the threaded pins.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 151

Hydraulics Superstructure

3.3.6.2 ASSEMBLING OF ANTI CAVITATION VALVE BLOCKS AT THE DISTRIBUTOR

MANIFOLD

Special tools: n/a

Additional equipment: 2 x threaded pin: M16 x 300

Anti cavitation valve block: 10 kg

Second person to hold the valve

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: Ensure that the mating surfaces are clean and free of paint before assembly.

Assembling of an ACV block with attached throttle check valve or diffuser block:

The anti cavitation valve is mounted to the distributor manifold by

means of the mounting bolts of the attached throttle check valve /
diffuser block. Both components are installed one after another
(using appropiate threaded pins to hold the anti cavitation valve in
position).

1. Insert threaded pins M16 x 300 in the two upper threads of

the mounting bolts.

2. Fit a new flange sealing at the ACV block.

3. Push the anti cavitation valve (Fig. 3-216, Pos. 3) via the
threaded pins.

4. Connect the return oil SAE-hose (Fig. 3-216, Pos. 1) at the

bottom side of the anti cavitation valve.

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines! Fig. 3-216
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

5. Assemble the throttle check valve (Fig. 3-214, Pos. 2), refer to section 3.3.6.4 on page 3-156 or the diffuser
block, refer to section 3.3.6.3 on page 3-154.

6. Continue assembling with step 6 on page 3-153.

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Superstructure Hydraulics

Assembling of an single ACV valve block:

1. Insert threaded pins M16 x 300 in the two upper threads of

the mounting bolts (Fig. 3-217, Pos. 1).

2. Fit a new flange sealing at the ACV block.

3. Move the anti cavitation valve (Fig. 3-217, Pos. 3) via the
threaded pins and assemble the lower two mounting bolts
(Fig. 3-217, Pos. 1).

4. Remove the threaded pins and assemble the upper two

mounting bolts.

5. Connect the return oil SAE-hose at the bottom side of the anti
cavitation valve (refer to Fig. 3-216, Pos. 1) and the SAE-tube
leading to the main control valve block at the front face of the Fig. 3-217
anti cavitation valve (refer to Fig. 3-193, Pos. 2 on
page 3-134).

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 3-218 Exemplaric sketch

6. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

7. Add specified hydraulic oil up to the specified level.

8. Check the hydraulic system for proper function and adjust if required.
Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL for further information.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 153

Hydraulics Superstructure

3.3.6.3 DISASSEMBLING OF THROTTLE CHECK VALVES AT THE DISTRIBUTOR

MANIFOLD

Special tools: n/a

Additional equipment: Crane

Oil drain pan
2 x threaded pin: M16 x 300

Throttle check valve: 18 kg

Second person to hold the valve

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

There are different types of throttle check valves installed at the manifold. For further information, refer to the
hydraulic diagram. To locate the throttle check valves on the manifold refer to part 10 STRUCTURE & FUNCTION,
chapter 8 in the SHOP MANUAL.

REMARKS: The disassembling of the throttle check valve is exemplarily explained at one nonspecific throttle
check valve. The disassembling of the other blocks is analogously the same.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

3. Open the cover (Fig. 3-219, Pos. 1) of the return oil filter.

4. Transfuse oil from the return manifold into the main oil reser-
voir, refer to the PARTS & SERVICE NEWS No. "AH10530".

5. After transfusing is complete close the cover of the return oil

filter.

6. Isolate the machine according to local regulations.

7. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

Fig. 3-219

3 - 154 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Hydraulics

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

8. Disconnect the return oil hose (Fig. 3-220, Pos. 1) and leak
oil hose (Fig. 3-220, Pos. 2) from the throttle check valve
(Fig. 3-220, Pos. 5).

9. Disconnect the SAE-tube (Fig. 3-220, Pos. 3) from the throttle

check valve.

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

10. Disassemble and replace the upper two mounting bolts

(Fig. 3-220, Pos. 4) by threaded pins M16 x 300.
Fig. 3-220
11. Disassemble the lower two mounting bolts (Fig. 3-220,
Pos. 4) and remove the throttle check valve (Fig. 3-220,
Pos. 5) via the threaded pins.

REMARKS: When the throttle check valve is removed hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

12. If required, screw the build-in SRV (Fig. 3-221, Pos. 1) out of
the valve body (Fig. 3-221, Pos. 2).

Fig. 3-221

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 155

Hydraulics Superstructure

3.3.6.4 ASSEMBLING OF THROTTLE CHECK VALVES AT THE DISTRIBUTOR

MANIFOLD

Special tools: n/a

Additional equipment: 2 x threaded pin: M16 x 300

Throttle check valve: 18 kg

Second person to hold the valve

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: Ensure that the mating surfaces are clean and free of paint before assembly.

1. If the built-in SRV (Fig. 3-222, Pos. 1) has been removed

from the valve body (Fig. 3-222, Pos. 2) screw the SRV in
and tighten it to the specified torque.

b Tightening torque for the built-in SRV: 300 Nm

Fig. 3-222

1. Insert threaded pins M16 x 300 in the two upper threads of

the mounting bolts (Fig. 3-223, Pos. 4).

2. Fit a new flange sealing at the throttle check valve block.

3. Move the throttle check valve (Fig. 3-223, Pos. 5) via the
threaded pins and assemble the lower two mounting bolts
(Fig. 3-223, Pos. 4).

4. Remove the threaded pins and assemble the upper two

mounting bolts.

5. Connect the return oil hose (Fig. 3-223, Pos. 1) and the leak
oil hose (Fig. 3-223, Pos. 2) from the throttle check valve
(Fig. 3-223, Pos. 5). Fig. 3-223

6. Connect the SAE-tube (Fig. 3-223, Pos. 3) at the throttle

check valve.

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Superstructure Hydraulics

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 3-224 Exemplaric sketch

7. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

8. Add specified hydraulic oil up to the specified level.

9. Check throttle check valve and the build in SRV for proper function and adjust if required.
Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL for further information.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 157

Hydraulics Superstructure

3.3.6.5 DISASSEMBLING OF THE DIFFUSER BLOCK ON THE DISTRIBUTOR

MANIFOLD (FSA ONLY)

Special tools: n/a

Additional equipment: Oil drain pan

2 x threaded pin: M16 x 300

Diffuser block: 14 kg

Second person to hold the attached diffuser block

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

Diffuser blocks are installed at the ports "L" and "D" on the manifold.
The anti cavitation valve is mounted to the distributor manifold by means of the mounting bolts of the attached dif-
fuser block.

REMARKS: The disassembling of the diffuser block is exemplarily explained with the port L diffuser block. The
disassembling of the port D block is analogously the same.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

3. Open the cover (Fig. 3-225, Pos. 1) of the return oil filter.

4. Transfuse oil from the return manifold into the main oil reser-
voir, refer to the PARTS & SERVICE NEWS No. "AH10530".

5. After transfusing is complete close the cover of the return oil

filter.

6. Isolate the machine according to local regulations.

7. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

Fig. 3-225

3 - 158 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Hydraulics

8. Disassemble the four bolts (Fig. 3-226, Pos. 2) and discon-

nect the SAE-tube (Fig. 3-226, Pos. 3) from the diffuser block
(Fig. 3-226, Pos. 1).
Discard the flat seals (Fig. 3-226, Pos. 4) of the SAE-flange
connection.

9. Disconnect the return oil hoses of the valve blocks at the

adjacent manifold ports.

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

Fig. 3-226

10. Disassemble and replace the upper two mounting bolts

(Fig. 3-227, Pos. 1) by threaded pins M16 x 300.

11. Disassemble the lower two mounting bolts (Fig. 3-227,

Pos. 1) and remove the diffuser block (Fig. 3-227, Pos. 2) via
the threaded pins.

REMARKS: Leave the anti cavitation valve in position, held by

the threaded pins.

Fig. 3-227

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 159

Hydraulics Superstructure

3.3.6.6 ASSEMBLING OF THE DIFFUSER BLOCK ON THE DISTRIBUTOR MANIFOLD

(FSA ONLY)

Special tools: n/a

Additional equipment: n/a

Diffuser: 14 kg

Second person to hold the attached diffuser block

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: Ensure that the mating surfaces are clean and free of paint before assembly.

1. Fit a new flange sealing at the diffuser block.

2. Move the diffuser block (Fig. 3-228, Pos. 2) via the threaded
pins against the anti cavitation valve (Fig. 3-228, Pos. 3) and
assemble the lower two mounting bolts (Fig. 3-228, Pos. 1).

3. Remove the threaded pins and assemble the upper two

mounting bolts.

Fig. 3-228

4. Assemble the SAE-tube (Fig. 3-226, Pos. 3) at the diffuser

block (Fig. 3-226, Pos. 1).
Discard the flat seals (Fig. 3-226, Pos. 4) of the SAE-flange
connection.

NOTE! Always replace the flat seal (Fig. 3-229, Pos. 4) at

SAE-flange connection.
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts (Fig. 3-229, Pos. 2) of

SAE-flange connection according to the
KOMATSU company standard "Torques for SAE-
flange connections", refer to section 6.6.5 on
page 6-19. Fig. 3-229

5. Reconnect the return oil hoses of the valve blocks at the adjacent manifold ports.

6. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

7. Add specified hydraulic oil up to the specified level.

3 - 160 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Hydraulics

3.3.6.7 DISASSEMBLING OF THE MANIFOLD

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Crane
Oil drain pan

Distributor manifold assembly: 700 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

3. Open the cover (Fig. 3-231, Pos. 1) of the return oil filter.

4. Transfuse oil from the return manifold into the main oil reser-
voir, refer to the PARTS & SERVICE NEWS No. "AH10530".

5. After transfusing is complete close the cover of the return oil

filter.

6. Isolate the machine according to local regulations.

7. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

Fig. 3-230

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 161

Hydraulics Superstructure

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

8. Disconnect all boom arc hoses (Fig. 3-231, Pos. 1) leading to

the attachment, refer to section 5.2.6.1 on page 5-80 (BHA)
or refer to section 5.3.6.1 on page 5-160 (FSA).

9. Disassemble the hydraulic piping (Fig. 3-231, Pos. 2) at the

back of the manifold.

10. Disconnect all hydraulic lines from the attached valve blocks:

– Disconnect all hydraulic lines from the anti cavitation valve

blocks, refer to section 3.3.6.1 on page 3-150.
– Disconnect all hydraulic lines from the throttle check
valves, refer to section 3.3.6.3 on page 3-154.
– Disconnect all hydraulic lines from the diffuser blocks, Fig. 3-231
refer to section 3.3.6.5 on page 3-158.
REMARKS: When a hydraulic line is disconnected hydraulic oil
will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

11. Sling the manifold assembly and attach a crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

12. Disassemble four mounting bolts (Fig. 3-231, Pos. 3). Clear the plate (Fig. 3-231, Pos. 4) of the filter assem-
bly.

13. Remove the manifold assembly using a crane.

14. If required remove the valve blocks and hydraulic pipes from the distributor manifold.

3 - 162 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Hydraulics

3.3.6.8 ASSEMBLING OF THE MANIFOLD

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Crane

Distributor manifold assembly: 700 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

REMARKS: Carry out assembling in reverse order of disassembling.

1. If required assemble the valve blocks and hydraulic pipes at the distributor manifold.

2. Sling the manifold assembly and attach a crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

3. Move the manifold into mounting position using a crane.

4. Assemble four mounting bolts (Fig. 3-232, Pos. 3). Mount the
plate (Fig. 3-232, Pos. 4) of the filter assembly.

5. Assemble the hydraulic piping (Fig. 3-232, Pos. 2) at the back

of the manifold.

6. Reconnect all hydraulic lines at the attached valve blocks:

– Reconnect all hydraulic lines at the anti cavitation valve

blocks, refer to section 3.3.6.2 on page 3-152.
– Reconnect all hydraulic lines at the throttle check valves,
refer to section 3.3.6.4 on page 3-156.
– Reconnect all hydraulic lines at the diffuser blocks, refer to
section 3.3.6.6 on page 3-160. Fig. 3-232
7. Reconnect all boom arc hoses (Fig. 3-232, Pos. 1) leading to
the attachment, refer to section 5.2.6.1 on page 5-80 (BHA)
or refer to section 5.3.6.1 on page 5-160 (FSA).

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 163

Hydraulics Superstructure

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 3-233 Exemplaric sketch

8. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

9. Add specified hydraulic oil up to the specified level.

10. Check the hydraulic system for proper function and adjust if required.
Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL for further information.

3 - 164 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Slew system

3.4 SLEW SYSTEM

3.4.1 SLEW GEAR BOX

Fig. 3-234 Slew gear box assembly, overview

(1) Slew gear box (7) Slew parking brake assembly

(2) Slew service brake valve (8) Adaptor ring

(3) Intermediate plate (9) Cover plates

(4) O-ring (10) Gear oil hose (Siebenhaar only)

(5) Slew motor (11) External gear oil tank (Siebenhaar only)

(6) Mounting bolt

Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL for further information relating the
hydraulic slew system.

REMARKS: The machine can be equipped with a swing gear either of manufacturer "L&S" or of manufacturer
"Siebenhaar". The disassembling and the assembling procedures of the swing gear by the different
manufacturers are analogously the same.
Refer to the data plate on each swing gear housing to find out the manufacturer of the swing gear.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 165

Slew system Superstructure

3.4.1.1 DISASSEMBLING OF THE SLEW GEAR BOX

Special tools: n/a

Additional equipment: Crane

Swivel hoist ring: 4 x M16

Slew motor with attached slew service brake valve: 260 kg

Slew gear box (Siebenhaar): 1700 kg
Slew gear box (L&S): 1880 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

REMARKS: The machine can be equipped either with a slew gear of manufacturer "L&S" or of manufacturer
"Siebenhaar". The disassembling and the assembling of the slew gear by different manufacturers are
analogously the same. Refer to the data plate on each slew gear housing to find out the manufac-
turer of the slew gear.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

3. Open the cover (Fig. 3-235, Pos. 1) of the return oil filter.

4. Transfuse oil from the return manifold into the main oil reser-
voir, refer to the PARTS & SERVICE NEWS No. "AH10530".

5. After transfusing is complete close the cover of the return oil

filter.

6. Isolate the machine according to local regulations.

7. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

Fig. 3-235

3 - 166 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Slew system

8. Disassemble the external gear oil tank (Fig. 3-236, Pos. 1)

(Siebenhaar gear only) also refer to Fig. 3-237.

9. Disassemble the platform (Fig. 3-236, Pos. 2).

Fig. 3-236

10. Disassemble the bleeder valves (Fig. 3-237, Pos. 1)

a Drain the gear oil from the slew gear (Fig. 3-237,
Pos. 3 respectively Pos. 5) at the drain coupling
(Fig. 3-237, Pos. 2),
- approx. 60 liters (Siebenhaar),
- approx. 42 liters (L&S)

Refer to the OPERATION & MAINTENANCE MAN-

UAL, chapter 4, section "SWING GEARS AND
MOTOR ADAPTER HOUSING - CHANGE OIL".

11. Disassemble the oil drain coupling (Fig. 3-237, Pos. 2) and if
equipped also disassemble the union (Fig. 3-237, Pos. 4)
from the slew gear (Fig. 3-237, Pos. 3 respectively Pos. 5).

Fig. 3-237

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 167

Slew system Superstructure

12. Disassemble slew motor (Fig. 3-238, Pos. 1) from the slew
gear box, refer to section 3.4.3.1 on page 3-177.

REMARKS: Leave the hydraulic hoses and the slew service

brake valve attached to the slew motor.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any
hydraulic lines under pressure may result in blindness, seri-
ous injury, permanent disfigurement, or scaring.

Make sure that the pressure is relieved before any hydraulic

lines will be disassembled.

13. Disconnect the oil pressure line from the slew parking brake.

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

14. Disassemble the cover plates (Fig. 3-238, Pos. 2).

15. Disassemble the protection caps (Fig. 3-238, Pos. 3) from the
bolt heads and disassemble the slew gear mounting bolts
(Fig. 3-238, Pos. 4). Discard the bolts.

16. Disconnect the lubrication line at the bottom end of the slew
gear.
Fig. 3-238

17. Insert swivel hoist rings (M16) displaced by 90° into the threads of the slew motor mounting bolts and attach a
crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

18. Disassemble the slew gear box (Fig. 3-238, Pos. 5) using a crane.

19. If required, disassemble the adaptor ring (Fig. 3-234, Pos. 8).

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3.4.1.2 ASSEMBLING OF THE SLEW GEAR BOX

Special tools: Feeler gauge (customary)

Additional equipment: Crane

Swivel hoist rings: 4 x M16
Threaded pins: M 24 x 600
MPG (Multi Purpose Grease)

Slew motor with attached slew service brake valve: 260 kg

Slew gear box (Siebenhaar): 1700 kg
Slew gear box (L&S): 1880 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! New gear boxes are delivered without gear oil.

REMARKS: The machine can be equipped either with a slew

gear of manufacturer "Siebenhaar" or of manufac-
turer "L&S". Refer to the data plate on each slew
gear housing to find out the manufacturer of the
slew gear.
Both slew gears are replaceable using a special
modification kit. Refer to the PARTS & SERVICE
NEWS No. "AH05535".

1. Ensure that the mating surfaces are clean and free of paint
before assembly.

2. Install the oil drain coupling (Fig. 3-239, Pos. 2) with the union
(Fig. 3-239, Pos. 4), if equipped, at the new slew gear box
(Fig. 3-239, Pos. 3 respectively Pos. 5).

3. Clean the bleeder valves (Fig. 3-239, Pos. 1) with com-

pressed air from inside to outside and reinstall at the new
slew gear box (Fig. 3-239, Pos. 3 respectively Pos. 5).

Fig. 3-239

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Slew system Superstructure

4. Insert swivel hoist rings (M16) displaced by 90° into the threads of the slew motor mounting bolts and attach a
crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

5. Install the new slew gear box (Fig. 3-240, Pos. 5) using a
crane.

6. Mount the slew gear box (Fig. 3-240, Pos. 5) to the super-
structure with new mounting bolts (Fig. 3-240, Pos. 4).
Do not completely tight the bolts yet.

REMARKS: Use new mounting bolts of grade 12.9.

Apply MPG (or roller bearing grease, or grease from
the CLS system).

7. Detach the crane.

8. Check the tooth backlash between slew ring and slew pinion
with a feeler gauge.
Refer to the PARTS & SERVICE NEWS No. "AH00511".

9. Tighten the mounting bolts (Fig. 3-240, Pos. 4) to the speci-

fied tightening torque:

b Tightening torque for slew gear box mounting

bolts: 1030 Nm

10. Reconnect the lubrication line at the bottom end of the slew
gear.

11. Assemble the cover plates (Fig. 3-240, Pos. 2).

12. Assemble the protection caps (Fig. 3-240, Pos. 3) on the bolt
heads.

13. Reconnect the oil pressure line at the slew parking brake.

14. Assemble slew motor (Fig. 3-238, Pos. 1) with attached brake
valve at the slew gear box, refer to section 3.4.3.2 on Fig. 3-240
page 3-180.

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15. Assemble the external gear oil tank (Fig. 3-236, Pos. 1)
(Siebenhaar gear only) also refer to Fig. 3-237.

16. Assemble the platform (Fig. 3-236, Pos. 2).

Fig. 3-241

d Fill specified gear oil into the slew gear,

- approx. 60 liters (Siebenhaar),
- approx. 42 liters (L&S).

Fill specified oil into the motor adapter housing,

- approx. 0.6 liters (L&S),
- up to level gauge marking (Siebenhaar).

Fill specified oil into the brake housing

(Siebenhaar only), approx. 0.2 liters.

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "SWING GEARS AND
MOTOR ADAPTER HOUSING - CHANGE OIL".
For the proper lubricants, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"FLUIDS AND LUBRICANTS".

NOTICE
BRAKE NOT BLED!
The swing parking brake can not be released completely due to air in the hydraulic system. This may
cause severe damage to the brake lamellas.

Before initial operation or after repairs on the hydraulic circuit, the swing parking brake must be bled to
prevent the brake lamellas from welding when swinging.
If not installed, a vent plug can be connected to the pressure port to bleed the brake.

17. Bleed the swing parking brake.

Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL.

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Slew system Superstructure

3.4.2 SLEW SERVICE BRAKE VALVE

3.4.2.1 DISASSEMBLING OF THE SLEW SERVICE BRAKE VALVE

Special tools: n/a

Additional equipment: Crane

Slew service brake valve: 110 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

3. Open the cover (Fig. 3-242, Pos. 1) of the return oil filter.

4. Transfuse oil from the return manifold into the main oil reser-
voir, refer to the PARTS & SERVICE NEWS No. "AH10530".

5. After transfusing is complete close the cover of the return oil

filter.

6. Isolate the machine according to local regulations.

7. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

Fig. 3-242

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8. Disconnect the service hoses (Fig. 3-243, Pos. 2), the return
hose (Fig. 3-243, Pos. 3), the leak oil hose (Fig. 3-243,
Pos. 4), and the pilot hose (Fig. 3-243, Pos. 5) from the slew
service brake valve (Fig. 3-243, Pos. 6).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

9. Attach the slew service brake valve (Fig. 3-243, Pos. 6) to a

crane.

Fig. 3-243

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

10. Disassemble the four mounting bolts (Fig. 3-243, Pos. 1) and take the slew service brake valve (Fig. 3-243,
Pos. 6) off the slew motor (Fig. 3-243, Pos. 7) using a crane.

11. Refer to Fig. 3-249 on page 3-180:

Discard the O-ring (Fig. 3-249, Pos. 3) fitted between the intermediate plate (Fig. 3-249, Pos. 5) and the slew
service brake valve (Fig. 3-249, Pos. 2).

REMARKS: When the slew service brake valve is disassembled, hydraulic oil from inside the valve will flow out.
Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

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Slew system Superstructure

3.4.2.2 ASSEMBLING OF THE SLEW SERVICE BRAKE VALVE

Special tools: Hydraulic testing kit, PN 232 315 40

Additional equipment: Crane

2 x Threaded pin: M20 x 250 mm

Slew service brake valve: 110 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: Ensure that the mating surfaces are clean and free of paint before assembly.

1. Refer to Fig. 3-249 on page 3-180:

Discard the O-ring (Fig. 3-249, Pos. 3) fitted between the intermediate plate (Fig. 3-249, Pos. 5) and the slew
service brake valve (Fig. 3-249, Pos. 2).

2. Insert two threaded pins M20 x 250 mm into threads of the

brake valve mounting bolts (Fig. 3-244, Pos. 1).

3. Attach the slew service brake valve (Fig. 3-244, Pos. 6) to a

crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine Fig. 3-244
part.

4. Move the slew service brake valve (Fig. 3-244, Pos. 6) into mounting position on top of the slew motor
(Fig. 3-244, Pos. 7). Note the O-ring at the intermediate plate!

5. Assemble two mounting bolts (Fig. 3-244, Pos. 1).

6. Remove the two threaded pins and assemble the leftover mounting bolts (Fig. 3-244, Pos. 1).

7. Connect the service hoses (Fig. 3-244, Pos. 2), the return hose (Fig. 3-244, Pos. 3), the leak oil hose
(Fig. 3-244, Pos. 4), and the pilot hose (Fig. 3-244, Pos. 5) at the slew service brake valve.

8. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
the PARTS & SERVICE NEWS No. "AH06519".

9. Add specified hydraulic oil up to the specified level.

10. Check the slew system for proper function and adjust it if required.
Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL.

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Superstructure Slew system

Please continue reading on the next page.

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Slew system Superstructure

3.4.3 SLEW MOTOR

Fig. 3-245 Slew motor assembly

(1) Bolt (7) Bolt

(2) Slew service brake valve (8) Washer

(3) O-ring (9) Slew motor

(4) Bolt (10) Slew gear

(5) Intermediate plate (11) O-ring

(6) O-ring

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Superstructure Slew system

3.4.3.1 DISASSEMBLING OF THE SLEW MOTOR

Special tools: n/a

Additional equipment: Crane

Oil drain pan

Slew motor: 110 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

3. Open the cover (Fig. 3-246, Pos. 1) of the return oil filter.

4. Transfuse oil from the return manifold into the main oil reser-
voir, refer to the PARTS & SERVICE NEWS No. "AH10530".

5. After transfusing is complete close the cover of the return oil

filter.

6. Isolate the machine according to local regulations.

7. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

Fig. 3-246

a Drain gear oil from the motor adapter housing, approx. 0.6 liters.
Refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "SWING GEAR AND
MOTOR ADAPTER HOUSING - CHANGE OIL".

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Slew system Superstructure

8. Disconnect the leak oil line (Fig. 3-247, Pos. 1) from the slew
motor (Fig. 3-247, Pos. 2).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

Fig. 3-247

Fig. 3-248 Disassembling of the slew motor

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Superstructure Slew system

9. Disassemble the four mounting bolts (Fig. 3-248, Pos. 1) and take off the slew service brake valve (Fig. 3-248,
Pos. 2), refer to section 3.4.5 on page 3-196.
Discard the O-ring (Fig. 3-248, Pos. 3).

REMARKS: The hydraulic hoses remain at the slew service brake valve.
When the slew service brake valve is removed, the oil inside the valve will flow out.
Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

10. Disassemble the four bolts (Fig. 3-248, Pos. 4) and take off the intermediate plate (Fig. 3-248, Pos. 5).
Discard the O-ring (Fig. 3-248, Pos. 6).

11. Disassemble eight bolts (Fig.Fig. 3-248 Fig. 3-248, Pos. 7) and washers (Fig. 3-248, Pos. 8). Discard the
bolts.

12. Attach the slew motor (Fig. 3-248, Pos. 9) to a crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

13. Pull the slew motor out of the slew gear (Fig. 3-248, Pos. 10) and place it on the ground using the crane.
Discard the O-ring (Fig.Fig. 3-247, Pos. 11).

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Slew system Superstructure

3.4.3.2 ASSEMBLING OF THE SLEW MOTOR

Special tools: Hydraulic testing kit, PN 232 315 40

Additional equipment: Paste Optimol Paste White T, PN 323 444 40

MPG (Multi Purpose Grease)

Slew motor: 110 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

Fig. 3-249 Installation of the slew motor

REMARKS: Ensure that the mating surfaces are clean and free of paint before assembly.

1. Apply "Optimol Paste White T" at the spline shaft of the slew motor (Fig. 3-249, Pos. 9).

2. Insert a new O-ring (Fig.Fig. 3-249, Pos. 11).

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Superstructure Slew system

3. Attach the slew motor to a crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

4. Move the slew motor into mounting position using the crane.

5. Assemble eight mounting bolts (Fig. 3-249, Pos. 7) of grade 10.9.

Apply MPG (or roller bearing grease, or grease from the CLS system) on heads and threads of the bolts and
tighten to the specified tightening torque.

b Tightening torque for slew motor mounting bolts: 265 Nm

6. Insert a new O-ring (Fig. 3-249, Pos. 6).

7. Assemble the intermediate plate (Fig. 3-249, Pos. 5) with four bolts (Fig. 3-249, Pos. 4).

8. Insert a new O-ring (Fig. 3-249, Pos. 3).

9. Assemble the slew service brake valve (Fig. 3-248, Pos. 2) with four mounting bolts (Fig. 3-248, Pos. 1), refer
to section 3.4.2.2 on page 3-174.

10. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

d Fill specified oil to the motor adapter housing,

- approx. 0.6 liters (L & S),
- up to level gauge marking (Siebenhaar).

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "SWING GEAR AND
MOTOR ADAPTER HOUSING - CHANGE OIL".
For the proper lubricants, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"FLUIDS AND LUBRICANTS".

11. Check the slew system for proper function and adjust it if required.
Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL.

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Slew system Superstructure

3.4.4 SLEW PARKING BRAKE

REMARKS: The machine can be equipped either with a slew parking brake of manufacturer "Siebenhaar" or of
manufacturer "L&S".
For replacing the "L&S" slew parking brake has to be disassembled/assembled.
The "Siebenhaar" slew parking brake assembly can be replaced completely.

Fig. 3-250 Slew parking brake (L&S)

(1) Disc housing (10) Thrust washer

(2) Thrust washer (11) Circlip

(3) Inner discs (12) Drive shaft

(4) Outer discs (13) Oil pressure port

(5) Sinus spacer ring (14) Bolt

(6) Piston (15) Bearing ring

(7) Quad ring with back up ring (16) Rotary shaft seal

(8) Quad ring with back up ring (17) Cylinder assembly

(9) Springs

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Superstructure Slew system

General:

Brake applied:

The outer disks engaged to the housing by serration and the inner disks in serrated connection with the drive shaft
are pressed together by the springs. This results in a fixed connection between housing and drive shaft due to the
friction between the spring pressurized discs.

Brake released:

Oil pressure via the pilot port reaches the bottom of the piston and forces the piston upwards against the thrust
washer and the spring force. This eliminates the spring force towards the disks so that the friction between the
discs is released and the inner shaft can rotate. Only the brake of the L&S gear box uses an additional spacer ring
(sinus ring) to keep the discs apart. It should reduce the friction in released condition.

The minimum release pressure is 12 bar. In normal working conditions, the releasing pressure X2 is about 35 bar.

REMARKS: The slew parking brake must only be applied with the superstructure at a complete standstill. Apply-
ing the parking brake with superstructure still slewing may result in severe damage to the brake.

NOTE! Only use the slew parking brake in emergency situations to stop the rotating superstructure.

If the parking brake has been used for an emergency stop, it is necessary to shut down the excavator
and to have the parking brake of the slew gear inspected and repaired if necessary. Contact your
Komatsu dealer for repairing the brakes.

3.4.4.1 DISASSEMBLING THE SLEW PARKING BRAKE (L&S)

Special tools: n/a

Additional equipment: Crane

Swivel hoist ring: 2 x M16

Slew motor with attached slew service brake valve: 260 kg

Bearing ring: 112 kg

Dogman/rigger

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter
3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

REMARKS: The slew parking brake is attached to the slew gear box with eight hexagon socket bolts.

5. Disassemble the slew motor from the slew gear box, refer to section 3.4.3.1 on page 3-177.
Leave the hydraulic hoses and the slew service brake valve attached to the slew motor.

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Slew system Superstructure

6. Install swivel hoist rings (M16) displaced by 180° into the threads of the slew motor mounting bolts and attach
a crane.

7. Disassemble the mounting bolts (Fig. 3-251, Pos. 1) at the

slew motor flange.

8. Disassemble the inner snap ring (Fig. 3-251, Pos. 2).

9. Disassemble the bearing ring (Fig. 3-251, Pos. 3) from the

slew gear box using a crane.

Fig. 3-251

Fig. 3-252 Slew parking brake (L & S)

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Superstructure Slew system

10. Check rotary shaft seal (Fig. 3-252, Pos. 16) for wear and damage. Replace it if required.

11. Disconnect the pressure hose from the oil pressure port (Fig. 3-252, Pos. 13).

REMARKS: When the pressure hose is disassembled, the oil inside the hose and the cylinder (Fig. 3-252,
Pos. 17) will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

WARNING
SPRING LOADED ASSEMBLY!
Serious injury, permanent disfigurement and scarring, or death may result.
There is a risk of parts blasting off when the socket head cap bolts (Fig. 3-252, Pos. 14) are disassembled
due to a spring loaded piston (Fig. 3-252, Pos. 6).

Loose the socket head cap bolts (Fig. 3-252, Pos. 14) alternately stepwise in order to release the springs.

12. Take off the cylinder assembly (Fig. 3-252, Pos. 17) with the piston.

13. Dismount all inner discs (Fig. 3-252, Pos. 3), all outer discs (Fig. 3-252, Pos. 4), and all sinus spacer rings
(Fig. 3-252, Pos. 5) from the disc housing (Fig. 3-252, Pos. 1).

14. Disassemble the drive shaft (Fig. 3-252, Pos. 12).

15. Disassemble the thrust washer (Fig. 3-252, Pos. 2) from the disc housing (Fig. 3-252, Pos. 1).

16. Check inner discs (Fig. 3-252, Pos. 3), outer discs (Fig. 3-252, Pos. 4), sinus spacer rings (Fig. 3-252, Pos. 5)
and thrust washer (Fig. 3-252, Pos. 2) for wear and damage. Replace if required.

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Slew system Superstructure

3.4.4.2 ASSEMBLING THE SLEW PARKING BRAKE (L&S)

Special tools: n/a

Additional equipment: Crane

Hydraulic power unit (60 bar) with fitting (M18 x 1.5)
Paste Optimol Paste White T, PN 323 444 40

Slew motor with attached slew service brake valve: 260 kg

Bearing ring: 112 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

Fig. 3-253 Slew parking brake (L & S)

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Superstructure Slew system

REMARKS: Replace all O-rings.

1. Assemble the thrust washer (Fig. 3-253, Pos. 2).

2. Assemble the drive shaft (Fig. 3-253, Pos. 12).

REMARKS: Apply "Optimol Paste White T" at the spline shaft.

3. Assemble new discs according to the following order:

At first an outer disc (Fig. 3-253, Pos. 4), then an inner disc (Fig. 3-253, Pos. 3) and then a sinus spacer ring
(Fig. 3-253, Pos. 5).

REMARKS: Apply oil to the discs.

DANGER
TOO HIGH PRESSURE APPLIED!
Serious injury, permanent disfigurement and scarring, or death will result.
The cylinder assembly will burst when the applied pressure exceeds 60 bar.

Do not apply any pressure that exceeds 60 bar to the cylinder assembly.

4. Before reinstallation, apply pressure (max. 60 bar) to the cylinder assembly (Fig. 3-253, Pos. 17), otherwise
the socket head cap bolts (Fig. 3-253, Pos. 14) are pre-stressed (spring loaded).

5. Install the cylinder assembly (Fig. 3-253, Pos. 17) with the piston and assemble the socket head cap bolts
(Fig. 3-253, Pos. 14).

6. Detach the crane.

7. Connect the pressure hose at the oil pressure port (Fig. 3-252, Pos. 13).

8. Install swivel hoist rings (M16) displaced by 180° into the

threads of the slew motor mounting bolts in the bearing ring
(Fig. 3-254, Pos. 3) and attach a crane.

9. Assemble the bearing ring (Fig. 3-254, Pos. 3) from the slew
gear box using a crane.

10. Assemble the mounting bolts (Fig. 3-254, Pos. 1) at the slew
motor flange.

11. Assemble the inner snap ring (Fig. 3-254, Pos. 2).

Fig. 3-254

12. Assemble the slew motor at the slew gear box, refer to section 3.4.3.2 on page 3-180.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 187

Slew system Superstructure

d Fill oil to the motor adapter housing,

approx. 0.6 liters.

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "SWING GEAR AND
MOTOR ADAPTER HOUSING - CHANGE OIL".
For the proper lubricant, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"FLUIDS AND LUBRICANTS".

NOTICE
BRAKE NOT BLED!
The swing parking brake can not be released completely due to air in the hydraulic system. This may
cause severe damage to the brake lamellas.

Before initial operation or after repairs on the hydraulic circuit, all swing parking brakes have to be vented
at the oil pressure port.

13. Bleed the swing parking brake at the pressure oil port (Fig. 3-253, Pos. 13).

14. Add specified hydraulic oil up to the specified level.

15. Check slew parking brake for function:

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 3 "WORKING INSTRUCTIONS".
Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL.

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Superstructure Slew system

3.4.4.3 DISASSEMBLING OF THE SLEW PARKING BRAKE ASSEMBLY

(SIEBENHAAR)

Special tools: n/a

Additional equipment: Crane

Hydraulic power unit (60 bar) with fitting (M18 x 1.5)
Paste Optimol Paste White T, PN 323 444 40

Slew motor with attached slew service brake valve: 260 kg

Slew parking brake assembly: 115 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter
3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

5. Disassemble the slew motor from the slew parking brake, refer to section refer to section 3.4.3.1 on
page 3-177. Leave the hydraulic hoses and the slew service brake valve attached to the slew motor.

a Drain the oil of the brake housing, approx. 0.3 liters.

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "SWING GEARS AND
MOTOR ADAPTER HOUSING - CHANGE OIL".

REMARKS: After draining the oil of the brake housing, cap the openings with blind plugs to avoid contamination.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure may result in
blindness, serious injury, permanent disfigurement, or scaring.

Make sure that the pressure is relieved before any hydraulic lines will be disassembled.

6. Disconnect the pilot oil pressure line from the slew parking brake.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

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Slew system Superstructure

7. Disassemble all filler and breather pipes (Fig. 3-255, Pos. 3)

from the slew parking brake (Fig. 3-255, Pos. 2) and cap the
openings with blind plugs to avoid contamination.

WARNING
SPRING LOADED ASSEMBLY!
Serious injury, permanent disfigurement and scarring, or
death may result.
The piston of the slew parking break assembly is spring
loaded.

It is necessary to release the brake manually (see following

procedure) before removing the mounting bolts (Fig. 3-255,
Pos. 1) attaching the complete slew parking brake
(Fig. 3-255, Pos. 2) to the slew gear box (Fig. 3-255, Pos. 4).

Never open the brake by removing the flange mounting bolts Fig. 3-255
(Fig. 3-256, Pos. 3) before the slew parking brake is manually
released.

Fig. 3-256 Slew parking brake (Siebenhaar), drawn released

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Releasing the slew parking brake manually:

8. Insert two bolts (Fig. 3-257, Pos. 1) of suitable length with

nuts (Fig. 3-257, Pos. 3) into the threaded borings
(Fig. 3-257, Pos. 2) of the piston (Fig. 3-257, Pos. 2) opposed
to each other.

9. Tighten each nut (Fig. 3-257, Pos. 3) alternately with a half

turn, to withdraw the piston (Fig. 3-257, Pos. 2) to the flange
(Fig. 3-257, Pos. 4).

REMARKS: Avoid tilting the piston!

Fig. 3-257

10. After releasing the slew parking brake manually only disassemble the mounting bolts (Fig. 3-255 / Fig. 3-256,
Pos. 1) attaching the complete slew parking brake (Fig. 3-255, Pos. 2) to the slew gear box.

WARNING
SPRING LOADED ASSEMBLY!
Serious injury, permanent disfigurement and scarring or death may result!
The piston of the slew parking break assembly is spring loaded.

Never open the brake for further maintenance by removing the flange mounting bolts (Fig. 3-256, Pos. 3)
before the slew parking brake is manually released!

11. Insert swivel hoist rings (M16) displaced by 180° into the threads of the slew motor mounting bolts attach a
crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

12. Disassemble the slew parking brake (Fig. 3-255, Pos. 2) from the slew gear box (Fig. 3-255, Pos. 4), using a
crane. Discard the O-ring (Fig. 3-255, Pos. 5).

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Slew system Superstructure

3.4.4.4 ASSEMBLING OF THE SLEW PARKING BRAKE ASSEMBLY (SIEBENHAAR)

Special tools: n/a

Additional equipment: Crane

Hydraulic power unit (60 bar) with fitting (M18 x 1.5)
Paste Optimol Paste White T, PN 323 444 40

Slew motor with attached slew service brake valve: 260 kg

Slew parking brake assembly: 115 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

Fig. 3-258 Slew parking brake (Siebenhaar), drawn released

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Superstructure Slew system

REMARKS: Ensure that the mating surfaces are clean and free of paint before assembly.

Releasing the slew parking brake manually:

1. Insert two bolts (Fig. 3-259, Pos. 1) of suitable length with

nuts (Fig. 3-259, Pos. 3) into the threaded borings
(Fig. 3-258, Pos. 2) of the piston (Fig. 3-259, Pos. 2) opposed
to each other.

2. Tighten each nut (Fig. 3-259, Pos. 3) alternately with a half

turn, to withdraw the piston Fig. 3-259, Pos. 2) to the flange
(Fig. 3-259, Pos. 4).

REMARKS: Avoid tilting the piston!

3. Turn the slew parking brake (Fig. 3-259, Pos. 2) until the
bores in the slew parking brake are aligned to the threads in Fig. 3-259
the adapter cover (Fig. 3-259, Pos. 4).

4. Apply paste Optimol Paste White T on the spline shaft at the

gear box (Fig. 3-260, Pos. 4).

5. Insert a new O-Ring (Fig. 3-260, Pos. 5).

6. Insert swivel hoist rings (M16) on the new pre-assembled

slew parking brake, displaced by 180° into the threads of the
slew motor mounting bolts and attach the brake assembly to
a crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine Fig. 3-260
part.

7. Centre the new pre-assembled slew parking brake (Fig. 3-260, Pos. 2) onto the adapter cover of the gear box
(Fig. 3-260, Pos. 4) using the crane.

8. Insert new mounting bolts (Fig. 3-258 / Fig. 3-260, Pos. 1) and tighten them crosswise.

9. Detach the crane.

10. Loosen each nut (Fig. 3-259, Pos. 3) alternately with a half turn, until the piston is fully home and completely
springloaded.

REMARKS: Avoid tilting the piston!

11. Disassemble the release bolts (Fig. 3-259, Pos. 1).

12. Assemble all filler and breather pipes (Fig. 3-260, Pos. 3) at the slew parking brake (Fig. 3-260, Pos. 2).

13. Connect the pilot oil pressure line at the slew parking brake.

14. Assemble the slew motor at the slew gear box, refer to section 3.4.3.2 on page 3-180.

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Slew system Superstructure

d Fill specified oil into the motor adapter housing, up to level gauge marking.
Fill specified oil into the brake housing, approx. 0.3 liters.

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section "SWING GEARS AND
MOTOR ADAPTER HOUSING - CHANGE OIL".
For the proper lubricants, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"FLUIDS AND LUBRICANTS".

NOTICE
BRAKE NOT BLED!
The swing parking brake can not be released completely due to air in the hydraulic system. This may
cause severe damage to the brake lamellas.

Before initial operation or after repairs on the hydraulic circuit, all swing parking brakes have to be vented
at the oil pressure port.

15. Bleed the swing parking brake at the pressure oil port.

16. Add specified hydraulic oil up to the specified level.

17. Check slew parking brake for function:

Refer to the OPERATION & MAINTENANCE MANUAL, chapter 3 "WORKING INSTRUCTIONS".
Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL.

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Please continue reading on the next page.

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Slew system Superstructure

3.4.5 SLEW CIRCLE LUBRICATION PINION (DUMMY WHEEL)

3.4.5.1 DISASSEMBLING OF THE SLEW CIRCLE LUBRICATION PINION ASSEMBLY

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Mobile elevator working platform

Pinion cover: 37.5 kg

Lubrication pinion assembly: 14.5 kg

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

REMARKS: A second person is required for the work at the lubrication pinion.

Fig. 3-261 Lubrication pinion assembly, disassembling and assembling

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Superstructure Slew system

1. Prepare an area of flat ground large enough to accommodate the machine, boom and mobile working plat-
form.

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

NOTE! Before maintenance, stop the engine and remove ignition key in order to prevent operation of the
lubrication system.
Assure that the system pressure of the lubrication system is relieved before maintenance.

4. Clear the lubrication line of the slew gear box from the pinion cover (Fig. 3-261, Pos. 2).

5. Disassemble all bolts (Fig. 3-261, Pos. 1) and remove the pinion cover (Fig. 3-261, Pos. 2).

6. Disconnect the lubrication line (Fig. 3-261, Pos. 3).

7. Disassemble the nuts (Fig. 3-261, Pos. 4) and take the lubrication pinion assembly (Fig. 3-261, Pos. 5) off the
superstructure.

3.4.5.2 ASSEMBLING OF THE SLEW CIRCLE LUBRICATION PINION ASSEMBLY

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Mobile elevator working platform

Pinion cover: 37.5 kg

Lubrication pinion assembly: 14.5 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

REMARKS: A second person is required for the work at the lubrication pinion.

1. Move the lubrication pinion assembly (Fig. 3-261, Pos. 5) into mounting position at the superstructure.

2. Assemble the nuts (Fig. 3-261, Pos. 4).

3. Reconnect the lubrication line (Fig. 3-261, Pos. 3).

4. Install the pinion cover (Fig. 3-261, Pos. 2), assemble all bolts (Fig. 3-261, Pos. 1).

5. Retain the lubrication line of the slew gear box at the pinion cover (Fig. 3-261, Pos. 2).

6. After installation is complete, the slew circle lubrication system has to be activated manually by switch 20S026
in the operator’s cab
The grease must come out of the lube channels in the lubrication pinions.

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Slew system Superstructure

3.4.6 SLEW CIRCLE

For wear limits of the slew circle bearing, refer to the PARTS & SERVICE NEWS No. "AH02513".
For additional information, refer to the PARTS & SERVICE NEWS No. "AH00511".

Fig. 3-262 Slew circle

(1) Slew circle (5) Bolt

(2) Bolt (6) Resilient sleeve

(3) Slew gear (7) Slew circle protection at lubrication pinion

(4) Slew circle protection (partly shown) (8) Superstructure platform

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Superstructure Slew system

3.4.6.1 DISASSEMBLING OF THE SLEW CIRCLE

Special tools: Mounting cross, PN 329 179 40

Hydraulic torque wrench, PN 232 614 40
Electro-hydraulic pump set, PN 793 375 73
46 mm hexagon impact socket wrench, PN 232 265 40

Additional equipment: Safety harness in conformity with DIN EN 361

Mobile elevator working platform
2 x crane (2nd. crane for superstructure lifting)
Swivel hoist rings: 4 x M36 x 220 (male)

Slew circle: 3500 kg

Dogman/rigger
Crane operators trained in dual crane lift

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Prepare an area of flat ground large enough to accommodate the machine, boom, and two cranes.

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter
3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

5. Mark location of both slew rings to superstructure and the car body as well for further investigations.

NOTICE
HAZARD OF CRASHING THE SUPERSTRUCTURE!
Severe damages to the superstructure may result.
Too weakly dimensioned supports may cause the superstructure to crash due to destruction of the sup-
ports.

Supports need to be substantial enough to carry total weight of the superstructure (without counter-
weight, fluids and attachment), total weight 64,000 kg.

6. Disassemble all swing circle protection covers (Fig. 3-262, Pos. 4) covering the swing circle.

7. Disassemble the pinion cover (Fig. 3-262, Pos. 7) and the lubrication pinion assembly, refer to section 3.4.5.1
on page 3-196.

8. Disassemble the superstructure from the car body (counterweight, fluids and attachment removed), refer to
section 3.11.1 on page 3-252.
Place the superstructure on appropriate supports, high enough to handle the mounting cross underneath the
swing circle.

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Slew system Superstructure

9. Disconnect all slew ring bearing lubrication lines (Fig. 3-263,

Pos. 2) from the inner slew ring (Fig. 3-263, Pos. 1).

10. Clear all hose straps (Fig. 3-263, Pos. 3) from the inner slew
ring.

Fig. 3-263

11. Position the mounting cross, PN 329 179 40 underneath the slew circle.

REMARKS: Make sure that the mounting cross including the swing circle can be moved underneath the super-
structure.

12. Attach the mounting cross to a crane.

The mounting cross is accessible from the center of the
machine in front of the manifold (Fig. 3-264, arrow).

NOTICE
DAMAGE AT HYDRAULIC LINES!
The sling accessory may damage the hydraulic pipes at the
front of the manifold while moving the swing circle using a
crane.

• Handle the sling accessory / move the crane with great care
in order to avoid damages.
• It is recommended to remove the pipes from the manifold Fig. 3-264
(Fig. 3-264, Pos. 1).

13. Lift the mounting cross under the swing circle using the crane.

14. Disassemble all mounting bolts (Fig. 3-265, Pos. 2) at the

inner slew ring (Fig. 3-265, Pos. 1) using the hydraulic torque
wrench.

Fig. 3-265

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Superstructure Slew system

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

15. Clear the wing circle (Fig. 3-266, Pos. 2) from the superstruc-
ture platform wing circle (Fig. 3-266, Pos. 3) and lower the Fig. 3-266
mounting cross (Fig. 3-266, Pos. 1) with the swing circle to
the ground using the crane.

The guides (Fig. 3-267, Pos. 2) ensure that the swing circle
(Fig. 3-267, Pos. 3) is aligned accurately with the superstructure
platform (Fig. 3-267, Pos. 1) while it is removed or installed.

They also assure the factory adjusted backlash of the swing gear-
ing in case the same swing circle will be reassembled.

REMARKS: Do not remove the guides.

Fig. 3-267

16. Move the mounting cross

17. Install four swivel hoist rings evenly distributed at the inner swing ring and attach a crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

18. Lift the swing circle off the mounting cross using the crane.

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Slew system Superstructure

3.4.6.2 ASSEMBLING OF THE SLEW CIRCLE

Special tools: Mounting cross, PN 379 383 40

Hydraulic torque wrench, PN 232 614 40
Electro-hydraulic pump set, PN 793 375 73
46 mm hexagon impact socket wrench, PN 232 265 40
Swing circle mounting kit:
– PN 768 222 73 (normal environmental condition)
– PN 768 928 73 (cold weather)

Additional equipment: Safety harness in conformity with DIN EN 361

Mobile elevator working platform
2 x crane (2nd. crane for superstructure lifting)
Laser device for checking the level of bearing area
International Compound No. 2, PN 324 969 40
Swivel hoist rings: 4 x M36 x 220 (male)

Slew circle: 3500 kg

Dogman/rigger
Crane operators trained in dual crane lift

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: The swing circle mounting kit contains new mounting bolts and all required tools for determining the
tightening torques for the mounting bolts.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

REMARKS: Mating surfaces must be absolutely fat-free. Even the solvent must be rinsed away before assem-
bling.

1. Disassemble the swing motors from the swing gear box, refer to section 3.4.3.1 on page 3-177.

2. Check the wear of the slew circle pinions at the slew gears, refer to the PARTS & SERVICE NEWS
No. "AH05518".

3. Check the level of bearing area with a laser device before installing a new slew ring. Refer to the PARTS &
SERVICE NEWS No. "AH00511".

4. Check the outer diameter of the new slew ring top surface and compare with the outer diameter of the factory
machined surface of the superstructure. Refer to the PARTS & SERVICE NEWS No. "AH00511".
Disassemble the shoulder by machining if necessary.

NOTICE
IMPROPER HANDLING OF THE SLEW CIRCLE!
Damages to the slew circle may result.

• Shocks to the slew circle (especially radial shocks) must be avoided.

• Transport and store the new slew circle exclusively with transport star fitted.
• It is strictly forbidden to hook up the new slew circle at the transport star.
• Hang up and/or transport and store the slew circle only horizontally.
• Only hang slew circle at four swivel hoist rings evenly distributed in screw circle of the inner slew ring.

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Superstructure Slew system

5. Clean the contact surfaces of the swing ring and the superstructure platform very carefully and thoroughly.

6. Prepare the bolts and washers of the swing circle mounting kit. Lubricate the threads and the head surface of
the bolts with International Compound No. 2, PN 324 969 40.

7. Install four swivel hoist rings evenly distributed at the inner swing ring and attach a crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

8. Place the swing circle onto the mounting cross using the crane.
Make sure that the mounting cross including the swing circle can be moved underneath the superstructure.

9. Remove the four swivel hoist rings from the inner slew ring.

10. Move the mounting cross with the swing circle underneath the superstructure.

11. Attach the mounting cross to a crane.

The mounting cross is accessible from the center of the
machine in front of the manifold (Fig. 3-264, arrow).

NOTICE
DAMAGE AT HYDRAULIC LINES!
The sling accessory may damage the hydraulic pipes at the
front of the manifold while moving the swing circle using a
crane.

• Handle the sling accessory / move the crane with great care
in order to avoid damages.
• It is recommended to remove the pipes from the manifold Fig. 3-268
(Fig. 3-264, Pos. 1).

12. Lift the mounting cross with the swing circle into mounting position.

13. Assemble the swing circle (Fig. 3-269, Pos. 3) at the super-
structure platform (Fig. 3-269, Pos. 1) according to the
PARTS & SERVICE NEWS No. "AH00511".

b Determine the tightening torque and tighten all

bolts of the inner swing ring crosswise to the
required torque, refer to the PARTS & SERVICE
NEWS No. "AH00511".

14. When assembling a new swing circle:

– Move the guides (Fig. 3-269, Pos. 2) inwards.

– After adjusting the tooth backlash between swing ring and
swing pinion according to the PARTS & SERVICE NEWS Fig. 3-269
No. "AH00511" fix the guides free of clearance to the inner
swing ring.
15. Detach the crane.

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Slew system Superstructure

16. After checking the tooth backlash according to the PARTS & SERVICE NEWS No. "AH00511" assemble the
swing motor, refer to section 3.4.3.2 on page 3-180.

17. Remount the superstructure onto the undercarriage, refer to section 3.11.2 on page 3-256.

18. Reconnect all slew ring bearing lubrication lines (Fig. 3-270,
Pos. 2) from the inner swing ring (Fig. 3-270, Pos. 1).

19. Retain all hose straps (Fig. 3-270, Pos. 3) at the inner slew
ring.

Fig. 3-270

20. Assemble the lubrication pinion assembly, refer to section 3.4.5.2 on page 3-197.

21. Assemble all slew circle protection covers and the pinion
cover (Fig. 3-271).

Fig. 3-271

22. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

23. Add specified hydraulic oil up to the specified level.

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Lubrication pumps Superstructure

3.5 LUBRICATION PUMPS

3.5.1 DISASSEMBLING OF THE LUBRICATION PUMP

Special tools: n/a

Additional equipment: Crane

Lubrication pump: 28 kg

Dogman/rigger

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

NOTE! Before further work, stop the engine and remove

ignition key in order to prevent operation of the lubri-
cation system.

3. Disconnect the hydraulic lines (Fig. 3-272, Pos. 1) and the

grease supply line (Fig. 3-272, Pos. 2) from the lubrication
pump (Fig. 3-272, Pos. 4).

4. Attach the lubrication pump to a crane at the installed hoist

ring (Fig. 3-272, Pos. 3).

Fig. 3-272

5. Disassemble the bolt (Fig. 3-273, Pos. 1) and pull the lubrica-
tion pump out of the grease barrel using the crane.

Fig. 3-273

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Superstructure Lubrication pumps

3.5.2 ASSEMBLING OF THE LUBRICATING PUMP

Special tools: n/a

Additional equipment: Crane

Lubrication pump: 28 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Attach the lubrication pump to a crane at the installed hoist ring (see Fig. 3-275, Pos. 3).

2. Install the lubrication pump in the grease barrel using the crane.

3. Assemble the bolt (Fig. 3-274, Pos. 1).

4. Detach the crane.

Fig. 3-274

5. Connect the hydraulic lines (Fig. 3-275, Pos. 1) and the

grease supply line (Fig. 3-275, Pos. 2) at the lubrication pump
(Fig. 3-275, Pos. 4).

6. After assembling, bleed the pump at the breather port, refer to

the PARTS & SERVICE NEWS No. "AH15824" (latest edi-
tion).

7. Adjust the lubrication pump speed and pump pressure.

Refer to part 10 STRUCTURE & FUNCTION, chapter 17 in
the SHOP MANUAL.

Fig. 3-275

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Operator’s cab Superstructure

3.6 OPERATOR’S CAB

3.6.1 DISASSEMBLING OF THE OPERATOR’S CAB

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Crane
Mobile elevator working platform
Tank for coolant storage
Oil drain pan

Operator’s cab: 3000 kg

Dogman/rigger
Service specialist for air conditioning systems

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

NOTE! Pay attention to the Fire Detection and Suppression System.

Refer to the separate manuals "Fire Detection and Actuating System" and "Fire Suppression Sys-
tem". The wires of the Fire Detection and Suppression System must not be bent excessively or be
damaged to remain functional.
All work on the Fire Detection, Actuation and Suppression System has to be carried out by well
trained specialists having the manufacturer’s certificate for working on such systems. The local rules
and directives regarding the installation procedure of the Fire Detection, Actuation and Suppression
Systems have to be observed.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations with the

access ladder (Fig. 3-276, Pos. 1) lowered to the ground.

4. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

REMARKS: To relieve the remaining pilot pressure connect an

open hose to the checkpoints M1.1 and M1.2 on the
valve cartridge block (Fig. 3-276).
When the hydraulic hoses are connected, hydraulic
oil from inside the piping will flow out. Catch it in an
oil pan.
Fig. 3-276

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Superstructure Operator’s cab

5. Remove the keys from the battery main switches.

6. Cover the X2-board and the electronic ports inside the cab
base as protection against dirt and water.

7. Inside the cab base disassemble the grommet plate

(Fig. 3-277, Pos. 2) from the cab base ceiling.

8. Unplug all harness connectors at the back side of the grom-

met plate.

9. Disassemble the connecting plate (Fig. 3-277, Pos. 1) from

the cab base ceiling.

Fig. 3-277

WARNING
HOT ENGINE COOLANT!
Personal injury from hot machine parts, hot coolant or steam may result.

Do not carry out the following work on a hot engine.

Wait until the temperature of the engine is below 50°C.

10. Disassemble the hoses of the operator’s cab heating from the back side of the connecting plate (Fig. 3-277,
Pos. 1).

11. Disconnect 5 harness connectors (Fig. 3-278, Pos. 1) inside

the cab base.

12. Disconnect the wires of the Fire Detection and Suppression

System.

NOTE! Pay attention to the Fire Detection and Suppression

System.
Refer to the separate manuals "Fire Detection and
Actuating System" and "Fire Suppression System".
The wires of the Fire Detection and Suppression
System must not be bent excessively or be dam-
aged to remain functional.
Fig. 3-278

13. Disconnect and clear the ground cable (Fig. 3-279, Pos. 1)
inside the cab base (Fig. 3-279, Pos. 2).

Fig. 3-279

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Operator’s cab Superstructure

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure may result in
blindness, serious injury, permanent disfigurement, or scaring.

Make sure that the pressure is relieved before any hydraulic lines will be disassembled.

Fig. 3-280 Hydraulic connections

14. Disconnect all the hydraulic hoses of the pilot controls (Fig. 3-280, Pos. 1) from the pilot control frame
(Fig. 3-280, Pos. 2).

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

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Superstructure Operator’s cab

15. Disassemble the grids (Fig. 3-281, Pos. 1 to 3) from the L.H.
side of the operator’s cab to access the cab mounts.

Fig. 3-281

16. Disassemble the bracket (Fig. 3-282, Pos. 1) covering the

jacking screw thread (Fig. 3-282, Pos. 2).

Fig. 3-282

WARNING
HAZARDOUS REFRIGERANT!
The refrigerant may cause frostbite and toxication when it comes in contact with the skin. The refrigerant
is also toxic when inhaled.

Any maintenance, repair or service at the air conditioning system must be carried out by authorized and
special skilled service specialists only.

17. Suck off the refrigerant from the air conditioning system.

REMARKS: For information about the air conditioning system refer to the PARTS & SERVICE NEWS
No. "AH06521".

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 211

Operator’s cab Superstructure

DANGER
REFRIGERANT UNDER HIGH PRESSURE!
May result in blindness, serious injury, permanent disfigure-
ment, or scaring.
The air conditioning system is pressurized.

Make sure that the refrigerant is sucked off from the system
before any lines will be opened.

18. Disconnect the refrigerant hoses of the air conditioning sys-

tem (Fig. 3-283, Pos. 4) below the grating. Fig. 3-283
Cap the openings with blind plugs to avoid contamination of
the air conditioning system.

19. On both sides remove the mounting bolts (Fig. 3-283, Pos. 1)
and resilient sleeves from all viscous mounts (Fig. 3-283,
Pos. 2).

20. Attach the operator’s cab (Fig. 3-284, Pos. 2) to a crane at

the lifting eye bolts (Fig. 3-284, Pos. 1) delivered with the cab.

Fig. 3-284

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

21. Lift operator’s cab away using the crane.

REMARKS: A second person is required to feed wires and hoses through the openings of the cab base.

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Superstructure Operator’s cab

3.6.2 ASSEMBLING OF THE OPERATOR’S CAB

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Crane
Mobile elevator working platform

Operator’s cab: 3000 kg

Dogman/rigger
Electrician with permission to work on high voltage systems
Service specialist for air conditioning systems

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

NOTE! Pay attention to the Fire Detection and Suppression System.

Refer to the separate manuals "Fire Detection and Actuating System" and "Fire Suppression Sys-
tem". The wires of the Fire Detection and Suppression System must not be bent excessively or be
damaged to remain functional.
All work on the Fire Detection, Actuation and Suppression System has to be carried out by well
trained specialists having the manufacturer’s certificate for working on such systems. The local rules
and directives regarding the installation procedure of the Fire Detection, Actuation and Suppression
Systems have to be observed.

REMARKS: It is recommended to replace the viscous cab mounts before the assembling of the operator’s cab,
refer to section 3.6.3 on page 3-218. Note the mounting position of the viscous cab mounts!

1. Attach the operator’s cab (Fig. 3-284, Pos. 2) to a crane at

the lifting eye bolts (Fig. 3-284, Pos. 1) delivered with the cab.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

Fig. 3-285
2. Lift the operator’s cab (Fig. 3-285, Pos. 2) into mounting posi-
tion using the crane.

REMARKS: A second person is required to feed wires and

hoses through the openings of the cab base.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 213

Operator’s cab Superstructure

3. Reconnect the refrigerant hoses of the air conditioning sys-

tem (Fig. 3-286, Pos. 4) below the grating.

4. Assemble new mounting bolts (Fig. 3-286, Pos. 1) of the

grade 10.9 with resilient sleeves at all viscous mounts
(Fig. 3-286, Pos. 2).
Apply MPG (or roller bearing grease, or grease from the CLS
system) and tighten the bolts to the specified tightening
torque.

b Tightening torque for the mounting bolts:

265 Nm

5. Detach the crane.

Fig. 3-286

6. Assemble the bracket (Fig. 3-287, Pos. 1) covering the jack-

ing screw thread (Fig. 3-287, Pos. 2).

Fig. 3-287

7. Assemble the grids (Fig. 3-288, Pos. 1 to 3).

Fig. 3-288

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Superstructure Operator’s cab

8. Inside the cab base replug all harness connectors at the back
side of the grommet plate (Fig. 3-289, Pos. 2).

9. Assemble the grommet plate at the cab base ceiling.

10. Connect the hoses of the operator’s cab heating at the back
side of the connecting plate (Fig. 3-289, Pos. 1).

11. Assemble the connecting plate (Fig. 3-289, Pos. 1) from the
cab base ceiling.

Fig. 3-289

12. Reconnect 5 harness connectors (Fig. 3-290, Pos. 1) inside

the cab base.

13. Reconnect the wires of the Fire Detection and Suppression

System.

NOTE! Pay attention to the Fire Detection and Suppression

System.
Refer to the separate manuals "Fire Detection and
Actuating System" and "Fire Suppression System".
The wires of the Fire Detection and Suppression
System must not be bent excessively or be dam-
aged to remain functional.
Fig. 3-290

14. Reconnect and retain the ground cable (Fig. 3-291, Pos. 1)
inside the cab base (Fig. 3-291, Pos. 2).

Fig. 3-291

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Operator’s cab Superstructure

Fig. 3-292 Hydraulic connections

15. Connect all the hydraulic hoses of the pilot controls (Fig. 3-292, Pos. 1) from the pilot control frame
(Fig. 3-292, Pos. 2).

16. Bleed air from the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

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Superstructure Operator’s cab

17. Add specified hydraulic oil up to the specified level.

WARNING
HAZARDOUS REFRIGERANT!
The refrigerant may cause frostbite and toxication when it comes in contact with the skin. The refrigerant
is also toxic when inhaled.

Any maintenance, repair or service at the air conditioning system must be carried out by authorized and
special skilled service specialists only.

18. Evacuate the air conditioning system and refill the system with refrigerant and compressor oil.
For information about evacuating and refilling of the air conditioning system, refer to the PARTS & SERVICE
NEWS No. "AH06521".

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 217

Operator’s cab Superstructure

3.6.3 CAB MOUNTS

3.6.3.1 DISASSEMBLING OF THE CAB MOUNTS

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Mobile elevator working platform

Viscous mount: 4.6 kg

Absorber plate 1 incl. viscous mount: 9 kg
Absorber plate 2 incl. viscous mounts: 12 kg
Absorber plate 3 incl. viscous mounts: 19.5 kg

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Prepare an area of flat ground large enough to accommodate the machine, boom and mobile elevator working
platform.

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. On the L.H. side if required:

Disassemble the grids (Fig. 3-293, Pos. 1 to 3) to access the
cab mounts.

Fig. 3-293

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Superstructure Operator’s cab

5. On the L.H. side if required:

Disassemble the bracket (Fig. 3-294, Pos. 1) covering the
jacking screw thread (Fig. 3-294, Pos. 2).

Fig. 3-294

6. On the corresponding side remove the mounting bolts

(Fig. 3-295, Pos. 1) and resilient sleeves from all viscous
mounts (Fig. 3-295, Pos. 3).

NOTE! Do not disassemble the mounting bolts (Fig. 3-295,

Pos. 1) on both sides of the cabin at the same time.

7. Disassemble the mounting bolts (Fig. 3-295, Pos. 2) of the

absorber plate with the viscous mount(s) (Fig. 3-295, Pos. 3)
to be disassembled.

8. Raise the Operator’s cab using the two jacking screws

(Fig. 3-295, Pos. 4) just enough to clear the absorber plate
assemblies.
Fig. 3-295
9. Remove the absorber plate assembly from beneath the oper-
ator’s cab.

10. Disassemble four bolts (Fig. 3-296, Pos. 1) at each viscous

mount (Fig. 3-296, Pos. 3) and dismount the viscous mount
from absorber plate (Fig. 3-296, Pos. 2).

Fig. 3-296 Absorber plate assembly

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Operator’s cab Superstructure

3.6.3.2 ASSEMBLING OF THE CAB MOUNTS

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Mobile elevator working platform
MPG (Multi Purpose Grease)

Viscous mount: 4.6 kg

Absorber plate 1 incl. viscous mount: 9 kg
Absorber plate 2 incl. viscous mounts: 12 kg
Absorber plate 3 incl. viscous mounts: 19.5 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Assemble the viscous mounts (Fig. 3-297, Pos. 3) at

absorber plate (Fig. 3-297, Pos. 2).

2. Insert new mounting bolts (Fig. 3-297, Pos. 1) of the grade

10.9 at the assembly.
Apply MPG (or roller bearing grease, or grease from the CLS
system) and tighten the bolts to the specified tightening
torque.

b Tightening torque for the mounting bolts: 63 Nm

NOTE! When mounting the viscous mounts (Fig. 3-297,

Pos. 3) at the absorber plate (Fig. 3-297, Pos. 2)
make sure that the pins (Fig. 3-297, Pos. 4) are
positioned as shown. Fig. 3-297 Note the mounting position!

3. If required raise the Operator’s cab using the two jacking

screws (Fig. 3-298, Pos. 4) just enough to insert the absorber
plate assemblies.

4. Insert the absorber plate assembly beneath the operator’s

cab.

NOTE!
When mounting the absorber plate assemblies make sure that
the pins (see Fig. 3-297, Pos. 4) in the viscous mounts are facing
in the correct direction:
• L.H. side of the cab: Pin is facing to the machine front side
• R.H. side of the cab: Pin is facing to the machine back side

5. Lower the Operator’s cab using the two jacking screws Fig. 3-298 Note the mounting position!
(Fig. 3-298, Pos. 4) completely and lock them with a nut.

6. Assemble new mounting bolts (Fig. 3-298, Pos. 2) of the grade 10.9 with resilient sleeves at the absorber plate
assemblies.
Apply MPG (or roller bearing grease, or grease from the CLS system) and tighten the bolts to the specified
tightening torque.

b Tightening torque for the mounting bolts (Fig. 3-298, Pos. 2): 265 Nm

3 - 220 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Operator’s cab

7. Assemble new mounting bolts (Fig. 3-298, Pos. 1) of the grade 10.9 with resilient sleeves at the viscous
mounts (Fig. 3-298, Pos. 3).
Apply MPG (or roller bearing grease, or grease from the CLS system) and tighten the bolts to the specified
tightening torque.

b Tightening torque for the mounting bolts (Fig. 3-298, Pos. 1): 265 Nm.

8. On the L.H. side if required:

Assemble the bracket (Fig. 3-299, Pos. 1) covering the jack-
ing screw thread (Fig. 3-299, Pos. 2).

Fig. 3-299

9. On the L.H. side if required:

Assemble the grids (Fig. 3-293, Pos. 1 to 3).

Fig. 3-300

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 221

Operator’s cab Superstructure

3.6.4 FRONT WINDOW (WINDSHIELD)

3.6.4.1 DISASSEMBLING OF THE FRONT WINDOW

Special tools: n/a

Additional equipment: Suction lifters with hoist rings

Safety harness in conformity with EN 361
Crane
Mobile elevator working platform

Front window: 95 kg

Dogman/rigger
A second person for help

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Disassemble the wiper arms (Fig. 3-301, Pos. 1).

5. Use suction lifters with hoist rings at the front window

(Fig. 3-301, Pos. 4) to sling the front window.

6. Disassemble the bolts (Fig. 3-301, Pos. 2). Hold nut

(Fig. 3-301, Pos. 3) from inside the cab.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.
Fig. 3-301

7. Disassemble the front window (Fig. 3-301, Pos. 4) using a

crane.

8. Check the flatness of the windshield opening using a ruler, correct it if necessary.
Maximal tolerance: 0.5 mm per 1 m

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Superstructure Operator’s cab

3.6.4.2 ASSEMBLING OF THE FRONT WINDOW

Special tools: n/a

Additional equipment: Suction lifters with hoist rings

Safety harness in conformity with EN 361
Crane
Mobile elevator working platform

Front window: 95 kg

Dogman/rigger
A second person for help

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

When assembling a bullet proof windshield carry out assembling according to the PARTS & SERVICE NEWS
No. "AH13423" (latest edition).

1. Apply plenty sealing material (silicone) to the frame of the

windshield.

2. Use suction lifters with hoist rings at the front window

(Fig. 3-302, Pos. 4) to sling the front window.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

3. Move the front window (Fig. 3-302, Pos. 4) into mounting Fig. 3-302
position using the crane.

REMARKS: Quickly align the bores because the sealing material

becomes sticky after a few minutes.

4. Assemble the bolts (Fig. 3-302, Pos. 2).

Hold nut (Fig. 3-302, Pos. 3) from inside the cab.

5. Assemble the wiper arms (Fig. 3-302, Pos. 1).

6. Check the correct end position of the wiper arm(s) after installation of the front window.

REMARKS: After installation of the front windshield the sealing material needs about 10 hours to harden.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 223

Operator’s cab Superstructure

3.6.5 OPERATOR’S SEAT

3.6.5.1 DISASSEMBLING OF THE OPERATOR’S SEAT

Special tools: n/a

Additional equipment: Crane

Operator’s seat: 62 kg

Dogman/rigger

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Disconnect the wire harness connector (Fig. 3-303, Pos. 1) of

the air suspension.

5. Disassemble both control lever carriers (Fig. 3-303, Pos. 2

and 3).

6. Disassemble all mounting bolts (Fig. 3-303, Pos. 4) from the

cover plate (Fig. 3-303, Pos. 5) and remove the operator’s
seat (Fig. 3-303, Pos. 8).

7. Disassemble the cover plate (Fig. 3-303, Pos. 5) by removing

all seat mounting bolts (Fig. 3-303, Pos. 6) and nuts
(Fig. 3-303, Pos. 7) from the operator’s seat.

REMARKS: A second person is required to carry the operator’s Fig. 3-303

seat out of the operator’s cab.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

8. Sling operator’s seat and lift it off the machine using a crane.

3 - 224 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Operator’s cab

3.6.5.2 ASSEMBLING OF THE OPERATOR’S SEAT

Special tools: n/a

Additional equipment: Crane

Operator’s seat: 62 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Disassemble both control lever carriers from the new seat.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

2. Sling operator’s seat and lift it on the machine using a crane.

REMARKS: A second person is required to carry the operator’s seat into the operator’s cab.

3. Assemble the cover plate (Fig. 3-304, Pos. 5) at the opera-

tor’s seat (Fig. 3-304, Pos. 8) by assembling all seat mount-
ing bolts (Fig. 3-304, Pos. 6) and nuts (Fig. 3-304, Pos. 7).

4. Move the operator’s seat into mounting position and assem-

ble all mounting bolts (Fig. 3-304, Pos. 4) at the cover plate
(Fig. 3-304, Pos. 5).

5. Reconnect the wire harness connector (Fig. 3-304, Pos. 1) of

the air suspension.

6. Assemble both control lever carriers (Fig. 3-304, Pos. 2 and

3).

Fig. 3-304

REMARKS: A second person is needed to carry the operator’s seat into the operator’s cab.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 225

Cab base Superstructure

3.7 CAB BASE

3.7.1 DISASSEMBLING OF THE CAB BASE

Special tools: Hydraulic torque wrench & aggregate set, PN 232 267 40
55 mm hexagon impact socket wrench, PN 232 267 40

Additional equipment: Safety harness in conformity with EN 361

Crane
Mobile elevator working platform
Oil drain pan

Cab base: 3059 kg

Emergency escape ladder: 47 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter
3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

5. Disassemble the operator’s cab (Fig. 3-305, Pos. 1), refer to

section 3.6.1 on page 3-208.

6. Disassemble the emergency escape ladder (Fig. 3-305,

Pos. 2) and the hand rails (Fig. 3-305, Pos. 3 and 4).

Fig. 3-305

7. Disconnect all wire harnesses leading into the cab base from the X2 board and the additional systems inside
the base.

8. Disassemble all the hydraulic hoses leading into the cab base.

3 - 226 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Cab base

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

9. Clear all wire harnesses, water hoses and hydraulic hoses from the bottom side of the cab base and pull them
out of the cab base.

10. Clear all wire harnesses, water hoses and hydraulic hoses from the side of the cab base.

11. Install four swivel hoist rings and attach the cab base
(Fig. 3-306, Pos. 1) to a crane, refer to Fig. 3-307.

12. Disassemble bolts (Fig. 3-306, Pos. 2) attaching the cab base
to the superstructure (Fig. 3-306, Pos. 2) using the hydraulic
torque wrench.

Fig. 3-306

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

13. Remove the cab base from superstructure platform using the
crane (Fig. 3-307). Fig. 3-307 Example

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 227

Cab base Superstructure

3.7.2 ASSEMBLING OF THE CAB BASE

Special tools: Hydraulic torque wrench & aggregate set, PN 232 267 40
55 mm hexagon impact socket wrench, PN 232 267 40

Additional equipment: Safety harness in conformity with EN 361

Crane
Mobile elevator working platform
MPG (Multi Purpose Grease)

Cab base: 3059 kg

Emergency escape ladder: 47 kg

Dogman/rigger
Electrician with permission to work on high voltage systems

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Install four swivel hoist rings and attach the cab base to a
crane (Fig. 3-308).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

Fig. 3-308 Example

2. Move the cab base into mounting position using the crane
(Fig. 3-308).

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Superstructure Cab base

3. Assemble new mounting bolts (Fig. 3-309, Pos. 2) of grade

10.9. attaching the cab base (Fig. 3-309, Pos. 1) to the super-
structure (Fig. 3-309, Pos. 2).
Apply MPG (or roller bearing grease, or grease from the CLS
system) on heads and threads of the bolts and tighten the
mounting bolts with the specified tightening torque using the
hydraulic torque wrench.

b Tightening torque for the cab base mounting

bolts (Fig. 3-309, Pos. 2): 3100 Nm.

4. Detach the crane.

Fig. 3-309

5. Retain all wire harnesses, water hoses and hydraulic hoses at the bottom side of the cab base.

6. Lead the wire harnesses, water hoses and hydraulic hoses into of the cab base.

7. Reconnect all wire harnesses at the X2 board and the additional systems inside the base.

8. Reconnect all the hydraulic hoses leading into the cab base at the control frame assembly.

9. Retain all wire harnesses, water hoses and hydraulic hoses at the side of the cab base.

10. Assemble the emergency escape ladder (Fig. 3-310, Pos. 2)

and the hand rails (Fig. 3-310, Pos. 3 and 4).

11. Assemble the operator’s cab (Fig. 3-310, Pos. 1), refer to
section 3.6.2 on page 3-213.

Fig. 3-310

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 229

Access Ladder Superstructure

3.8 ACCESS LADDER

Fig. 3-311 Access ladder assembly

(1) Access ladder (5) Washer

(2) Self-locking nut (6) Pivot pin

(3) Ladder bearing assembly (7) Access ladder cylinder

(4) Cotter pin

3 - 230 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Access Ladder

3.8.1 DISASSEMBLING OF ACCESS LADDER

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Oil draining pan
Crane
Mobile elevator working platform

Access ladder: 130 kg

Dogman/rigger

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations with the

access ladder (Fig. 3-311, Pos. 1) lowered to the ground.

4. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

REMARKS: To relieve the remaining pilot pressure connect an

open hose to the checkpoints M1.1 and M1.2 on the
valve cartridge block (Fig. 3-312).
When the hydraulic hoses are connected, hydraulic
oil from inside the piping will flow out. Catch it in an
oil pan.
Fig. 3-312

5. Disconnect the wiring harness from the ladder light switch [70S018] and clear the wiring harness from the
access ladder (Fig. 3-311, Pos. 1).

6. Secure the access ladder cylinder (Fig. 3-311, Pos. 7) in its position.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 231

Access Ladder Superstructure

Fig. 3-313 Access ladder assembly

7. Disassemble the cotter pin (Fig. 3-313, Pos. 4).

8. Clear the access ladder (Fig. 3-313, Pos. 1) by removing the pivot pin (Fig. 3-313, Pos. 6) from the access
ladder cylinder piston rod.

9. Attach the access ladder to a crane.

10. Disassemble the self locking nuts (Fig. 3-313, Pos. 2) and the bolts (Fig. 3-313, Pos. 3) from the ladder bear-
ing assemblies.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

11. Disassemble the ladder bearing assemblies and the ladder using the crane. Rest it on the ground.

3 - 232 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Access Ladder

3.8.2 ASSEMBLING OF ACCESS LADDER

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Crane
Mobile elevator working platform
MPG (Multi Purpose Grease)

Access ladder: 130 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Attach the access ladder (Fig. 3-313, Pos. 1) to a crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

2. Move the ladder into mounting position using the crane.

3. Assemble the bolts (Fig. 3-313, Pos. 3) and the self locking nuts (Fig. 3-313, Pos. 2) at the ladder bearing
assemblies tighten the self locking nuts with the specified tightening torque.

b Tightening procedure for the self-locking nuts (Fig. 3-313, Pos. 2):
Tighten the nuts until thy have contact with the ladder carrier frame. Then tighten the nuts by
turning them by 45° (1/8 turn).

4. Attach the lower end of the access ladder to the crane.

5. Apply MPG (or roller bearing grease, or grease from the CLS system) on the pivot pin (Fig. 3-313, Pos. 6) at
the access ladder cylinder piston rod.

6. Assemble the pivot pin (Fig. 3-313, Pos. 6) at the piston rod of the access ladder cylinder (Fig. 3-313, Pos. 7).
Move the ladder up/down using the crane for easier aligning of the bores.

7. Assemble the cotter pin (Fig. 3-313, Pos. 4) to secure the pivot pin.

8. Unfix the access ladder cylinder (Fig. 3-313, Pos. 7).

9. Detach the crane.

10. Reconnect the wiring harness at the ladder light switch [70S018] and retain the wiring harness along the
access ladder (Fig. 3-313, Pos. 1).

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 233

Access Ladder Superstructure

3.8.3 DISASSEMBLING OF ACCESS LADDER CYLINDER

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Oil draining pan
Mobile elevator working platform

Access ladder cylinder: 13 kg

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

Fig. 3-314 Access ladder assembly

NOTE! Provide an adequate working platform for safe access to the access ladder bearing.
Always wear the safety harness when working on high-lying or elevated working positions.

1. Prepare an area of flat ground large enough to accommodate the machine, boom and elevator working plat-
form.

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3 - 234 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Access Ladder

3. Isolate the machine according to local regulations with the

access ladder (Fig. 3-314, Pos. 1) lowered to the ground.

4. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

REMARKS: To relieve the remaining pilot pressure connect an

open hose to the checkpoints M1.1 and M1.2 on the
valve cartridge block (Fig. 3-315).
When the hydraulic hoses are connected, hydraulic
oil from inside the piping will flow out. Catch it in an
oil pan.
Fig. 3-315

DANGER
HYDRAULIC PRESSURE!
The pilot hydraulic system may be pressurized. Opening any hydraulic lines under pressure may result in
blindness, serious injury, permanent disfigurement, or scaring.

Assure that the pilot pressure in the hydraulic system is completely relieved before disconnecting any
hydraulic hoses.

5. Disconnect the hydraulic hoses from the access ladder cylinder (Fig. 3-314, Pos. 7).

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

6. Disassemble both cotter pins (Fig. 3-313, Pos. 4).

7. Disassemble both pivot pins (Fig. 3-314, Pos. 6).

REMARKS: A second person is required to hold the cylinder when the pivot pins are disassembled.

8. Remove the access ladder cylinder (Fig. 3-314, Pos. 7).

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 235

Access Ladder Superstructure

3.8.4 ASSEMBLING OF ACCESS LADDER CYLINDER

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Mobile elevator working platform

Access ladder cylinder: 13 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

Fig. 3-316 Access ladder assembly

9. Bring the access ladder cylinder (Fig. 3-316, Pos. 7) into mounting position for the pivot pins (Fig. 3-316,
Pos. 6).

10. Apply MPG (or roller bearing grease, or grease from the CLS system) on the pivot pins (Fig. 3-316, Pos. 6)

11. Assemble the pivot pins at the piston rod of the access ladder cylinder.

12. Assemble the cotter pins (Fig. 3-316, Pos. 4) to secure the pivot pins.

13. Reconnect the hydraulic hoses at the access ladder cylinder.

14. Add specified hydraulic oil up to the specified level.

3 - 236 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Access Ladder

Please continue reading on the next page.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 237

Counterweight Superstructure

3.9 COUNTERWEIGHT

Fig. 3-317 Counterweight

A1/A2 Lifting eye (2) Lifting situation for vertical transport

A3 Lifting eye (3) Lifting situation for horizontal transport

(1) Counterweight (welded box design) (4) Lifting situation for raising up the counter-
weight

NOTE! Make sure that the maximum rope angle depending on the lifting situation (Fig. 3-317, Pos. 2 to 4) is
not exceeded.

DANGER
RISK OF EXPLOSION! (Non-full casting counterweight only)
Failure to properly expel the gases from the counterweight chambers can result in an explosion with
serious personal injury or death.

The chambers of the counterweight are filled with a mixture of concrete, granulated ore and steel pellets.
This mixture can create explosive gases which will accumulate in the chambers of the counterweight.
Before any welding, flame-cutting, grinding or drilling procedures are carried out on the counterweight it
is vital to expel these gases from the counterweight chambers.
Follow the instructions given in PARTS & SERVICE NEWS No. AH04518, latest release, for expelling the
gases from the counterweight chambers.

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Superstructure Counterweight

3.9.1 DISASSEMBLING OF THE COUNTERWEIGHT

Special tools: Hydraulic torque wrench & aggregate set, PN 232 758 40
65 mm hexagon impact socket wrench (1 1/2"), PN 232 521 40

Additional equipment: Safety harness in conformity with EN 361

Mobile elevator working platform
Crane

Counterweight: 27,650 kg

Dogman/rigger

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the OPERATION & MAINTENANCE MANUAL, chapter
3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

5. If equipped, disassemble the extinguishing tanks (Fig. 3-318,

Pos. 1 or 2) of the Fire Detection and Suppression System
from the counterweight (Fig. 3-318, Pos. 3).

NOTE! Pay attention to the Fire Detection and Suppression

System.
Refer to the separate manuals "Fire Detection and
Actuating System" and "Fire Suppression System".
The wires of the Fire Detection and Suppression
System must not be bent excessively or be dam-
aged to remain functional.
All work on the Fire Detection, Actuation and Sup-
pression System has to be carried out by well
trained specialists having the manufacturer’s certifi-
cate for working on such systems. The local rules Fig. 3-318 Example
and directives regarding the installation procedure
of the Fire Detection, Actuation and Suppression
Systems have to be observed.

6. Disassemble the hand rails from the counterweight.

This step is optional, but recommended because the hand rail may get damaged while handling the counter-
weight using the crane during disassembling and assembling procedure.

7. Disassemble all custom equipment from the counterweight.

8. Unplug the harness connectors of the lighting equipment. Clear the harness from the counterweight.

REMARKS: Also unplug/disconnect and clear all additional harnesses of custom systems connected to the coun-
terweight.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 239

Counterweight Superstructure

Fig. 3-319 Counterweight bolt connection

9. Attach the counterweight (Fig. 3-319, Pos. 1) to a crane at the lifting eyes on top of the counterweight (see
Fig. 3-317 on page 3-238). Make sure that the maximum rope angle of 40° for horizontal transport is not
exceeded.

10. Disassemble all mounting bolts (Fig. 3-319, Pos. 2).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

11. Remove the counterweight from the superstructure platform (Fig. 3-319, Pos. 3) using the crane.

3 - 240 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Counterweight

3.9.2 ASSEMBLING OF THE COUNTERWEIGHT

Special tools: Hydraulic torque wrench, PN 232 615 40
Electro-hydraulic pump set, PN 793 375 73
65 mm hexagon impact socket wrench (1 1/2"), PN 232 521 40

Additional equipment: Safety harness in conformity with EN 361

Mobile elevator working platform
Crane
MPG (Multi Purpose Grease)

Counterweight: 27,650 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

REMARKS: Assure that the mounting surfaces are absolutely free of dirt, oil, fat and paint before installation.

1. Attach the counterweight (Fig. 3-319, Pos. 1) to a crane at the lifting eyes on top of the counterweight (see
Fig. 3-317 on page 3-238). Make sure that the maximum rope angle of 40° for horizontal transport is not
exceeded.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

2. Move the counterweight into mounting position at the superstructure platform (Fig. 3-319, Pos. 3) using the
crane.

REMARKS: Assemble new mounting bolts (Fig. 3-319, Pos. 2) of grade 10.9.
Apply MPG (or roller bearing grease, or grease from the CLS system) on heads and threads of the
bolts and tighten the mounting bolts with the specified tightening torque:

b Tightening torque for mounting bolts: 4950 Nm

3. If removed assemble the hand rails at the counterweight.

4. Detach the crane.

5. Connect the harness connectors of the lighting equipment. Retain the harness at the counterweight.

REMARKS: Also reconnect and retain all additional harnesses of custom systems connected to the counter-
weight.

6. Assemble all custom equipment from the counterweight.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 241

Counterweight Superstructure

7. If equipped, assemble the extinguishing tanks (Fig. 3-320,

Pos. 1 or 2) of the Fire Detection and Suppression System at
the counterweight (Fig. 3-320, Pos. 3).

NOTE! Pay attention to the Fire Detection and Suppression

System.
Refer to the separate manuals "Fire Detection and
Actuating System" and "Fire Suppression System".
The wires of the Fire Detection and Suppression
System must not be bent excessively or be dam-
aged to remain functional.
All work on the Fire Detection, Actuation and Sup-
pression System has to be carried out by well
trained specialists having the manufacturer’s certifi-
cate for working on such systems. The local rules Fig. 3-320 Example
and directives regarding the installation procedure
of the Fire Detection, Actuation and Suppression
Systems have to be observed.

3 - 242 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Counterweight

Please continue reading on the next page.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 243

Fuel tank Superstructure

3.10 FUEL TANK

3.10.1 DISASSEMBLING OF THE FUEL TANK

Hydraulic torque wrench & aggregate set, PN 232 759 40
Special tools:
46 mm hexagon impact socket wrench (1"), PN 793 788 73

Safety harness in conformity with EN 361

Mobile elevator working platform
Additional equipment:
Empty fuel storage tank (4500 liters)
Crane

Fuel tank (empty): 2300 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section
6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Prepare an area of flat ground large enough to accommodate the machine, boom and crane.

2. Park the machine on the prepared flat area and position the bucket on the ground.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional
working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved
to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Disassemble the operator’s cab (Fig. 3-321, Pos. 4), refer to

section 3.6.5.1 on page 3-224.

5. Disassemble the handrails (Fig. 3-321, Pos. 1), the handlebar

(Fig. 3-321, Pos. 2) and the platforms from the fuel tank.

6. Disassemble the handrail (Fig. 3-321, Pos. 3) from the steps.

Fig. 3-321

7. Disassemble the hinged covers below the fuel tank.

3 - 244 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Fuel tank

DANGER
INFLAMMABLE FUEL!
Serious injury, permanent disfigurement and scarring, or death will result from burns caused by burning
fuel.

DO NOT smoke or use an open flame when working at fuel lines.

8. Attach a drain hose and open drain coupling.

a Drain the fuel at the drain coupling, approx.

4500 liters (max.).

9. Remove the brackets (Fig. 3-322, Pos. 1) and clear the

hydraulic hoses.

10. Remove the brackets (Fig. 3-322, Pos. 2) to clear the wire
harnesses.

REMARKS: Wire harnesses and hydraulic hoses remain in

place.

11. Disconnect and clear the harness connector from the pres- Fig. 3-322
sure transducer for fuel level indication at the ball cock
(Fig. 3-322, Pos. 3).

12. If equipped, disassemble the heating device from the fuel

tank.

13. Open the hose clamps and clear the hoses of the air condi-
tioning system and the fuel hoses from the inner machine
side of the fuel tank.

14. Disconnect and clear the fuel supply hose (Fig. 3-323, Pos. 2)
and the fuel return hoses (Fig. 3-323, Pos. 1 & 4) from the
fuel tank.

REMARKS: When the fuel hoses are disconnected, the fuel

inside the hoses will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

15. Disconnect and clear the wire harness connector from the
fuel shut-off solenoid valve (Fig. 3-323, Pos. 3).

Fig. 3-323

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 245

Fuel tank Superstructure

16. Disassemble the grids (Fig. 3-324, Pos. 1) from the fuel tank.

17. Disassemble the cover (Fig. 3-324, Pos. 2) and clear the
breather hose (Fig. 3-324, Pos. 3) from the roof frame.

18. Disconnect the breather hose (Fig. 3-324, Pos. 3) from the
bleeder valve on the cover (Fig. 3-324, Pos. 4).

Fig. 3-324 VR300 system, tank - top view

19. Disconnect the jet sensor hoses (Fig. 3-325, Pos. 1 + 2) and
the filling hose (Fig. 3-325, Pos. 3) from the fuel receiver
(Fig. 3-325, Pos. 4).

20. Disassemble the hose clamp assembly (Fig. 3-325, Pos. 7) to

clear the hoses.

21. Clear the breather hose (Fig. 3-325, Pos. 5) from the tank
superstructure platform (Fig. 3-325, Pos. 6).

22. Pull the hoses (Fig. 3-325, Pos. 1, 2 & 5) upwards through the
opening in the superstructure platform (Fig. 3-325, Pos. 6).

Fig. 3-325 VR300 system, tank - rear view

23. Disconnect the jet sensor hoses (Fig. 3-326, Pos. 1 + 2) from
the jet sensor (Fig. 3-326, Pos. 3) and remove the hoses from
the fuel tank (Fig. 3-326, Pos. 4).

24. Disassemble the jet sensor from the fuel tank.

Fig. 3-326 VR300 system, jet sensor

3 - 246 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Fuel tank

25. Insert swivel hoist rings into the threads (Fig. 3-327, arrows)
and attach the fuel tank to a crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

26. Disassemble the mounting bolts (Fig. 3-326, Pos. 2) and lift
the fuel tank (Fig. 3-326, Pos. 1) off the machine.

Fig. 3-327

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 247

Fuel tank Superstructure

3.10.2 ASSEMBLING OF THE FUEL TANK

Hydraulic torque wrench & aggregate set, PN 232 759 40
Special tools:
46 mm hexagon impact socket wrench (1"), PN 793 788 73

Safety harness in conformity with EN 361

Mobile elevator working platform
Additional equipment:
Crane
MPG (Multi Purpose Grease)

Fuel tank (empty): 2300 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.5 on page 6-12.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Insert swivel hoist rings into the threads (Fig. 3-328, arrows)
and attach the fuel tank to a crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

2. Move the fuel tank (Fig. 3-328, Pos. 1) into mounting position
using the crane.

3. Assemble new mounting bolts (Fig. 3-328, Pos. 2) of grade

10.9.
Apply MPG (or roller bearing grease, or grease from the CLS
system) and tighten the bolts to the specified tightening
torque using the hydraulic torque wrench. Fig. 3-328

b Tightening torque for fuel tank mounting bolts:

1770 Nm.

3 - 248 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Fuel tank

4. Assemble the jet sensor (Fig. 3-329, Pos. 3) at the fuel tank
(Fig. 3-329, Pos. 4).

5. Connect the jet sensor hoses (Fig. 3-326, Pos. 1 + 2) at the

jet sensor.

Fig. 3-329 VR300 system, jet sensor

6. Feed the jet sensor hoses (Fig. 3-330, Pos. 1 +2) and the
breather hose (Fig. 3-330, Pos. 5) through the opening in the
superstructure platform (Fig. 3-330, Pos. 6).

7. Connect the jet sensor hoses (Fig. 3-330, Pos. 1 + 2) and the
filling hose (Fig. 3-330, Pos. 3) from the fuel receiver
(Fig. 3-330, Pos. 4).

8. Retain the hoses using the hose clamp assembly (Fig. 3-330,
Pos. 7).

9. Retain the breather hose (Fig. 3-330, Pos. 5) at the super-

structure platform (Fig. 3-330, Pos. 6) and the fuel tank.

Fig. 3-330 VR300 system, tank - rear view

10. Retain the breather hose (Fig. 3-324, Pos. 3) at the roof
frame and the fuel tank.

11. Connect the breather hose (Fig. 3-326, Pos. 3) at the bleeder
valve on the cover (Fig. 3-326, Pos. 4).

12. Assemble the cover (Fig. 3-326, Pos. 2).

13. Assemble the grids (Fig. 3-326, Pos. 1) at the fuel tank.

Fig. 3-331 VR300 system, tank - top view

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 249

Fuel tank Superstructure

14. Install the hose clamps and retain the hoses of the air condi-
tioning system and the fuel hoses at the inner machine side of
the fuel tank.

15. Connect and retain the fuel supply hose (Fig. 3-332, Pos. 2)
and the fuel return hoses (Fig. 3-332, Pos. 1 & 4) from the
fuel tank.

REMARKS: When the fuel hoses are disconnected, the fuel

inside the hoses will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

16. Reconnect and retain the wire harness connector of the fuel
shut-off solenoid valve (Fig. 3-332, Pos. 3).

Fig. 3-332

17. Attach drain hose and open drain coupling.

a Drain the fuel at the drain coupling, approx.

4500 liters (max.).

18. Assemble the brackets (Fig. 3-333, Pos. 1) and retain the
hydraulic hoses.

19. Assemble the brackets (Fig. 3-333, Pos. 2) to retain the wire
harnesses.

20. Reconnect and retain the harness connector at the pressure

transducer for fuel level indication at the ball cock (Fig. 3-333,
Pos. 3).
Fig. 3-333
21. If equipped, install the heating device at the fuel tank.

22. Assemble the hinged covers below the fuel tank.

23. Assemble the operator’s cab (Fig. 3-334, Pos. 4), refer to
section 3.6.5.2 on page 3-225.

24. Assemble the handrails (Fig. 3-334, Pos. 1), the handlebar
(Fig. 3-334, Pos. 2) and the platforms from the fuel tank.

25. Assemble the handrail (Fig. 3-334, Pos. 3) at the steps.

Fig. 3-334

3 - 250 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Fuel tank

d Refill the fuel tank, approx. 4500 liters (max.).

DANGER
INFLAMMABLE FUEL!
Serious injury, permanent disfigurement and scarring, or
death will result from burns caused by burning fuel.

DO NOT smoke or use an open flame when working at fuel

lines.

26. Bleed the fuel feeding lines at both engines:

– Assure that the emergency shut off valve is opened.

– Disconnect the feeding lines (Fig. 3-335, Pos. 1) at the
engines’ high pressure pumps (Fig. 3-335, Pos. 2).
– Wait until the fuel flows out. Catch the leaking fuel in an oil
pan. Fig. 3-335
– Reconnect the feeding line.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 251

Superstructure lifting Superstructure

3.11 SUPERSTRUCTURE LIFTING

3.11.1 DISASSEMBLING THE SUPERSTRUCTURE FROM THE

UNDERCARRIAGE
Special tools: Hydraulic torque wrench, PN 232 614 40
Electro-hydraulic pump set, PN 793 375 73
46 mm hexagon impact socket wrench (1"), PN 232 265 40

Additional equipment: Safety harness in conformity with EN 361

Mobile elevator working platform
Empty hydraulic oil storage tank (3000 liters)
2x crane

Superstructure without attachment and counterweight: 61,000 kg

Dogman/rigger
Crane operators trained in dual crane lift
Electrician with permission to work on high voltage systems

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Prepare an area of flat ground large enough to accommodate the machine, boom and two cranes.

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Close the hand wheel (Fig. 3-336, Pos. 1) of main shut off
valve between suction oil reservoir and main oil reservoir.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.

Fig. 3-336

3 - 252 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Superstructure lifting

4. Open the cover (Fig. 3-337, Pos. 1) of the return oil filter.

5. Transfuse oil from the return manifold and the suction oil res-
ervoir into the main oil reservoir, refer to the PARTS & SER-
VICE NEWS No. "AH10530".

6. After transfusing is complete close the cover of the return oil

filter.

7. Isolate the machine according to local regulations.

8. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".
Fig. 3-337

9. Relieve the pressure in the track tensioning system by open-

ing the ball cock (Fig. 3-338, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 3-338

10. Disassemble the counterweight from the superstructure, refer to section 3.9.1 on page 3-239.

11. Disassemble the complete attachment and the boom arc hoses, refer to section 5.2 on page 5-6 for the back-
hoe attachment or refer to section 5.3 on page 5-96 for the face shovel attachment.

12. Reassemble the pins of both boom cylinder foot bearings.

13. Mark and disconnect the SAE-hydraulic hoses (Fig. 3-339,

Pos. 2) from the rotary joint (Fig. 3-339, Pos. 1).

14. Disconnect the hydraulic hoses (Fig. 3-339, Pos. 3 to 5) from

the rotary joint.

Fig. 3-339

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 253

Superstructure lifting Superstructure

Fig. 3-340 Superstructure lifting (exemplaric sketch)

3 - 254 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Superstructure lifting

15. Install the shackles delivered with the machine to the flanges of the counterweight and attach both shackles to
a crane (Fig. 3-340).

NOTICE
DAMAGE TO THE BOOM CYLINDER FOOT BEARING PINS!
Using wire ropes or chains for lifting the superstructure may damage the machined surface of the pins.

Do not use wire ropes or chains.

Only use slings on the boom cylinder foot bearing pins.

16. Attach the superstructure by means of the boom cylinder pins to a second crane (Fig. 3-340).

17. Disassemble all bolts (Fig. 3-340, Pos. 3) and washers (Fig. 3-340, Pos. 2) attaching the slew circle to the
undercarriage.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

NOTE! Before lifting the superstructure, make sure that the crane operators are trained in dual crane lift.

NOTICE
CRASHING OF THE SUPERSTRUCTURE!
Severe damages to the superstructure may result.
Too weakly dimensioned supports may cause the superstructure to crash due to destruction of the sup-
ports.

Supports need to be substantial enough to carry total weight of the superstructure (without counter-
weight, fluids and attachment), total weight 61,000 kg.

18. Lift off the superstructure using the two cranes and rest it on appropriate supports on the ground.

19. Remove the mounting bolts (Fig. 3-341, Pos. 1) and disas-
semble the torque support lever (Fig. 3-341, Pos. 2) from the
rotary joint (Fig. 3-341, Pos. 3).

Fig. 3-341

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 255

Superstructure lifting Superstructure

3.11.2 ASSEMBLING THE SUPERSTRUCTURE ONTO THE

UNDERCARRIAGE
Special tools: Hydraulic torque wrench, PN 232 614 40
Electro-hydraulic pump set, PN 793 375 73
46 mm hexagon impact socket wrench, PN 232 265 40
Swing circle mounting kit:
– PN 768 222 73 (normal environmental condition)
– PN 768 928 73 (cold weather)

Additional equipment: Safety harness in conformity with EN 361

Mobile elevator working platform
2x crane
Laser device for checking the level of bearing area
International Compound No. 2, PN 324 969 40
MPG (Multi Purpose Grease)

Superstructure without attachment and counterweight: 60,450 kg

Dogman/rigger
Crane operators trained in dual crane lift
Electrician with permission to work on high voltage systems

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: The slew circle mounting kit contains new mounting bolts and all required tools for determining the
tightening torques for the mounting bolts.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Clean the contact surfaces of the slew ring and the undercarriage very carefully and thoroughly.

2. Check the level of the bearing area with a laser device before installing a new slew ring, refer to the PARTS &
SERVICE NEWS No. "AH00511".

NOTE! Before lifting the superstructure, make sure that the crane operators are trained in dual crane lift.

3. Attach the superstructure to two cranes and lift it up. Refer to Fig. 3-342.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

4. Move the superstructure into mounting position and align the superstructure to the undercarriage according to
to the PARTS & SERVICE NEWS No. "AH00511" using the cranes.

3 - 256 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Superstructure lifting

Fig. 3-342 Superstructure lifting (exemplaric sketch)

5. Lower the superstructure onto the undercarriage and assemble the swing circle at the undercarriage accord-
ing to the PARTS & SERVICE NEWS No. "AH00511".

b Determine the tightening torque for the mounting bolts (Fig. 3-342, Pos. 1) according to the
PARTS & SERVICE NEWS No. "AH00511" and tighten all bolts of the inner swing ring cross-
wise to the required torque using the hydraulic torque wrench.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 257

Superstructure lifting Superstructure

6. Assemble the torque support lever (Fig. 3-343, Pos. 2) at the

rotary joint (Fig. 3-343, Pos. 3).

7. Assemble new mounting bolts (Fig. 3-343, Pos. 1) of grade

10.9.
Apply MPG (or roller bearing grease, or grease from the CLS
system) and tighten the bolts to the specified tightening
torque:

b Tightening torque for torque support lever

mounting bolts: 265 Nm

Fig. 3-343

REMARKS: Make sure that the torque support lever (Fig. 3-344,
Pos. 1) fits into the cam (Fig. 3-344, Pos. 2) at the
superstructure.

Fig. 3-344

8. Connect the SAE-hydraulic hoses (Fig. 3-345, Pos. 2) from

the rotary joint (Fig. 3-345, Pos. 1).

9. Connect the hydraulic hoses (Fig. 3-345, Pos. 3 to 5) from the

rotary joint.

Fig. 3-345

3 - 258 PC3000-6 SHOP-50 06279-xD-GB-1

Superstructure Superstructure lifting

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 3-346 Exemplaric sketch

10. Assemble the counterweight from the superstructure, refer to section 3.9.2 on page 3-241.

11. Assemble the complete attachment and the boom arc hoses, refer to section 5.2 on page 5-6 for the backhoe
attachment or refer to section 5.3 on page 5-96 for the face shovel attachment.

12. Close the ball cock (Fig. 3-347, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 3-347

13. Open the main shut off valve completely.

14. Bleed air from the hydraulic system, refer to OPERATION & MAINTENANCE MANUAL, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

15. Add specified hydraulic oil up to the specified level.

SHOP-50 06279-xD-GB-1 PC3000-6 3 - 259

Superstructure lifting Superstructure

Please continue reading on the next page.

3 - 260 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage

4 UNDERCARRIAGE

NOTE! In addition to the provisions listed here, full compliance with general safety regulations in chapter
"Safety" is required.

SHOP-50 06279-xD-GB-1 PC3000-6 4 -1

Undercarriage overview Undercarriage

4.1 UNDERCARRIAGE OVERVIEW

Fig. 4-1 PC3000-6, undercarriage overview

4 -2 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Undercarriage overview

Legend for Fig. 4-1:

(1) Car body (9) Travel gear

(2) Track tensioning valve block (10) Track group

(3) Carrier roller (11) Track roller

(4) High pressure accumulator (12) Sprocket

(5) Crawler carrier (13) Low pressure accumulator

(6) Travel brake valve block (overspeed valve) (14) Track tensioning cylinder

(7) Rotary joint (15) Guide wheel

(8) Travel motors

SHOP-50 06279-xD-GB-1 PC3000-6 4 -3

Travel System Undercarriage

4.2 TRAVEL SYSTEM

4.2.1 CRAWLER TRACK

4.2.1.1 CHANGING THE CRAWLER TRACK

Special tools: n/a

Additional equipment: Personal Protective Equipment (PPE)

Dozer
Chain hoist
Welding equipment

Crawler track 800 mm: 12,880 kg

Crawler track 1000 mm: 15,280 kg
Pin: 9.2 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: Make sure that the wear of the track group was measured according to the PARTS & SERVICE
NEWS No. "AH02521".

Fig. 4-2 Required space and driving speeds - exemplified overview

REMARKS: The minimum length of the workspace is according to Fig. 4-2: 6 × Le+ Ld + 2 m
Le = Length of the crawler carrier ⇔ half the length of the full unrolled crawler track
Ld = Length of the dozer
Ve = Speed of the excavator at Qmin

In the following procedure a dozer is linked to the upper part of the crawler track (tractive side) with a chain to hold/
guide it while unrolling from the crawler carrier. The relative velocity of the upper part of the crawler track is twice
the travel speed of the excavator (Ve) so the travel speed of the dozer must be twice the travel speed of the exca-
vator.

1. Prepare an area of flat ground with a length as shown in Fig. 4-2.

2. Park the machine and the dozer according to Fig. 4-2.

3. Isolate the machine according to local regulations

4 -4 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

4. Disassemble the cover (Fig. 4-3, Pos. 1).

Fig. 4-3

5. Close the ball cock (Fig. 4-4, Pos. 1) behind the service open-
ing.

REMARKS: This is done to prevent the respective track tension-

ing cylinders to get pressurized while running the
excavator.

Fig. 4-4

6. Relieve the pressure in the track tensioning system by open-

ing the ball cock (Fig. 4-5, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 4-5

SHOP-50 06279-xD-GB-1 PC3000-6 4 -5

Travel System Undercarriage

REMARKS: Open the crawler track at the guide wheel side

(refer to Fig. 4-10 on page 4-8) for crawler track
exchange.

7. Flame-cut the square nuts (Fig. 4-6, Pos. 2) and the bolts
(Fig. 4-6, Pos. 1) at one track shoe.

NOTE! Ensure nothing flammable is in the working area

during flame-cutting and welding work.
When flame-cutting or welding follow the welding
precautions, refer to section 2.3.3 on page 2-9.

8. Pull out two pins (Fig. 4-6, Pos. 3) out of the track shoe
(Fig. 4-6, Pos. 4) to open the crawler track.

Fig. 4-6

9. Sling the upper end of the track group using a chain and link it
to a dozer in front of the excavator (Fig. 4-7).

10. De-isolate the machine according to local regulations.

11. Switch 11S150 to Qmin.

DANGER
MOVING EXCAVATOR AND DOZER!
Serious injury or death will result by getting run over or
crushed.

Make sure nobody stays in driving direction of the excavator Fig. 4-7
or the dozer.
Make sure nobody stays next to the crawler carrier.

12. Drive the excavator and the dozer backwards slowly and follow with the dozer to re-roll the crawler track from
the excavator (Fig. 4-7).

NOTE! The dozer must drive twice as fast as the excavator and travels the double distance, refer to Fig. 4-2
on page 4-4.

13. When the upper end of the crawler track runs off the sprocket stop the excavator. Continue to drive the dozer
slowly and deposit the open end of the track on the ground. Stop the dozer.

14. Before unchaining the dozer support the crawler track between the carrier rollers using appropriate blocks
(Fig. 4-7, Pos. 1).

15. Unchain the dozer.

4 -6 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

16. Remove the chain from the old track group.

17. Align the new track group on the ground behind the old track
group.

REMARKS: Note the running direction of the new track group.

Make sure that the new track group has the correct
running direction as shown in Fig. 4-8.

18. Continue to drive the excavator backwards slowly on the new

crawler track until the end of the of the crawler track is nearly
reached.

19. Remove the old, removed crawler track from the ground.

20. Bring the dozer in front of the excavator.

21. Sling the end of the new crawler track at the sprocket using a
chain and link it to the dozer in front of the excavator.

DANGER
MOVING EXCAVATOR AND DOZER!
Serious injury or death will result by getting run over or
crushed.

Make sure nobody stays in driving direction of the excavator Fig. 4-8
or the dozer.
Make sure nobody stays next to the crawler carrier.

22. Remove the supporting blocks (Fig. 4-9, Pos. 1).

23. Drive the excavator forward slowly followed by the dozer and
pick up the crawler track with the sprocket.

NOTE! The dozer must drive twice as fast as the excavator

and travels the double distance, refer to Fig. 4-2 on
page 4-4.

24. Continue to drive the excavator and the dozer slowly to pull
up the crawler track (Fig. 4-9).

Fig. 4-9

SHOP-50 06279-xD-GB-1 PC3000-6 4 -7

Travel System Undercarriage

25. Stop the excavator and the dozer, when the guide wheel
reaches the end of the track group (approximately 3 track
shoes away from the end of the track group).

26. Place the track group over the guide wheel as shown in
Fig. 4-10.

NOTE! Block the crawler track in the lower run to prevent

the track shoes against knocking over, using appro-
priate blocks.

27. Unchain the dozer.

28. Isolate the machine according to local regulations.

Fig. 4-10

29. Align the holes (Fig. 4-11, Pos. 3) in the two open track shoes
(Fig. 4-11, Pos. 2) in front of the guide wheel (Fig. 4-11,
Pos. 1) using a hoist.

Fig. 4-11

4 -8 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

30. Insert the pin (Fig. 4-12, Pos. 4) into the holes (Fig. 4-12,
Pos. 3).

NOTE! Each time the crawler track is opened two new bolts
and two new square nuts must be installed.

31. Install new bolts (Fig. 4-12, Pos. 1), washers (Fig. 4-12,
Pos. 2), and nuts (Fig. 4-12, Pos. 3) at the track shoes
(Fig. 4-12, Pos. 5).

32. Weld the nuts (Fig. 4-12, Pos. 3) to the bolts (Fig. 4-12,
Pos. 1).

33. Weld the square nuts to the bolts.

Fig. 4-12
NOTE! Ensure nothing flammable is in the working area
during flame-cutting and welding work.
When flame-cutting or welding follow the welding
precautions, refer to section 2.3.3 on page 2-9.

The bolts (Fig. 4-13, Pos. 1) lock the pins (Fig. 4-13, Pos. 2).
Therefore one side of the bolt’s head is hardened. This side must
face the pin.

REMARKS: The hardened side (Fig. 4-13, arrow) of the bolt

heads are marked.

Fig. 4-13

34. Close the ball cock (Fig. 4-14, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 4-14

35. Switch 11S150 to back normal condition.

SHOP-50 06279-xD-GB-1 PC3000-6 4 -9

Travel System Undercarriage

NOTICE
RISK TO DAMAGE THE TRACK TENSIONING CYL-
INDERS!
The track tensioning cylinders may get damaged when mov-
ing the excavator with closed ball cock.

The ball cock must always be in open position before moving

the excavator for work.

36. Open the ball cock (Fig. 4-15, Pos. 1) behind the service
opening in the crawler carrier. Fig. 4-15

37. Assemble the cover (Fig. 4-16, Pos. 1).

Fig. 4-16

4 - 10 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

4.2.2 SPROCKET

4.2.2.1 DISASSEMBLING OF THE SPROCKET

Special tools: Hydraulic torque wrench & aggregate set, PN 232 267 40
55 mm hexagon impact socket wrench, PN 232 267 40

Additional equipment: Personal Protective Equipment (PPE)

Crane
Dozer

Sprocket: 1280 kg

Dogman/rigger

Fig. 4-17 Required space and driving speeds - exemplified overview

REMARKS: The approximated length of the workspace is according to Fig. 4-17: 4 × Le+ Ld
Le = Length of the crawler carrier ⇔ half the length of the full unrolled crawler track
Ld = Length of the dozer
Ve = Speed of the excavator at Qmin

In the following procedure a dozer is linked to the upper part of the crawler track (tractive side) with a chain to hold/
guide it while unrolling from the crawler carrier. The relative velocity of the upper part of the crawler track is twice
the travel speed of the excavator (Ve) so the travel speed of the dozer must be twice the travel speed of the exca-
vator.

1. Prepare an area of flat ground with a length as shown in Fig. 4-17.

2. Park the machine and the dozer according to Fig. 4-17.

3. Isolate the machine according to the local regulations.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 11

Travel System Undercarriage

4. Relieve the pressure in the track tensioning system by open-

ing the ball cock (Fig. 4-18, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 4-18

5. Open the track group at the sprocket end, refer to section 4.2.1.1 on page 4-4.

6. Sling the upper end of the crawler track using a chain and link
it to a dozer behind the excavator.

REMARKS: The dozer must stand in a distance of more than the

length of the full unrolled crawler track.

7. Switch 11S150 to Qmin.

8. De-isolate the machine according to local regulations.

Fig. 4-19

DANGER
MOVING EXCAVATOR AND DOZER!
Serious injury or death will result by getting run over or crushed.

Make sure nobody stays in driving direction of the excavator or the dozer.
Make sure nobody stays next to the crawler carrier.

9. Drive the excavator and the dozer forwards slowly and unroll the track group from the excavator (refer to
Fig. 4-17 and Fig. 4-20).

10. Drive the excavator and the dozer forwards slowly and unroll the crawler track from the excavator (refer to
Fig. 4-19).

REMARKS: The dozer must drive twice as fast as the excavator and travels the double distance.

4 - 12 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

11. When the upper end of the track group is over the carrier roll
next to the sprocket, stop the excavator and the dozer.

12. Fasten the track group to the carrier roll to hold it in position.

13. Drive the excavator backwards slowly at Qmin until the

sprocket runs completely free (refer to Fig. 4-20).

REMARKS: The track group will build a loop behind the idler.

14. Isolate the machine according to local regulations.

Fig. 4-20

NOTICE
SHARP SPROCKET EDGES!
The lifting equipment may get damaged by sharp edges at
the sprocket.

In order to avoid damage to the lifting devices, use edge pro-

tection.

15. Sling sprocket (Fig. 4-21) using a crane.

Fig. 4-21

REMARKS: The travel parking brake may need to be released to allow sprocket to turn slightly to find centre of
gravity.
Released pressure: 35 bar

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

16. Disassemble the mounting bolts (Fig. 4-22, Pos. 1) using the
hydraulic torque wrench. Fig. 4-22
17. Remove the sprocket (Fig. 4-22, Pos. 2) from the travel gear
(Fig. 4-22, Pos. 3) using a crane.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 13

Travel System Undercarriage

4.2.2.2 ASSEMBLING OF THE SPROCKET

Special tools: Hydraulic torque wrench & aggregate set, PN 232 267 40
55 mm hexagon impact socket wrench, PN 232 267 40

Additional equipment: Personal Protective Equipment (PPE)

Crane
Dozer
Coating compound "INTERZINC 697", PN 674 997 40
MPG (Multi Purpose Grease)

Sprocket: 1280 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: The sprocket can be installed in both directions.

1. Apply surface coating with coating compound "INTERZINC

697" at the contact surface (Fig. 4-23, Pos. 1) of the sprocket,
refer to section 6.4.1 on page 6-5.

REMARKS: The travel parking brake may need to be released to

allow the travel gear to rotate if needed to align bolts
when fitting the new sprocket.

Released pressure: 35 bar

Fig. 4-23

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

2. Sling sprocket (Fig. 4-21) and lift it up using a crane.

Fig. 4-24
REMARKS: In order to avoid damage to the lifting devices, use
edge protection at all sharp edges.

4 - 14 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

3. Align the sprocket (Fig. 4-25, Pos. 2) to the travel gear

(Fig. 4-25, Pos. 3).

REMARKS: Assemble mounting bolts (Fig. 4-25, Pos. 1) of

grade 10.9.
Apply MPG (or roller bearing grease, or grease from
the CLS system) on heads and threads of the bolts
and tighten the bolts to the specified torque using
the hydraulic torque wrench.

b Tightening torque for sprocket mounting bolts

(Fig. 4-25, Pos. 1): 3100 Nm

Fig. 4-25

4. Sling the upper end of the track group using a chain and link it
to a dozer behind the excavator.

5. Remove the supporting blocks (Fig. 4-26, Pos. 1).

6. Pull the track group back over the track frame and over the
sprocket by driving the dozer slowly (Fig. 4-26).

NOTE: Make sure that the track group does not spur the
sprocket. It must be lead over the sprocket.

7. When the track group is pulled to the end, drive the dozer
slowly back to allow the track group to fit into the sprocket.

8. Detach the chain and the dozer from the track group. Fig. 4-26

9. Slowly drive the excavator forward at Qmin until the sprocket

contrives into the track group part on the ground.

10. Continue driving until approx. 2 track shoes are located

behind the imagined center-line of the sprocket.

11. Align the holes (Fig. 4-27, Pos. 3) in the two open track shoes
(Fig. 4-27, Pos. 2) using hoists.

REMARKS: Block the track shoes using an appropriate wedge

(Fig. 4-27, Pos. 1). Hold the track pads of the upper
track group part in position by pushing it against the
sprocket (Fig. 4-27, arrow).

12. Insert the pins to rejoin the track group, refer to Fig. 4-27
section 4.2.1.1 on page 4-4.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 15

Travel System Undercarriage

13. Close the ball cock (Fig. 4-28, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 4-28

14. Switch 11S150 back to normal condition.

4 - 16 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

4.2.3 GUIDE WHEELS (IDLERS)

4.2.3.1 DISASSEMBLING OF THE GUIDE WHEEL ASSEMBLY

Special tools: n/a

Additional equipment: Crane

Guide wheel assembly: 1590 kg

Dogman/rigger

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to the local regulations.

4. Disassemble the cover (Fig. 4-29, Pos. 1).

Fig. 4-29

5. Close the ball cock (Fig. 4-4, Pos. 1) behind the service open-
ing.

REMARKS: This is done to prevent the respective track tension-

ing cylinders to get pressurized while running the
excavator.

Fig. 4-30

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 17

Travel System Undercarriage

6. Relieve the pressure in the track tensioning system by open-

ing the ball cock (Fig. 4-31, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 4-31

7. Unroll the crawler track only that far that the guide wheel is free, refer to section 4.2.1.1 on page 4-4.

8. Remove bolts (Fig. 4-32, Pos. 1) and remove the stop plates
(Fig. 4-32, Pos. 2) from both sides of the guide wheel assem-
bly (Fig. 4-32, Pos. 3).

WARNING
HAZARD OF SQUEEZING AND SHEARING!
May result in serious injury to hands and fingers from
squeezing and sharing due to violent pressure from sliding
parts.

Ensure to keep hands away for the component sliding sur-

faces during removal.
Fig. 4-32

9. Sling guide wheel assembly (Fig. 4-33, Pos. 3).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

Fig. 4-33
10. Extract the guide wheel assembly from the track frame using
a crane.

REMARKS: For further disassembling and replacement of the floating seals refer to the Operation & Maintenance
Manual, chapter 4, section "GUIDE WHEELS - REPLACE FLOATING SEALS".

4 - 18 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

4.2.3.2 ASSEMBLING OF THE GUIDE WHEEL ASSEMBLY

Special tools: n/a

Additional equipment: Crane

Guide wheel assembly: 1590 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Sling guide wheel assembly (Fig. 4-34, Pos. 3).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

Fig. 4-34

WARNING
HAZARD OF SQUEEZING AND SHEARING!
May result in serious injury to hands and fingers from
squeezing and sharing due to violent pressure from sliding
parts.

Ensure to keep hands away from the component sliding

surfaces during any movement of the assembly.
Align the parts with great caution. Never handle between
sliding block and crawler carrier.

Fig. 4-35
2. Align the sliding blocks (Fig. 4-35, Pos. 2) and insert the
guide wheel assembly (Fig. 4-35, Pos. 1) into the crawler car-
rier using a crane.

REMARKS: Observe the mounting position of the sliding blocks (Fig. 4-35, Pos. 2).

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 19

Travel System Undercarriage

3. Assemble the stop plates (Fig. 4-36, Pos. 2) at both sides of

the guide wheel assembly (Fig. 4-36, Pos. 3).

4. Assemble the bolts (Fig. 4-36, Pos. 1) and nuts.

Fig. 4-36

5. Pull up and close the crawler track, refer to section 4.2.1.1 on page 4-4.

6. Close the ball cock (Fig. 4-14, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 4-37

NOTICE
RISK TO DAMAGE THE TRACK TENSIONING CYL-
INDERS!
The track tensioning cylinders may get damaged when mov-
ing the excavator with closed ball cock.

The ball cock must always be in open position before moving

the excavator for work.

7. Open the ball cock (Fig. 4-15, Pos. 1) behind the service
opening in the crawler carrier. Fig. 4-38

4 - 20 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

8. Assemble the cover (Fig. 4-39, Pos. 1).

Fig. 4-39

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 21

Travel System Undercarriage

4.2.4 TRACK TENSIONING ACCUMULATORS

The hydraulic track tensioning system automatically maintains the
correct track tension. The pilot oil pressure of the travel brake
release circuit is used to pressurize the four adjusting cylinders.
The resulting force moves the guide wheels toward the front, until
the correct track tension is obtained. External forces acting upon
the guide wheels are absorbed through the pressure accumula-
tors (Fig. 4-40, Pos. 1 and 2).

Two different types of pressure accumulators are installed:

A high pressure (150 bar) bladder accumulator (Fig. 4-40, Pos. 1)
and a low pressure (31 bar) diaphragm type accumulator
(Fig. 4-40, Pos. 2).

Fig. 4-40

4.2.4.1 DISASSEMBLING OF THE LOW PRESSURE ACCUMULATORS

Special tools: n/a

Additional equipment: Oil drain pan

Low pressure accumulator: 12 kg

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Isolate the machine according to local regulations.

2. Relieve the pressure in the track tensioning system by open-

ing the ball cock (Fig. 4-41, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 4-41

4 - 22 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

3. Disassemble the cover (Fig. 4-42, Pos. 1)

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.

Fig. 4-42

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any
hydraulic lines under pressure will result in blindness, seri-
ous injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic

lines will be removed.

4. Disconnect the pressure hose (Fig. 4-43, Pos. 1).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

5. Remove four bolts (Fig. 4-43, Pos. 2) and remove the pres-
sure accumulator (Fig. 4-43, Pos. 3).

6. Remove socket (Fig. 4-43, Pos. 4) and union (Fig. 4-43,

Pos. 5).

Fig. 4-43

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 23

Travel System Undercarriage

4.2.4.2 ASSEMBLING OF THE LOW PRESSURE ACCUMULATORS

Special tools: Testing and refilling device, PN 761 520 73

Additional equipment: n/a

Low pressure accumulator: 12 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Insert the pressure accumulator (Fig. 4-44, Pos. 3) and

assemble four bolts (Fig. 4-44, Pos. 2)

2. Assemble the socket (Fig. 4-44, Pos. 4) and the union

(Fig. 4-44, Pos. 5).

3. Connect the pressure hose (Fig. 4-44, Pos. 1).

DANGER
EXPLOSION HAZARD!
Blindness, serious injury, permanent disfigurement, scaring,
or death will result due to an exploding accumulator.

Only fill pressure accumulators with nitrogen gas (N2). Do

not use any other gases due to explosion hazard!

4. Fill the pressure accumulator with nitrogen gas (N2), refer to

the PARTS & SERVICE NEWS No. "AH01531".

Fig. 4-44

5. Assemble the cover (Fig. 4-39, Pos. 1).

Fig. 4-45

4 - 24 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

6. Close the ball cock (Fig. 4-14, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 4-46

7. Bleed air from the track tensioning system. Refer to the Operation & Maintenance Manual, chapter 4, section
"CRAWLER TRACK - INSPECTION".

8. Add hydraulic oil up to the specified level.

9. Check the track tension system and adjust if required.

Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL for further information.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 25

Travel System Undercarriage

4.2.4.3 DISASSEMBLING OF THE HIGH PRESSURE ACCUMULATORS

Special tools: n/a

Additional equipment: Oil drain pan

High pressure accumulator: 23 kg

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Isolate the machine according to local regulations.

2. Relieve the pressure in the track tensioning system by open-

ing the ball cock (Fig. 4-47, Pos. 1) at the track tensioning
valve block inside the car body.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.

Fig. 4-47

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure may result in
blindness, serious injury, permanent disfigurement, or scaring.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

3. Disconnect the pressure hose assembly (Fig. 4-48, Pos. 1).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

4. Open two clamp clips (Fig. 4-48, Pos. 2) and remove the
pressure accumulator (Fig. 4-48, Pos. 3).

5. Remove the socket (Fig. 4-48, Pos. 4) from the pressure

accumulator (Fig. 4-48, Pos. 3).

Fig. 4-48

REMARKS: The same type of assembly is installed at the other side of the car body for the second crawler car-
rier.

4 - 26 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

4.2.4.4 ASSEMBLING OF THE HIGH PRESSURE ACCUMULATORS

Special tools: Testing and refilling device, PN 761 520 73

Additional equipment: n/a

High pressure accumulator: 23 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Insert the pressure accumulator (Fig. 4-49, Pos. 3) into the

clamp clips (Fig. 4-49, Pos. 2).

2. Tighten the clamp clips.

3. Assemble the socket (Fig. 4-49, Pos. 4) at the pressure accu-

mulator.

4. Reconnect the pressure hose assembly (Fig. 4-49, Pos. 1).

Fig. 4-49

DANGER
EXPLOSION HAZARD!
Blindness, serious injury, permanent disfigurement, scaring, or death will result due to an exploding accu-
mulator.

Only fill pressure accumulators with nitrogen gas (N2). Do not use any other gases due to explosion haz-
ard!

5. Fill the pressure accumulator with nitrogen gas (N2), refer to the PARTS & SERVICE NEWS No. "AH01531".

6. Close the ball cock (Fig. 4-50, Pos. 1) at the track tensioning
valve block inside the car body.

7. Bleed air from the track tensioning system. Refer to the Oper-
ation & Maintenance Manual, chapter 4, section "CRAWLER
TRACK - INSPECTION".

8. Add hydraulic oil up to the specified level.

9. Check the track tension system and adjust if required.

Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in
the SHOP MANUAL for further information.

Fig. 4-50

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 27

Travel System Undercarriage

4.2.5 TRACK TENSION VALVE BLOCK

4.2.5.1 DISASSEMBLING OF THE TRACK TENSIONING VALVE BLOCK

Special tools: n/a

Additional equipment: Chain hoist

Oil drain pan

Track tensioning valve block: 40 kg

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Isolate the machine according to local regulations.

2. Relieve the pressure in the track tensioning system by open-

ing the ball cock (Fig. 4-51, Pos. 1) at the track tensioning
valve block inside the car body.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.

Fig. 4-51

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any
hydraulic lines under pressure will result in blindness, seri-
ous injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic

lines will be removed.

3. Disconnect all pipes (Fig. 4-52, Pos. 2) and hoses (Fig. 4-52,
Pos. 3) from the track tensioning valve block (Fig. 4-52, Fig. 4-52
Pos. 1).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

4 - 28 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

4. Find an appropriate suspension point for the chain hoist and

sling the track tensioning valve block (Fig. 4-53, Pos. 1).

5. Remove four mounting bolts (Fig. 4-53, Pos. 2) or nuts

(Fig. 4-53, Pos. 3) respectively.

6. Move the track tensioning valve block away from the car body
(Fig. 4-53, Pos. 4) and let it down to the ground using the
chain hoist.

Fig. 4-53

4.2.5.2 ASSEMBLING OF THE TRACK TENSIONING VALVE BLOCK

Special tools: n/a

Additional equipment: Chain hoist

Track tensioning valve block: 40 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Find an appropriate suspension point for the chain hoist and

sling the track tensioning valve block (Fig. 4-54, Pos. 1).

2. Move the track tensioning valve block into mounting position

at the car body (Fig. 4-54, Pos. 4) using the chain hoist.

3. Assemble four mounting bolts (Fig. 4-54, Pos. 2) and nuts

(Fig. 4-54, Pos. 3).

Fig. 4-54

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 29

Travel System Undercarriage

4. Connect all pipes (Fig. 4-55, Pos. 2) and hoses (Fig. 4-55,
Pos. 3) at the track tensioning valve block (Fig. 4-55, Pos. 1).

Fig. 4-55

5. Close the ball cock (Fig. 4-56, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 4-56

6. Bleed air from the track tensioning system. Refer to the Operation & Maintenance Manual, chapter 4, section
"CRAWLER TRACK - INSPECTION".

7. Add hydraulic oil up to the specified level.

8. Check the track tension system and adjust if required.

Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL for further information.

REMARKS: For adjusting the pressure increasing valve and further information relating the pressure increasing
valve refer to the PARTS & SERVICE NEWS No. "AH06544".

4 - 30 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

4.2.6 TRACK TENSIONING CYLINDERS

4.2.6.1 DISASSEMBLING OF THE TRACK TENSIONING CYLINDERS

Special tools: n/a

Additional equipment: Crane

Oil drain pan

Track tension cylinder: 188 kg each

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area, with the attachment placed at the gear box cover, counter-
weight above guide wheels.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Disassemble the guide wheel assembly, refer to section 4.2.3.1 on page 4-17.

5. Disassemble the cover (Fig. 4-57, Pos. 1).

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.

Fig. 4-57

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 31

Travel System Undercarriage

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any
hydraulic lines under pressure will result in blindness, seri-
ous injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic

lines will be removed.

6. Disconnect the pressure hose (Fig. 4-58, Pos. 1) from the

track tension cylinder. Fig. 4-58

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

7. Pull the track tension cylinders (Fig. 4-59, Pos. 1) out to one
half using the retracting devices (Fig. 4-59, arrow).

8. Sling the track tension cylinder and pull the cylinder out of its
guidance in the crawler carrier (Fig. 4-59, Pos. 2) using a
crane.

Fig. 4-59

4 - 32 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

4.2.6.2 ASSEMBLING OF THE TRACK TENSIONING CYLINDERS

Special tools: n/a

Additional equipment: Crane

Track tension cylinder: 188 kg each

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: Carry out assembling in reverse order to Disassembling.

1. Sling the track tension cylinder and fit the cylinder into guid-
ance in the crawler carrier (Fig. 4-60, Pos. 2) using a crane.

REMARKS: The retracting devices (Fig. 4-60, arrow) must face

downwards.

2. Move the cylinders into the crawler carrier until fully home.

Fig. 4-60

3. Connect the pressure hose (Fig. 4-61, Pos. 1) at the track

tension cylinder.

Fig. 4-61

4. Assemble the guide wheel assembly, refer to section 4.2.3.2 on page 4-19.

5. Bleed air from the track tensioning system. Refer to the Operation & Maintenance Manual, chapter 4, section
"CRAWLER TRACK - INSPECTION".

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 33

Travel System Undercarriage

6. Assemble the cover (Fig. 4-62, Pos. 1).

Fig. 4-62

7. Add hydraulic oil up to the specified level.

8. Check the track tension system and adjust if required.

Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL for further information.

4 - 34 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

4.2.7 SUBSTITUTE THE HYDRAULIC HOSES OF THE TRACK

TENSIONING SYSTEM
Special tools: n/a

Additional equipment: Oil drain pan

Hydraulic hose: 23 kg max. (depending on length)

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20

4.2.7.1 PRECURSORY WORK

1. Prepare an area of flat ground large enough to accommodate the machine.

2. Park the machine on the prepared flat ground area.

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the track tensioning system by open-

ing the ball cock (Fig. 4-63, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 4-63

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 35

Travel System Undercarriage

Fig. 4-64 Hydraulic hoses of the track tensioning system

4 - 36 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

4.2.7.2 REPLACE THE HYDRAULIC HOSES INSIDE THE CAR BODY

Hydraulic hoses: Fig. 4-64, Pos. 1 to 5 and 10

1. Carry out the precursory work, refer to section 4.2.7 on page 4-35.

2. Open the hose clamps (Fig. 4-64, Type. A...E) to clear the hydraulic hoses the car body.

3. Disconnect both ends of the hydraulic hoses to be removed and replace the hose by a new one.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

4. Install a new hydraulic hose in reverse order of disassembling.

Follow the hints for hydraulic hose installation, refer to section 6.4.2 on page 6-7.

5. Carry out the subsequent work, refer to section 4.2.7.5 on page 4-39.

4.2.7.3 REPLACE THE HYDRAULIC HOSE BETWEEN CAR BODY AND CRAWLER
FRAME
Hydraulic hose: Fig. 4-64, Pos. 6 resp. Fig. 4-66, Pos. 1

1. Carry out the precursory work, refer to section 4.2.7 on

page 4-35.

2. Disassemble the cover (Fig. 4-65, Pos. 1).

Fig. 4-65

3. Disconnect the hose (Fig. 4-66, Pos. 1) from the shut-off cock
(Fig. 4-66, Pos. 2).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

4. Connect the new hose to the old one using an appropriate

union.

5. Clear the hydraulic hose from the undercarriage by opening

the clamp (Fig. 4-64, Type. A) near the high pressure accu-
mulator.
Fig. 4-66

6. Disconnect the hose (Fig. 4-64, Pos. 6) and pull it out.

REMARKS: At this, the new hose is pulled in place.

7. Disconnect the old hose and the union from the new hose and install it in reverse order to Disassembling.

8. Carry out the subsequent work, refer to section 4.2.7.5 on page 4-39.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 37

Travel System Undercarriage

Fig. 4-67 Hydraulic hoses of the track tensioning system

4 - 38 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

4.2.7.4 REPLACE THE HYDRAULIC HOSES INSIDE THE CRAWLER FRAME

Hydraulic hose: Fig. 4-64, Pos. 7 to 9

1. Carry out the precursory work, refer to section 4.2.7 on

page 4-35.

2. Remove the covers (Fig. 4-68, Pos. 1 and 2).

Fig. 4-68

3. Open the respective hose clamps (Fig. 4-67, F) to clear the hydraulic hoses (Fig. 4-67, Pos. 7 and 8) from the
crawler frame.

4. Disconnect both ends of the hydraulic hoses (Fig. 4-67, Pos. 7 to 9) and remove the hydraulic hoses.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

5. Install a new hydraulic hose in reverse order to Disassembling.

6. Carry out the subsequent work, refer to section 4.2.7.5 on page 4-39.

4.2.7.5 SUBSEQUENT WORK

1. Assemble the covers (Fig. 4-68, Pos. 1 / 2) as required.

2. Close the ball cock (Fig. 4-69, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 4-69

3. Bleed air from the track tensioning system. Refer to the Operation & Maintenance Manual, chapter 4, section
"CRAWLER TRACK - INSPECTION".

4. Add hydraulic oil up to the specified level.

5. Check the track tension system and adjust if required.

Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL for further information.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 39

Travel System Undercarriage

4.2.8 TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE)

4.2.8.1 DISASSEMBLING OF THE TRAVEL BRAKE VALVE BLOCK

Special tools: n/a

Additional equipment: Chain hoist

Oil drain pan

Travel brake valve block: 95 kg

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Open the cover (Fig. 4-70, Pos. 1) of the return oil filter.

2. Transfuse oil from the return manifold into the main oil reser-
voir, refer to the PARTS & SERVICE NEWS No. "AH10530".

3. After transfusing is complete close the cover of the return oil

filter.

4. Isolate the machine according to local regulations.

5. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

Fig. 4-70

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

4 - 40 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

6. Disconnect the SAE high pressure lines (Fig. 4-71, Pos. 1).

7. Disassemble the adapters (Fig. 4-71, Pos. 2) of the leakage

oil lines from the travel brake valve block (Fig. 4-71, Pos. 4).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

8. Sling the travel brake valve block (Fig. 4-71, Pos. 4).

9. Remove the mounting bolts (Fig. 4-71, Pos. 3) and lift off the
travel brake valve block using a chain hoist.
Fig. 4-71

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 41

Travel System Undercarriage

4.2.8.2 ASSEMBLING OF THE TRAVEL BRAKE VALVE BLOCK

Special tools: n/a

Additional equipment: Chain hoist

Travel brake valve block: 95 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Sling the travel brake valve block (Fig. 4-72, Pos. 4) and
move the travel brake valve block into mounting position
using a chain hoist.

2. Assemble the mounting bolts (Fig. 4-72, Pos. 3) and the

adapters (Fig. 4-72, Pos. 2) of the leakage oil lines at the
travel brake valve block (Fig. 4-72, Pos. 4).

3. Connect the SAE high pressure lines (Fig. 4-72, Pos. 1).

Fig. 4-72

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 4-73 Exemplaric sketch

4. Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

5. Add hydraulic oil up to the specified level.

6. Check the travel system and adjust if required.

Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL for further information.

4 - 42 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

4.2.9 TRAVEL MOTOR

4.2.9.1 DISASSEMBLING OF THE TRAVEL MOTORS

Special tools: n/a

Additional equipment: Crane

Oil drain pan

Travel motor: 155 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area with the attachment placed at the travel gear end of the
machine, counterweight above guide wheels.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

3. Open the cover (Fig. 4-74, Pos. 1) of the return oil filter.

4. Transfuse oil from the return manifold into the main oil reser-
voir, refer to the PARTS & SERVICE NEWS No. "AH10530".

5. After transfusing is complete close the cover of the return oil

filter.

6. Isolate the machine according to local regulations.

7. Relieve the pressure in the hydraulic system, refer to the

OPERATION & MAINTENANCE MANUAL, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

Fig. 4-74

8. Disassemble the travel motor protection cover. If equipped, remove the complete track drive protection.

a Drain oil of the motor adapter housing, approx. 1.5 liters.

Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, BRAKE AND
MOTOR ADAPTER HOUSING - CHANGE OIL".

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 43

Travel System Undercarriage

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

9. Mark and disconnect the pressure hoses (Fig. 4-75, Pos. 1)

and the leak oil hose (Fig. 4-75, Pos. 4) from the travel motor
(Fig. 4-75, Pos. 3).
Discard the flat seals (Fig. 4-75, Pos. 5).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

10. Sling travel motor (Fig. 4-75, Pos. 3) and remove the mount-
ing bolts (Fig. 4-75, Pos. 2). Discard the bolts.

Fig. 4-75

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

11. Extract the travel motor from the motor adapter housing using a crane.

4 - 44 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

4.2.9.2 ASSEMBLING OF THE TRAVEL MOTORS

Special tools: n/a

Additional equipment: Crane

Paste Optimol Paste White T, PN 323 444 40
MPG (Multi Purpose Grease)

Travel motor: 155 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: Ensure that the mating surfaces are clean and free of paint before assembly.

1. Apply "Optimol Paste White T" at the spline shaft of the travel
motor (Fig. 4-76, Pos. 3) before attaching the travel motor to
the motor adapter housing.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.
Fig. 4-76

2. Sling travel motor (Fig. 4-76, Pos. 3) and attach it to the motor
adapter housing using the crane.

3. Assemble new mounting bolts (Fig. 4-76, Pos. 2) of grade 10.9.

Apply MPG (or roller bearing grease, or grease from the CLS system) and tighten the bolts to the specified
tightening torque.

b Tightening torque for travel motor mounting bolts: 510 Nm

4. Connect the pressure hoses (Fig. 4-76, Pos. 1) and the leak oil hose (Fig. 4-76, Pos. 4) at the travel motor.

NOTE! Always replace the flat seals (Fig. 4-76, Pos. 5) at the SAE-flange connections!
A flat and level sealing surface is essential for proper sealing!

b Tighten the mounting bolts of SAE-flange connections according to the KOMATSU company
standard "Torques for SAE-flange connections", refer to section 6.6.5 on page 6-19.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 45

Travel System Undercarriage

5. Assemble the travel motor protection cover. If equipped, remove the complete track drive protection.

d Refill oil of the motor adapter housing, approx. 1.5 liters.

Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, BRAKE AND
MOTOR ADAPTER HOUSINGS - CHANGE OIL".

6. Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

7. Add specified hydraulic oil up to the specified level.

8. Check the travel system and adjust if required.

Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL for further information.

4 - 46 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

Please continue reading on the next page.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 47

Travel System Undercarriage

4.2.10 TRAVEL PARKING BRAKE

Fig. 4-77 Travel parking brake assembly

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Undercarriage Travel System

Legend for Fig. 4-77:

(1) Brake housing with direct flange to hydrau- (8) Piston seal ring
lic motor

(2) Control pressure port to release the brake (9) Drive shaft seal

(3) Clip ring (10) Ring

(4) Inner disc carrier (11) Springs, 36 main springs and 18 adjustment
springs

(5) Disc package, inner and outer disc (12) Disc support ring

(6) Clip ring (13) Spring carrier and force release piston

(7) Input drive shaft (14) Oil drain plug, disc lubrication oil

Brake applied:

The outer discs engaged to the housing (Fig. 4-77, Pos. 1) by serration and the inner discs in serration connection
with the carrier (Fig. 4-77, Pos. 4) are pressed together by the springs (Fig. 4-77, Pos. 11). This results in a fixed
connection between housing (Fig. 4-77, Pos. 1) and carrier (Fig. 4-77, Pos. 4).

Brake released:

Oil pressure via the control pressure port (Fig. 4-77, Pos. 2) forces the piston (Fig. 4-77, Pos. 13) against the
springs (Fig. 4-77, Pos. 11). This function eliminates the spring force onto the discs, thus the brake is released.

REMARKS: The release pressure is 35 bar.

4.2.10.1 DISASSEMBLING OF THE TRAVEL PARKING BRAKE

Special tools: n/a

Additional equipment: Crane

Oil drain pan

Travel parking brake: 75 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area with the attachment placed at the travel gear, counter-
weight above guide wheels.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 49

Travel System Undercarriage

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

5. Place wedges at front and rear side of both crawlers and lower the bucket onto the ground.

a Drain oil of the motor adapter housing, approx. 1.5 liters.

Drain oil of the brake housing, approx. 0.12 liters.

Refer to the Operation & Maintenance Manual,

chapter 4, section "TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE
OIL".

6. Disassemble the travel motor (Fig. 4-78, Pos. 3) but leave all
hoses connected, refer to section 4.2.9.1 on page 4-43.

REMARKS: Support the travel motor, so that the hydraulic hoses

are not stressed.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.
Fig. 4-78

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure may result in
blindness, serious injury, permanent disfigurement, or scaring.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

7. Remove the pressure hose (Fig. 4-78, Pos. 1) and the breather hose (Fig. 4-78, Pos. 2) from the travel park-
ing brake (Fig. 4-78, Pos. 4).

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

8. Attach the travel parking brake assembly to a crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

9. Disassemble the mounting bolts of the travel parking brake and remove the travel parking brake by pulling it
out of the travel gear box (Fig. 4-78, Pos. 5) using the crane.

REMARKS: When the travel parking brake is removed, a rest of oil from inside the brake will flow out.
Catch it in an oil pan to avoid contamination.

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Undercarriage Travel System

4.2.10.2 ASSEMBLING OF THE TRAVEL PARKING BRAKE

Special tools: n/a

Additional equipment: Crane

Paste Optimol Paste White T, PN 323 444 40
Portable pressure source (hydraulic or air)

Travel parking brake: 75 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

REMARKS: Ensure that the mating surfaces are clean and free
of paint and old sealing agent before assembly.

1. Apply "Optimol Paste White T" at the input spline shaft of the
travel gear box (Fig. 4-79, Pos. 5) before attaching the travel
parking brake (Fig. 4-79, Pos. 3).

2. Attach the travel parking brake assembly to a crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts. Fig. 4-79

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

3. Attach the ravel parking brake assembly (Fig. 4-76, Pos. 3) to the travel gear box (Fig. 4-79, Pos. 5) using the
crane. Assemble the mounting bolts of the travel parking brake.

REMARKS: The travel brake must be released to allow proper aligning of the mounting bolt borings.
Therefore first install a portable pressure source to the pressure port (Fig. 4-79, Pos. 1) (M18 x 1.5)
at the travel parking brake and apply 35 bar.

d Refill oil of the motor adapter housing, approx. 1.5 liters.

Refill oil of the brake housing, approx. 0.12 liters.

Refer to the Operation & Maintenance Manual,

chapter 4, section "TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS".

REMARKS: Filling of the brake housing has to be done with the engine stopped and the brakes applied to pre-
vent overfilling.

4. Bleed the travel parking brake and check for proper function.
Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL for further information.

5. Add specified hydraulic oil up to the specified level.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 51

Travel System Undercarriage

4.2.11 TRAVEL GEAR BOX

Fig. 4-80 Travel gear box, overview

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Undercarriage Travel System

4.2.11.1 DISASSEMBLING OF THE TRAVEL GEAR BOX

Special tools: Hydraulic torque wrench & aggregate set, PN 232 267 40
55 mm hexagon impact socket wrench, PN 232 267 40

Additional equipment: Crane

Oil drain pan

Travel gear box: 2600 kg

Lower drive motor protection: 298 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area with the attachment placed at the travel gear box, counter-
weight above guide wheels.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

5. Disassemble the sprocket (Fig. 4-80, Pos. 3), refer to section 4.2.2.1 on page 4-11.

6. Disassemble the travel motor (Fig. 4-80, Pos. 4), leave all hoses connected, refer to section 4.2.9.1 on
page 4-43.

REMARKS: Support the travel motor, so that the hydraulic hoses are not stressed.

a Drain oil of the spur gear housing, approx. 7.5 liters.

Drain oil of the planetary gear housing, approx. 60 liters.

Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, BRAKE AND
MOTOR ADAPTER HOUSINGS - CHANGE OIL".

7. If equipped, disassemble the driving performance meter (Fig. 4-80, Pos. 7) from the travel gear box.

8. Attach the lower drive motor protection (Fig. 4-80, Pos. 5) to a crane at the lifting eyes.

9. Disassemble the mounting bolts (Fig. 4-80, Pos. 6) which hold the lower drive motor protection and remove
the protection using the crane.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 53

Travel System Undercarriage

Fig. 4-81 Travel gear box Disassembling

4 - 54 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Travel System

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure may result in
blindness, serious injury, permanent disfigurement, or scaring.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

10. Disconnect all hoses from the travel parking brake (Fig. 4-82,
Pos. 1), refer to section 4.2.10.1 on page 4-49.

11. Disconnect the breather hoses (Fig. 4-82, Pos. 2) from the
travel gear box (Fig. 4-82, Po. 3).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

Fig. 4-82

12. Sling the travel gear box using two swivel hoist rings at sprocket flange (Fig. 4-81, Pos. 2).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

13. Remove the remaining mounting bolts (Fig. 4-81, Pos. 6) and extract the travel gear box from the crawler car-
rier (Fig. 4-81, Pos. 1) using a crane.

14. If required:
Disassemble the travel parking brake from the travel gear box, refer to section 4.2.10.1 on page 4-49.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 55

Travel System Undercarriage

Fig. 4-83 Travel gear box Disassembling and installation

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Undercarriage Travel System

4.2.11.2 ASSEMBLING OF THE TRAVEL GEAR BOX

Special tools: Hydraulic torque wrench & aggregate set, PN 232 267 40
55 mm hexagon impact socket wrench, PN 232 267 40

Additional equipment: Crane

Coating compound "INTERZINC 697", PN 674 997 40
MPG (Multi Purpose Grease)

Travel gear box: 2600 kg

Lower drive motor protection: 298 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Apply surface coating with coating compound "INTERZINC

697" at the contact surface (Fig. 4-84, Pos. 1) of the new
travel gear box, refer to section 6.4.1 on page 6-5.

REMARKS: Ensure that the mating surfaces are clean and free
of paint and old sealing agent before assembly.

2. At first put five new mounting bolts (Fig. 4-83, Pos. 6) of

grade 10.9 into the top five bores of at the crawler carrier
(Fig. 4-83, Pos. 1).

REMARKS: There is not enough space to insert the bolts if the

travel gear box is already attached.
Fig. 4-84

3. Sling the travel gear box (Fig. 4-83, Pos. 2) using two swivel hoist rings at sprocket flange.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

4. Insert the travel gear box (Fig. 4-83, Pos. 2) into the crawler carrier (Fig. 4-83, Pos. 1) using a crane.

5. Assemble new mounting bolts (Fig. 4-83, Pos. 6) of grade 10.9 and new nuts. Note the next step 6!
Apply MPG (or roller bearing grease, or grease from the CLS system) and tighten the bolts to the specified
tightening torque using the hydraulic torque wrench.

b Tightening torque for travel gear box mounting bolts (Fig. 4-83, Pos. 6) and nuts: 3100 Nm

6. Assemble the lower drive motor protection (Fig. 4-83, Pos. 5) using the crane.
Use the longer mounting bolts at the lower drive motor protection (Fig. 4-83, Pos. 5). Note the previous step 5!

7. Assemble the sprocket (Fig. 4-83, Pos. 3), refer to section 4.2.2.2 on page 4-14.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 57

Travel System Undercarriage

8. If required:
Assemble the travel parking brake on the new travel gear box, refer to section 4.2.10.2 on page 4-51.

9. Assemble the travel motor (Fig. 4-83, Pos. 4), refer to section 4.2.9.2 on page 4-45.

10. If equipped, Assemble the driving performance meter (Fig. 4-80, Pos. 7) at the travel gear box.

d Refill oil of the spur gear housing, approx. 7.5 liters

Refill oil of the planetary gear housing, approx. 60 liters
Refill oil of the adapter housing, approx. 1.5 liters
If required: Refill oil of the parking brake, approx. 0.12 liters

Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, BRAKE AND
MOTOR ADAPTER HOUSINGS".

REMARKS: Filling of the brake housing has to be done with the engine stopped and the brakes applied to pre-
vent overfilling.

11. Bleed the travel parking brake and check for proper function.
Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL for further information.

12. Add specified hydraulic oil up to the specified level, refer to the Operation & Maintenance Manual, chapter 4,
section "FILLING THE HYDRAULIC SYSTEM".

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Undercarriage Travel System

Please continue reading on the next page.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 59

Travel System Undercarriage

4.2.12 CARRIER ROLLER

4.2.12.1 DISASSEMBLING OF THE CARRIER ROLLER ASSEMBLY

Special tools: n/a

Additional equipment: Hydraulic jack 8...10 tonnes (depending on installed track group (800 /
1000 mm))
Forklift (as the most economical device)
Chain hoist

Carrier roller assembly: 205 kg

1. Prepare an area of flat ground large enough to accommodate the machine, boom and forklift.

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the track tensioning system by open-

ing the ball cock (Fig. 4-85, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 4-85

5. Push up track shoe assembly (Fig. 4-86, Pos. 3) at the carrier

roller assembly (Fig. 4-86, Pos. 2) to be disassembled using
a hydraulic jack (Fig. 4-86, Pos. 1).

NOTE! Additionally to the hydraulic jack, secure the track

shoe assembly using appropriate supports.

Fig. 4-86

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Undercarriage Travel System

6. Push the forks (Fig. 4-87, Pos. 1) of a forklift together that far,
that the forks can not come in contact with the pedestals
(Fig. 4-87, Pos. 3) but the outer diameter of the carrier roller
(Fig. 4-87, Pos. 2) can rest on the forks.

NOTE! If the forks can not be locked in that position, use a

chain hoist at the forks to prevent them from sliding
apart.

7. Move the forks under the carrier roller.

8. Remove mounting bolts (Fig. 4-87, Pos. 4).

Fig. 4-87

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfall of heavy machine parts.

When moving machine parts using a forklift, make sure that nobody steps below or in close range to the
lifted machine part or within range of dangers of the forklift.

9. Lift the carrier roller assembly off the pedestal using the forklift.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 61

Travel System Undercarriage

4.2.12.2 ASSEMBLING OF THE CARRIER ROLLER ASSEMBLY

Special tools: n/a

Additional equipment: Forklift (as the most economical device)

Chain hoist

Carrier roller assembly: 205 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfall of heavy machine parts.

When moving machine parts using a forklift, make sure that nobody steps below or in close range to the
lifted machine part or within range of dangers of the forklift.

1. Lift the carrier roller assembly into the crawler carrier using a fork lift (see Fig. 4-87 on page 4-61).

REMARKS: Note the mounting position of the carrier rollers

(Fig. 4-88, Pos. 2). The filler plug (Fig. 4-88, Pos. 1)
must face the outside of the excavator.

2. Assemble the mounting bolts (Fig. 4-88, Pos. 3).

Fig. 4-88

3. Check the lubricant level in the carrier roller. For the proper lubricant, refer to the Operation & Maintenance
Manual, chapter 4, section "FLUIDS AND LUBRICANTS" and FILLING CAPACITIES.
The following positions of the oil level and filler plug have been defined for checking the oil level in the carrier
rollers:

– 9.00 o'clock or 3.00 o'clock position, equal to 90° angle from TOP position of the plug to left or to the
right = MINIMUM oil level.
– 9.30 o'clock or 2.30 o'clock position, equal to 75° angle from TOP position of the plug to left or to the
right = MAXIMUM oil level (factory filling).
4. Tighten the filler plug to the specified tightening torque.

b Tightening torque for the carrier roller filler plug: 70 Nm

5. Remove the hydraulic jack from the crawler chain.

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Undercarriage Travel System

6. Close the ball cock (Fig. 4-89, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 4-89

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Travel System Undercarriage

4.2.13 TRACK ROLLER

4.2.13.1 DISASSEMBLING OF THE TRACK ROLLER ASSEMBLY

Special tools: Safety unit for changing track rollers, PN 921 166 40
Tool for changing track rollers (optional, contact KOMATSU service)

Additional equipment: Crane

Forklift (optional, instead of the tool for changing track rollers)
Chain hoist (if forklift is used)

Track roller assembly: 296 kg

Dogman/rigger

1. Prepare an area of flat ground large enough to accommodate the machine, boom and forklift (or crane if used).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Relieve the pressure in the track tensioning system by open-

ing the ball cock (Fig. 4-90, Pos. 1) at the track tensioning
valve block inside the car body.

4. Jack up the machine with the work equipment.

Fig. 4-90

5. Support the track rollers with the safety unit for changing track
rollers, PN 921 142 40 (Fig. 4-91, Pos. 1).

6. Lower the machine and place the work equipment on the

ground.

7. Isolate the machine according to local regulations.

8. Support the track roller assembly (Fig. 4-91, Pos. 2) from the
bottom side using a forklift.
Alternatively the changing tool for track rollers can be used,
refer to Fig. 4-93.

NOTE! If the forks of the forklift can not be locked in the

required position, use a chain hoist at the forks to Fig. 4-91 Use of the safety unit
prevent them from sliding.

9. Remove the track roller mounting bolts (Fig. 4-91, Pos. 3).

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Undercarriage Travel System

REMARKS: The track roller mounting bolts (Fig. 4-92, Pos. 1)

are secured with lever-nuts (Fig. 4-92, Pos. 2)
inside the crawler frame.
When the bolts are removed, the nuts may slip away
from their mounting position.

10. Remove the track roller assembly using the forklift or the spe-
cial tool.

Fig. 4-92

11. Remove the track roller assembly using the forklift or the special tool (see Fig. 4-93).

Changing tool for track rollers

REMARKS: Make sure that both sides of the tool are balanced
(e.g. with the new track roller assembly).

Contact the KOMATSU service for further informa-

tion.

Fig. 4-93 Optional use of the special tool

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 65

Travel System Undercarriage

4.2.13.2 ASSEMBLING OF THE TRACK ROLLER ASSEMBLY

Special tools: Safety unit for track rollers changing, PN 921 166 40
Tool for changing track rollers (optional, contact KOMATSU service)

Additional equipment: Crane

Forklift (optional, instead of the tool for changing track rollers)
Chain hoist (if forklift is used)

Track roller assembly: 296 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Move the track roller assembly into mounting position using the forklift or the special tool (see Fig. 4-93 on
page 4-65).

NOTE! If the forks of the forklift can not be locked in that position, use a chain hoist at the forks to prevent
them from sliding.

REMARKS: When inserting the track roller mounting bolts

(Fig. 4-94, Pos. 1), hold the lever-nuts (Fig. 4-94,
Pos. 2) inside the crawler frame by hand for the first
convolutions.

REMARKS: Observe the mounting position of the track rollers.

The oil plug must face the outside of the excavator.

Fig. 4-94

2. Assemble the mounting bolts (Fig. 4-91, Pos. 3) to mount the

track roller assembly (Fig. 4-91, Pos. 2).

3. Jack up the machine with the work equipment.

4. Remove the safety unit for changing track rollers (Fig. 4-91,
Pos. 1).

Fig. 4-95 Use of the safety unit

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Undercarriage Travel System

5. Check the lubricant level in the track roller. For the proper lubricant, refer to the Operation & Maintenance
Manual, chapter 4, section "FLUIDS AND LUBRICANTS" and FILLING CAPACITIES.
The following positions of the oil level and filler plug have been defined for checking the oil level in the track
rollers:

– 9.00 o'clock or 3.00 o'clock position, equal to 90° angle from TOP position of the plug to left or to the
right = MINIMUM oil level.
– 9.30 o'clock or 2.30 o'clock position, equal to 75° angle from TOP position of the plug to left or to the
right = MAXIMUM oil level (factory filling).
6. Replace the copper sealing ring at the filler plug and tighten the filler plug to the specified tightening torque.

b Tightening torque for the track roller filler plug: 70 Nm

7. Close the ball cock (Fig. 4-96, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 4-96

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 67

Car body Undercarriage

4.3 CAR BODY

4.3.1 DISASSEMBLING OF THE CAR BODY AND THE CRAWLER

CARRIERS
Special tools: Hydraulic torque wrench, PN 793 376 73 + PN 793 374 73
Electro-hydraulic pump set, PN 793 375 73

Additional equipment: 2 x Crane

Car body: 19,500 kg

Crawler carrier assembly: 31,900 kg each with track group 800 mm
Crawler carrier assembly: 36,150 kg each with track group 1000 mm

Dogman/rigger
Crane operators trained in dual crane lift

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

4. Isolate the machine according to local regulations.

5. Disassemble the cover (Fig. 4-97, Pos. 1).

Fig. 4-97

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Undercarriage Car body

6. Close the ball cock (Fig. 4-98, Pos. 1) behind the service
opening.

Fig. 4-98

7. Remove the superstructure from the car body, refer to section 3.11.1 on page 3-252.

8. Disconnect all hydraulic lines from both travel motors, refer to section 4.2.9.1 on page 4-43.

9. Disconnect all hydraulic lines and breather hoses from both travel parking brakes, refer to section 4.2.10.1 on
page 4-49.

10. Disconnect the breather hoses from both travel gear boxes, from brakes and the adapter housing, refer to
section 4.2.11.1 on page 4-53.

11. Disconnect the pressure hoses (Fig. 4-99, Pos. 1) for the
track tensioning from the shut-off cocks (Fig. 4-99, Pos. 2)
inside the crawler carrier.

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

12. Remove the hoses from the crawler carrier.

Fig. 4-99

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 69

Car body Undercarriage

Putting the undercarriage on supporting stands

Fig. 4-100 Undercarriage attached to cranes

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

13. Attach the car body to two cranes at the installed attachment points (Fig. 4-100) and lift it up using the cranes.

NOTE! Before lifting the undercarriage make sure that the crane operators are trained in dual crane lift.

4 - 70 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Car body

NOTICE
HAZARD OF CRASHING THE UNDERCARRIAGE!
Severe damages to the undercarriage may result.
Too weakly dimensioned supports may cause the undercar-
riage to crash due to destruction of the supports.

Supports need to be substantial enough to carry total weight

of the undercarriage (91,800 kg).

14. Support the car body with appropriate stands so that all of the
track rollers are clear of the track roller path. Fig. 4-101
REMARKS: Place stands between the cross-ties (Fig. 4-101,
Pos. 1) in a manner that the mounting bolts can be
removed.

15. Detach the crane from the car body.

Separating car body and crawler carriers

Fig. 4-102 Crawler carriers attached to cranes

16. Attach a crawler carrier assembly to two cranes (Fig. 4-102).

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 71

Car body Undercarriage

Fig. 4-103 Crawler carrier mounting bolts

4 - 72 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Car body

17. Remove all mounting bolts (Fig. 4-103, Pos. M48) and the two measuring bolts (Fig. 4-103, Pos. 7) attaching
the crawler carrier assembly to the car body using the hydraulic torque wrench.
Discard the bolts.

REMARKS: Use the hydraulic torque wrench and wrench socket with reaction arm, refer to section 6.4.3 on
page 6-10.

For hints using the torque wrench refer to chapter 9 "Supplier’s documentation", "AVANTI
HYTORQUE".

NOTE! Before lifting the crawler carrier, make sure that the crane operators are trained in dual crane lift.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

18. Remove the left crawler carrier assembly using two cranes.
Place the crawler carrier on the ground and safeguard it against toppling using appropriate blocks.

19. Carry out the steps 16 to 18 to remove the second crawler carrier assembly.

Disassembling all installations from the car body

20. Disassemble all installations from the car body if required:

– Disassemble the rotary joint from the car body, refer to section 4.3.3.1 on page 4-82.
– Disassemble the high pressure accumulators from the car body, refer to section 4.2.4.3 on page 4-26.
– Disassemble the track tensioning valve from the car body, refer to section 4.2.5.1 on page 4-28.
– Disassemble the travel brake valve blocks from the car body, refer to section 4.2.8.1 on page 4-40.
– Disassemble all hydraulic hoses from the car body.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 73

Car body Undercarriage

4.3.2 ASSEMBLING OF THE CAR BODY AND THE CRAWLER

CARRIERS
Special tools: Hydraulic torque wrench, PN 793 376 73 + PN 793 374 73
Electro-hydraulic pump set, PN 793 375 73

Additional equipment: 2 x Crane

International Compound No. 2, PN 324 969 40

Car body: 19,500 kg

Crawler carrier assembly: 31,900 kg each with track group 800 mm
Crawler carrier assembly: 36,150 kg each with track group 1000 mm

Dogman/rigger
Crane operators trained in dual crane lift

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

Assembling all installations into the car body

1. Assemble all installations of the car body if required:

– Assemble the rotary joint from the car body, refer to section 4.3.3.2 on page 4-84.
– Assemble the high pressure accumulators from the car body, refer to section 4.2.4.4 on page 4-27.
– Assemble the track tensioning valve from the car body, refer to section 4.2.5.2 on page 4-29.
– Assemble the travel brake valve blocks from the car body, refer to section 4.2.8.2 on page 4-42.
– Assemble all hydraulic hoses from the car body.

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Undercarriage Car body

Assembling car body and crawler carriers

Fig. 4-104 Crawler carriers attached to cranes

2. Attach the R.H. side crawler carrier assembly to two cranes (Fig. 4-104).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfall of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

NOTE! Before lifting the crawler carrier, make sure that the crane operators are trained in dual crane lift.

3. Lift up the R.H. side crawler carrier and place it on the ground using the cranes.

4. Align the crawler carrier horizontally (in both directions) very precisely and safeguard it against toppling using
appropriate blocks.

REMARKS: Assure that the mounting surfaces are absolutely free of dirt, oil, fat and paint before installation.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 75

Car body Undercarriage

Fig. 4-105 Assembly of the car body

5. Attach the car body to two cranes at the installed attachment points (Fig. 4-105).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfall of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

NOTE! Before lifting the car body, make sure that the crane operators are trained in dual crane lift.

4 - 76 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Car body

REMARKS: Note the running direction of the crawler track and

the crawler carrier.

6. Lift the car body up and align the car body with the crawler
carrier (Fig. 4-105).
The mounting flanges’ bottoms must rest cleanly on the car-
rier plate.

7. Insert the corresponding hydraulic line (Fig. 4-106, Pos. 1)

into the side frame before attaching the car body.

8. Install new mounting bolts, refer to section 4.3.2.1 on

page 4-80.

9. Connect the hydraulic line (Fig. 4-106, Pos. 1) at the shut-off Fig. 4-106
cock (Fig. 4-106, Pos. 2).

10. Support the other side of the car body with appropriate supporting stands so that the free side of the car body
is approx. 200 mm higher than the already attached side.

11. Detach the cranes.

NOTICE
HAZARD OF CRASHING THE UNDERCARRIAGE!
Severe damages to the undercarriage may result.
Too weakly dimensioned supports may cause the undercar-
riage to crash due to destruction of the supports.

Supports need to be substantial enough to carry total weight

of the undercarriage (91,800 kg).

REMARKS: Place stands between the cross-ties (Fig. 4-107,

Pos. 1) in a manner that the mounting bolts can be Fig. 4-107
inserted.

12. Attach the L.H. side crawler carrier to two cranes at the installed attachment points (according to Fig. 4-104 on
page 4-75).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfall of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

NOTE! Before lifting the crawler carrier, make sure that the crane operators are trained in dual crane lift.

13. Lift the crawler carrier up and align it with the car body using the cranes.
The mounting flanges’ bottoms must rest cleanly on the carrier plate.
Insert the hydraulic line for the track tensioning system into the side frame before attaching the car body (see
Fig. 4-106).

14. Install new mounting bolts, refer to section 4.3.2.1 on page 4-80.

15. Connect the hydraulic line (refer to Fig. 4-106, Pos. 1) at the shut-off cock (refer to Fig. 4-106, Pos. 2).

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 77

Car body Undercarriage

16. Lift the undercarriage as far as it is necessary to remove the supporting stands using two cranes.

17. Remove the supporting stands from below the undercarriage.

18. Let down the undercarriage onto the crawler tracks and detach the cranes.

19. Connect all hydraulic lines at both travel motors, refer to section 4.2.9.2 on page 4-45.

20. Connect all hydraulic lines and breather hoses at both travel parking brakes, refer to section 4.2.10.2 on
page 4-51.

21. Connect the breather hoses at both travel gear boxes, from brakes and the adapter housing, refer to
section 4.2.11.2 on page 4-57.

22. Assemble the superstructure onto the car body, refer to section 3.11.2 on page 3-256.

NOTICE
RISK TO DAMAGE THE TRACK TENSIONING CYL-
INDERS!
The track tensioning cylinders may get damaged when mov-
ing the excavator with closed ball cock.

The ball cock must always be in open position before moving

the excavator for work.

23. Open the ball cock (Fig. 4-108, Pos. 1) behind the service
opening in the crawler carrier. Fig. 4-108

24. Assemble the cover (Fig. 4-109, Pos. 1).

Fig. 4-109

4 - 78 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Car body

Please continue reading on the next page.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 79

Car body Undercarriage

4.3.2.1 INSTALL CRAWLER CARRIER MOUNTING BOLTS

Special tools: Hydraulic torque wrench, PN 793 376 73 + PN 793 374 73

Electro-hydraulic pump set, PN 793 375 73
Measuring device, PN 928 476 40

Additional equipment: International Compound No. 2, PN 324 969 40

Fig. 4-110 Crawler carrier mounting bolts

4 - 80 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Car body

The required tightening torque for all fastening bolts has to be determined with the 4 measuring bolts (Fig. 4-110,
Pos. 7), which dimension is analogous to the fastening bolts (Fig. 4-110, Pos. M48). The required axial tension
force of the bolts depends on the elongation of the fastening bolts.

REMARKS: The tightening torque must be determined at the first assembly of the excavator at the operation site,
for the first inspection and after 1000 operation hours, or after replacing either crawler carrier or car
body.

The required measuring device, PN 928 476 40, is delivered with the excavator. To determine the tightening
torque, 4 specially prepared measuring bolts are supplied besides the normal fastening bolts. The measuring bolts
can be recognized by the machined area at the end of the bolt.

1. Insert new bolts (M48) with resilient sleeves and pre-tighten with the specified pre-tightening torque.
Lubricate all bolts (head supporting surface and thread) with International Compound No. 2, PN 324 969 40.
Clean bottom and top surface of the resilient sleeves and contact areas completely.

– The two measuring bolts (Fig. 4-110, Pos. 7) will be installed later.
– The mounting bolts marked with "S" have to be installed from inside the car body.
REMARKS: Use the hydraulic torque wrench and wrench socket with reaction arm, refer to section 6.4.3 on
page 6-10.

For hints using the torque wrench refer to chapter 9 "Supplier’s documentation", "AVANTI
HYTORQUE".

b Pre-tightening torque for crawler carrier mounting bolts: 2100 Nm

2. Determine the tightening torque for the mounting bolts using the two measuring bolts (Fig. 4-110, Pos. 7), refer
to the PARTS & SERVICE NEWS No. "AH11507".

3. Install the two measuring bolts and tighten all mounting bolts including the measuring bolts with the deter-
mined torque.

4. Check the torque of the crawler carrier mounting bolts after 1000 operating hours, refer to the PARTS & SER-
VICE NEWS No. "AH11507".

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 81

Car body Undercarriage

4.3.3 ROTARY JOINT

4.3.3.1 DISASSEMBLING OF THE ROTARY JOINT

Special tools: n/a

Additional equipment: Crane

Swivel hoist ring: 4x M16
Crane

Rotary joint: 215 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Relieve the pressure in the track tensioning system by open-

ing the ball cock (Fig. 4-111, Pos. 1) at the track tensioning
valve block inside the car body.

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait

until the temperature of the hydraulic oil is below 50 °C.

Fig. 4-111

4. Open the cover (Fig. 4-112, Pos. 1) of the return oil filter.

5. Transfuse oil from the return manifold into the main oil reser-
voir, refer to the PARTS & SERVICE NEWS No. "AH10530".

6. Relieve the pressure in the hydraulic system, refer to the

Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

7. Isolate the machine according to local regulations.

Fig. 4-112

4 - 82 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Car body

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure may result in
blindness, serious injury, permanent disfigurement, or scaring.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

8. Mark and disconnect all hydraulic hoses and pipes from the rotary joint.
Discard the flat seals of the SAE-flange connections.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

9. Disassemble the mounting bolts (Fig. 4-113, Pos. 1) and

remove the torque support lever (Fig. 4-113, Pos. 2) from the
rotary joint (Fig. 4-113, Pos. 3).

10. Insert swivel hoist rings into the threads of the torque support
lever mounting bolts.

11. Attach a crane to the installed swivel hoist rings at the rotary
joint.

NOTICE
RISK OF RIPPING OFF HYDRAULIC LINES!
Move the sling accessory carefully between the pipe work/
hoses at the manifold to prevent the hydraulic lines from
being damaged or ripped off.

Fig. 4-113
REMARKS: The rotary joint is accessible from above, from
between the pipe work at the distributor manifold at
the centre of the machine

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfall of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

12. Disassemble all mounting bolts (Fig. 4-113, Pos. 4) and lift the rotary joint (Fig. 4-113, Pos. 3) off the support
plate in the car body (Fig. 4-113, Pos. 5) using a crane.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 83

Car body Undercarriage

4.3.3.2 ASSEMBLING OF THE ROTARY JOINT

Special tools: n/a

Additional equipment: Crane

Swivel hoist ring: 4x M16
MPG (Multi Purpose Grease)

Rotary joint: 215 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Insert swivel hoist rings into the threads of the torque support lever mounting bolts.

2. Attach a crane to the installed swivel hoist rings.

NOTICE
RISK OF RIPPING OFF HYDRAULIC LINES!
Move the sling accessory carefully between the pipe work/hoses at the manifold to prevent the hydraulic
lines from being damaged or ripped off.

3. Place the new rotary joint (Fig. 4-114, Pos. 3) on the support
plate in the car body (Fig. 4-114, Pos. 5) using the crane.

4. Assemble new mounting bolts (Fig. 4-114, Pos. 4) of grade

10.9 at the rotary joint (Fig. 4-114, Pos. 3).
Apply MPG (or roller bearing grease, or grease from the CLS
system) and tighten the bolts to the specified tightening
torque.

b Tightening torque for rotary joint mounting bolts

(Fig. 4-114, Pos. 4): 265 Nm

5. Assemble new mounting bolts (Fig. 4-114, Pos. 1) of grade

10.9 at the torque support lever (Fig. 4-114, Pos. 2).
Apply MPG (or roller bearing grease, or grease from the CLS
system) and tighten the bolts to the specified tightening
torque.

b Tightening torque for torque support lever Fig. 4-114

mounting bolts (Fig. 4-114, Pos. 1): 265 Nm

4 - 84 PC3000-6 SHOP-50 06279-xD-GB-1

Undercarriage Car body

REMARKS: Make sure that the torque support lever (Fig. 4-115,
Pos. 1) fits into the cam (Fig. 4-115, Pos. 2) at the
superstructure.

Fig. 4-115

6. Connect all hydraulic hoses and pipes from the rotary joint.

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 4-116 Exemplaric sketch

7. Close the ball cock (Fig. 4-96, Pos. 1) at the track tensioning
valve block inside the car body.

Fig. 4-117

8. Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

9. Add hydraulic oil up to the specified level.

10. Check the track tension system and the travel system for proper function.
Refer to part 10 STRUCTURE & FUNCTION, chapter 10 in the SHOP MANUAL for further information.

SHOP-50 06279-xD-GB-1 PC3000-6 4 - 85

Car body Undercarriage

Please continue reading on the next page.

4 - 86 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment

5 ATTACHMENT

NOTE! In addition to the provisions listed here, full compliance with general safety regulations in chapter
"Safety" is required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 -1

Repair procedures Attachment

5.1 REPAIR PROCEDURES

Only carry out the repair procedures in this section. Any other action of refurbishment has to be carried out by
approved REMAN-shops only.

5.1.1 REPLACEMENT OF BUSHINGS AT THE ATTACHMENT

Special tools: n/a

Additional equipment: Welding torch

Personal Protective Equipment (PPE)
Liquid nitrogen

5.1.1.1 REMOVAL OF THE BUSHINGS

The bushings are press fitted into the bores. To remove the bushings the radial pressing force must be released.

NOTICE
DAMAGED BUSHING SEAT!
The bore for the bushing may be damaged due to excessive
heat or by gas fusion welding with the bush.

Do not melt down the bushing material completely.

1. Heat up the inner bushing (Fig. 5-118, Pos. 1) in a narrow

straight band over the whole length of the bushing using a
welding torch (Fig. 5-118, Pos. 2).
Fig. 5-118
REMARKS: When the bushing has cooled down again the radial
pressing force is reduced.

2. Drive out the bushing from the bore.

3. Measure the bore diameter and check for ovality after the bushing is removed.

4. At hydraulic cylinder eyes:

Compare the dimensions with the wear and tear limits for the cylinder bushings.
If the dimensions do not match the specifications have the cylinder refurbished in a certificated REMAN-shop.

5 -2 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Repair procedures

5.1.1.2 INSTALLATION OF THE BUSHINGS

DANGER
LIQUID NITROGEN!
Serious injuries caused by cryogenic burns or frostbite will result when it comes in contact with unpro-
tected skin. As liquid nitrogen evaporates it will reduce the oxygen concentration in the air and might act
as an asphyxiant in confined spaces.

Wear Personal Protective Equipment (protective gloves, shoes, and a face shield) to avoid injuries caused
by cryogenic burns or frostbite
Always work in well vented areas to avoid asphyxia.
Follow the safety instructions given in the PARTS & SERVICE NEWS "AH11511".

5. Cool down the bushing according to the PARTS & SERVICE NEWS "AH11511".

6. Insert the cooled down bushing into the bore until fully home.
Note that the groove for the seal rings inside the bushing must always face outwards.

REMARKS: Pay attention to the position of the lubricating holes and the lubrication grooves when installing the
bushing.
For hydraulic cylinder bushings refer to the PARTS & SERVICE NEWS No. "AH06545".

Some collar bushings (e.g. the boom foot bearings) at the attachment are equipped with thrust rings that are
shrink-fitted on the collar bushings.

Always replace bushings and thrust rings together at the same time!

Collar bushings with shrink-fitted rings:

In case the collar bushing (Fig. 5-119, Pos. 2) is equipped with a

ring (Fig. 5-119, Pos. 1) shrink-fit new rings onto the collar bush-
ings:

7. Assure that the ring is free from dirt and burrs.

NOTICE
TOO HIGH TEMPERATURE!
The ring is hardened. A too high temperature would weaken
the ring resulting in excessive wear.

Do not exceed the max. temperature of 150°C.

8. Heat the ring up to 100°C ... 150°C.

9. Bring the ring onto the collar of the installed (yet cooled down) Fig. 5-119
collar bushing until fully home.

REMARKS: Lubrication grooves (if present) in the ring have to

be aligned to the lubrication grooves in the collar of
the bushing (Fig. 5-119).

SHOP-50 06279-xD-GB-1 PC3000-6 5 -3

Repair procedures Attachment

5.1.2 GENERAL INSTALLATION INSTRUCTIONS FOR ATTACHMENT

PINS

Fig. 5-120 General installation instructions for attachment pins (example)

5 -4 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Repair procedures

Special tools: n/a

Additional equipment: Paste Aluminium Anti-Seize, PN 509 623 98

Personal Protective Equipment (PPE)
MPG (Multi Purpose Grease)
Push rod for pin installation, part of the tool set delivered with the
machine.

REMARKS: The instructions given below is general procedure. Whenever installing an attachment pin use the
method below in conjunction with the individual pin installation procedure.

1. Clean the pins and bushings very carefully and thoroughly. These parts must be completely free of dirt, corro-
sion, or any protective coating.

2. Disassemble the seal rings (Fig. 5-120, Pos. 1) from inside the bushings. Discard the seal rings.

3. Completely fill the bushing’s grooves (Fig. 5-120, Pos. 2) with MPG (or roller bearing grease, or grease from
the CLS system).

4. Insert new seal rings into the grooves of the bushings (Fig. 5-120, Pos. 3).

5. Apply MPG (or roller bearing grease, or grease from the CLS system) on every bushing at the assembly
(Fig. 5-120, Pos. 4).

6. Apply paste Aluminium Anti-Seize to the pin bearing (Fig. 5-120, Pos. 5).

7. Apply paste Aluminium Anti-Seize to the portion (Fig. 5-120, Pos. 6) of the pin (Fig. 5-120, Pos. 8) that is fixed
in the second (untreated) pin bearing.

8. Align the cylinder with the bearing. Make sure seal rings are in centered position.

9. Install the pin (Fig. 5-120, Pos. 8).

10. Secure the pin with the locking parts (Fig. 5-120, Pos. 9 to12).

SHOP-50 06279-xD-GB-1 PC3000-6 5 -5

Backhoe Attachment

5.2 BACKHOE

5.2.1 OVERVIEW

Fig. 5-1 BHA attachment overview

(1) Undercarriage with car body and side (6) Boom cylinder
frames

(2) Superstructure (7) Stick cylinder

(3) Boom (8) Bucket cylinder

(4) Stick (9) Bucket link rod

(5) Bucket (Backhoe) (10) Steering rod

5 -6 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

Please continue reading on the next page.

SHOP-50 06279-xD-GB-1 PC3000-6 5 -7

Backhoe Attachment

5.2.2 PIN SEALING BUCKET - STEERING ROD - BUCKET LINK ROD

Fig. 5-2 Backhoe pin sealing - overview

5 -8 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

Legend for Fig. 5-2:

(1) Bucket (backhoe) (5) Steering rod

(2) Bucket link rod (6) Seal fixing ring (halves)

(3) Bucket cylinder (7) Seal ring

(4) Stick

The seal rings (Fig. 5-2, Pos. 7) are held in position by seal fixing rings (Fig. 5-2, Pos. 6).

The seal fixing rings are located on both sides as follows:

– Between bucket (Fig. 5-2, Pos. 1) and bucket link rod (Fig. 5-2, Pos. 2)
– Between bucket (Fig. 5-2, Pos. 1) and stick (Fig. 5-2, Pos. 4)
– Between bucket link rod (Fig. 5-2, Pos. 2) and bucket cylinder (Fig. 5-2, Pos. 3)
– Between steering rod (Fig. 5-2, Pos. 5) and bucket cylinder (Fig. 5-2, Pos. 3)

SHOP-50 06279-xD-GB-1 PC3000-6 5 -9

Backhoe Attachment

5.2.3 BOOM

5.2.3.1 DISASSEMBLING OF THE BOOM

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

2x crane
Mobile elevator working platform

Boom: 22,760 kg
Pin boom/superstructure: 110 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate the machine, boom and two cranes.

2. Park the machine on the prepared flat ground area with the attachment in an appropriate position for stick
removal, refer to section 5.2.4.1 on page 5-24.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

5. Disassemble the stick, refer to section 5.2.4.1 on page 5-24.

6. Disassemble the stick cylinders from the boom, refer to section 5.2.4.3 on page 5-32.

7. De-isolate the machine according to local regulations.

8. Lower the boom so that the boom cylinders are in or close to

horizontal position and support the boom with appropriate
supporting stands (Fig. 5-3, Pos. 1).

9. Relieve the pressure in the hydraulic system, refer to the

Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

10. Isolate the machine according to local regulations.

11. Unplug and clear all wire harnesses from the boom.

Fig. 5-3

12. Disassemble the boom cylinders, refer to section 5.2.3.3 on page 5-15.

13. Disconnect the boom arc hoses and the grease feed lines from the boom, refer to section 5.2.6 on page 5-80.

5 - 10 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

14. Attach the boom to a crane at the installed lifting points

(Fig. 5-4).

Fig. 5-4

15. Disassemble the two bolts (Fig. 5-5, Pos. 1) and the shackle
(Fig. 5-5, Pos. 2) securing the pin (Fig. 5-5, Pos. 3) of both
boom foot bearings.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.
Fig. 5-5

REMARKS: Disassemble both pins (Fig. 5-5, Pos. 3) from the

bushes (Fig. 5-5, Pos. 4) of the boom foot bearings

16. Check bushings (Fig. 5-5, Pos. 4) for wear and damages.
Replace if required.

17. Remove the boom using the crane and place it on the ground and in an appropriate position.

Working steps and checks in the aftermath of disassembling:

18. Disassemble the seal rings from inside the bushings (Fig. 5-6,
Pos. 1 and 2). Discard the seal rings.

19. Check the bushings (Fig. 5-6, Pos. 1 and 2) of the boom foot
bearing and replace if required, refer to section 5.1.1.1 on
page 5-2.

Fig. 5-6

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 11

Backhoe Attachment

5.2.3.2 ASSEMBLING OF THE BOOM

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

2 x crane
Mobile elevator working platform
MPG (Multi Purpose Grease)
Paste Aluminium Anti-Seize, PN 509 623 98

Boom: 22,760 kg
Pin boom/superstructure: 110 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Install new seals into the grooves (Fig. 5-7, Pos. 2) of the
bushings (Fig. 5-7, Pos. 1) in the boom foot bearings at the
boom.

2. Install the seals into the grooves of the bushes with grease
and center them within the bushes.

Fig. 5-7

3. Apply MPG (or roller bearing grease, or grease from the CLS system) on every bushing at the assembly!

4. Attach the boom to a crane at the installed lifting points

(Fig. 5-8).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

Fig. 5-8

5 - 12 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from squeezing and sharing due to violent pressure from
sliding parts.

Align the parts with great caution. Never put hands through or into the bushings when aligning parts.

5. Align the boom to the boom foot bearings at the superstructure using the crane.

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the boom may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pins, the seals can get sheared between pin and the
sharp groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-9,
Pos. 2) within the bushings (Fig. 5-9, Pos. 1).
Fig. 5-9

6. Assemble both pins (Fig. 5-10, Pos. 3) of the boom foot bear-
ings.

REMARKS: Apply paste Aluminium Anti-Seize at the fixed por-

tion of the pin and the bushing (Fig. 5-5, Pos. 4) of
the pin bearing, refer to section 5.1.2 on page 5-4.

7. Assemble the shackles (Fig. 5-5, Pos. 2) and two bolts

(Fig. 5-10, Pos. 1) to secure the pins (Fig. 5-10, Pos. 3) at
both boom foot bearings.

Fig. 5-10

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 13

Backhoe Attachment

8. Move the boom so that the boom cylinders can be assembled

in or close to horizontal position using a crane (Fig. 5-11).

9. Support the boom with appropriate supporting stands

(Fig. 5-11, Pos. 1).

10. Detach the crane from the boom.

11. Assemble the boom cylinders, refer to section 5.2.3.4 on

page 5-20.

Fig. 5-11

12. Connect the boom arc hoses and the grease feed lines at the boom, refer to section 5.2.6 on page 5-80.

13. Replug and retain all wire harnesses at the boom.

14. Assemble the stick cylinders at the boom, refer to section 5.2.4.4 on page 5-37.

15. De-isolate the machine according to local regulations.

16. Switch 11S150 to Qmin.

17. At Qmin move the boom in an appropriate position for stick assembling, refer to section 5.2.4.1 on page 5-24.

18. Assemble the stick, refer to section 5.2.4.2 on page 5-28.

19. Switch 11S150 back to normal condition.

20. De-isolate the machine according to local regulations.

21. Perform the complete bleeding procedure for the attachment cylinders, refer to the PARTS & SERVICE NEWS
No. "AH06524".

22. Add hydraulic oil up to the specified level.

23. Check for leaks and the cylinders operation.

24. Check the hydraulic oil level again and add oil if required.

5 - 14 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

5.2.3.3 DISASSEMBLING OF BOOM CYLINDERS

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

2 x crane
Mobile elevator working platform
Oil drain pan
2 x swivel hoist ring M30

Boom cylinder: 2660 kg

Pin boom cylinder/boom: 84 kg
Pin boom cylinder/superstructure: 85 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

REMARKS: At first the wear of the bushes in the hydraulic cylinder should be checked, refer to the PARTS &
SERVICE NEWS No. "AH08508".

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area and position the
bucket on the ground with the bucket cylinders in fully
extended position (Fig. 5-12).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to a location with appropriate ground condi-
tion.

3. Isolate the machine according to the local regulations.

4. Relieve the pressure in the hydraulic system, refer to the

Operation & Maintenance Manual, chapter 3, section Fig. 5-12
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 15

Backhoe Attachment

5. Insert swivel hoist rings M30 into the threads (Fig. 5-13,
Pos. 1) at the boom cylinder (Fig. 5-13, Pos. 2).

Fig. 5-13

6. Attach the corresponding boom cylinder (Fig. 5-14,

Pos. 5) to a crane using the swivel hoist rings.

7. Disassemble the bolts (Fig. 5-14, Pos. 3) and the shackle

(Fig. 5-14, Pos. 4) securing the pin (Fig. 5-14, Pos. 2).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

8. Disassemble the pin (Fig. 5-14, Pos. 2) of the boom cylinder

foot bearing.

9. Check bushings (Fig. 5-14, Pos. 1) for wear and damages.

Replace if required.

Fig. 5-14

10. De-isolate the machine according to local regulations.

11. Switch 11S150 to Qmin.

12. Fully retract the boom cylinder at Qmin.

13. Tie the eye at the piston rod side to the cylinder body using appropriate gear e.g. stress ribbons to prevent the
piston rod from moving while the hydraulic hoses are disconnected
(correspondingly, as shown in Fig. 5-162 on page 5-108).

14. Isolate the machine according to local regulations.

15. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

5 - 16 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

16. Lift the boom cylinder in a horizontal position (Fig. 5-15).

Fig. 5-15

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

17. Disconnect the SAE-hydraulic hoses from the cylinder, refer to section 5.2.6.2 on page 5-84.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

18. Disconnect the grease line of the central lubrication system from the boom cylinder eye at the boom.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 17

Backhoe Attachment

19. Additionally attach the rear end of the boom cylinder

(Fig. 5-16, Pos. 5) to the crane using a sling.

20. Disassemble the bolts (Fig. 5-16, Pos. 1) and the shackle
(Fig. 5-16, Pos. 2) securing the pin.

REMARKS: The catches (Fig. 5-16, Pos. 3) are welded to the

boom (Fig. 5-16, Pos. 6).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

21. Disassemble the pin (Fig. 5-16, Pos. 4) connecting the boom
cylinder to the boom (refer to Fig. 5-17).

NOTE! Sling the pin as soon as it is possible and support it

using a crane to prevent the pin from falling.
Fig. 5-16

REMARKS: Use two puller bolts (Fig. 5-17, Pos. 2) in the

threads at the pin (Fig. 5-17, Pos. 1) to pull the pin
out of the pin bearing.

Fig. 5-17

22. Lower the boom cylinder to the ground and place it in an appropriate position using a crane.

23. Check bushes for wear and damage. Replace if required.

5 - 18 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

Working steps and checks in the aftermath of disassembling:

24. Disassemble the seal rings (Fig. 5-18, Pos. 2) from inside the
bushings (Fig. 5-18, Pos. 1). Discard the seal rings.

25. Check the bushings (Fig. 5-18, Pos. 1) of the boom cylinder
for wear and damage.
Replace the bushings if required, refer to section 5.1.1 on
page 5-2.

Fig. 5-18

26. If required, remove the pipe work from the removed cylinder(s). Discard the seals, fit the caps to the cylinder(s)
openings to avoid environmental contamination.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 19

Backhoe Attachment

5.2.3.4 ASSEMBLING OF BOOM CYLINDERS

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

2 x crane
Mobile elevator working platform
2 x swivel hoist ring M30
MPG (Multi Purpose Grease)
Paste Aluminium Anti-Seize, PN 509 623 98

Boom cylinder: 2660 kg

Pin boom cylinder/boom: 84 kg
Pin boom cylinder/superstructure: 85 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Clean the pins and bushings very carefully and thoroughly.

These parts must be completely free of dirt, corrosion, or any
protective coating.

2. At first only insert new seal rings (Fig. 5-19, Pos. 2) into the
grooves of the bushings (Fig. 5-19, Pos. 1)

REMARKS: For details refer to Fig. 5-22 on page 5-21.

3. Install the hydraulic pipe at the boom cylinder, if required.

Note the hints given with Fig. 5-21 on page 5-21!

4. Apply MPG (or roller bearing grease, or grease from the CLS
system) on every bushing at the assembly.
Fig. 5-19

5. Tie the eye at the piston rod side to the cylinder body using a wire rope to prevent the piston rod from moving
while the hydraulic hoses are disconnected (correspondingly, as shown in Fig. 5-79 on page 5-54).

6. Insert swivel hoist rings M30 into the threads (Fig. 5-13,
Pos. 1) at the boom cylinder (Fig. 5-13, Pos. 2).

7. Attach the crane at the swivel hoist ring.

Attach the other end of the boom cylinder to the crane using a
sling.

NOTE! The cylinder may be lifted and moved in horizontal

position only.

Fig. 5-20

5 - 20 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from
squeezing and sharing due to violent pressure from sliding
parts.

Align the parts with great caution. Never put hands through
or into the bushings when aligning parts.

8. Lift the boom cylinder (Fig. 5-21, Pos. 5) into mounting posi-
tion and align the boom cylinder to the boom (Fig. 5-21, Fig. 5-21
Pos. 6) using the crane.

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the boom cylinder may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pins, the seals can get sheared between pin and the
sharp groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-22,
Pos. 2) within the bushing (Fig. 5-22, Pos. 1).
Fig. 5-22

9. Assemble the pin (Fig. 5-21, Pos. 4) connecting the boom cylinder to the boom.
Align the pin’s head to the catches (Fig. 5-21, Pos. 3).

REMARKS: Apply paste Aluminium Anti-Seize at the fixed portion of the pin and the pin fixing point of the pin
bearing, refer to section 5.1.2 on page 5-4.

10. Assemble the shackle (Fig. 5-21, Pos. 2) and the bolts (Fig. 5-21, Pos. 1) to secure the pin (Fig. 5-21, Pos. 4).

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 21

Backhoe Attachment

11. Connect the SAE-hydraulic hoses at the boom cylinder, refer to section 5.2.6.2 on page 5-84.

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 5-23 Exemplaric sketch

12. De-isolate the machine according to local regulations.

13. Switch 11S150 to Qmin.

14. Fully retract the boom cylinder at Qmin.

15. Remove the wire rope securing the piston rod to the boom cylinder body.

16. Insert new seal rings (Fig. 5-24, Pos. 1) into the grooves of
the bushings (Fig. 5-24, Pos. 2).

REMARKS: For details refer to Fig. 5-27 on page 5-23.

Fig. 5-24

WARNING
AIR IN THE HYDRAULIC CYLINDER!
May result in personal injury due to slightly jerky movements
of the cylinder when it is operated. The jerky movements are
caused by the air in the cylinder which is compressible.

Make sure that nobody is in close range to the cylinder when

it is operated with only one end connected to the attachment.

17. Extend and retract the boom cylinder slowly at Qmin 2...3
times as far as possible to partly bleed the cylinder. Fig. 5-25
18. Detach the already mounted side of the boom cylinder from
the crane.

19. Lower the cylinder until the piston rod points in the direction of
the mounting location at the superstructure (Fig. 5-25).

5 - 22 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from
squeezing and sharing due to violent pressure from sliding
parts.

Align the parts with great caution. Never put hands through
or into the bushings when aligning parts.

20. Extend / retract the boom cylinder slowly at Qmin and use the
crane to align the eye of the boom cylinder (Fig. 5-26, Pos. 5)
to the cylinder foot bearing at the superstructure.

21. Isolate the machine according to local regulations.

Fig. 5-26

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the boom cylinder may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pins, the seals can get sheared between pin and the
sharp groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-27,
Pos. 2) within the bushing (Fig. 5-27, Pos. 1).
Fig. 5-27

22. Assemble the pin (Fig. 5-26, Pos. 2) of the boom cylinder foot bearing.

23. Assemble the bolts (Fig. 5-26, Pos. 3) and the shackle (Fig. 5-26, Pos. 4) to secure the pin.

24. Switch 11S150 back to normal condition.

25. De-isolate the machine according to local regulations.

26. Perform the bleeding procedure for the boom cylinders. Refer to the PARTS & SERVICE NEWS "AH06524".

27. Add hydraulic oil up to the specified level.

28. Check for leaks and the cylinders operation.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 23

Backhoe Attachment

5.2.4 STICK ASSEMBLY

5.2.4.1 DISASSEMBLING OF THE STICK

Special tools: Thread protector PN 409 329 40

Additional equipment: Safety harness in conformity with EN 361

Swivel hoist ring M20
3 x crane
Mobile elevator working platform

Stick: 8715 kg
Stick incl. steering and bucket cylinders: 17500 kg
Pin stick/boom: 711 kg
Nut-cap: 35 kg

Dogman/rigger
Crane operators trained in dual crane lift

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area with the attachment in an appropriate position for bucket
removal, refer to section 5.2.5.1 on page 5-43.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

3. Isolate the machine to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

5. Disassemble the bucket, refer to section 5.2.5.1 on page 5-43.

6. Fully retract the bucket cylinders.

7. Tie the cylinder piston rods of both bucket cylinders using wire ropes, to prevent the piston rod from moving
while the hydraulic hoses are disconnected.

8. Use appropriate gear (e.g. stress ribbons) to fix the bucket cylinders to the stick.

9. Disconnect and clear all attached wire harnesses from the stick.

10. Disconnect the grease feeding lines leading to the stick.

5 - 24 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

11. Disconnect the SAE-hydraulic hoses (Fig. 5-28, Pos. 1 & 2)

from the bucket cylinders (Fig. 5-28, Pos. 3).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

Fig. 5-28

12. Support both stick cylinders (Fig. 5-29, Pos. 1) with blocks
(Fig. 5-29, Pos. 2) between stick cylinders and boom
(Fig. 5-29, Pos. 3).

Fig. 5-29

13. Attach the stick assembly (Fig. 5-30) to two cranes.

Fig. 5-30

14. Disassemble the pins connecting the stick cylinders to the stick, refer to section 5.2.4.3 on page 5-32.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 25

Backhoe Attachment

15. Disassemble the lock of the nut-cap (Fig. 5-31, Pos. 1) at the
pin connecting the stick with the boom by removing the cotter
pin (Fig. 5-31, Pos. 2) from the bore (Fig. 5-31, Pos. 3) and
then removing the bolt (Fig. 5-31, Pos. 2).

16. Insert a swivel hoist ring M20 into the nut-cap (Fig. 5-31,
Pos. 1) and attach it to a crane.

Fig. 5-31

17. Disassemble the nut-cap (Fig. 5-32, Pos. 2) from the pin
(Fig. 5-32, Pos. 4).

18. Fit the "Thread Protector" PN 409 329 40 onto the thread of
the pin.

19. Remove the O-ring (Fig. 5-32, Pos. 1) from the nut-cap.

NOTE! Before clearing the stick, make sure that the crane
operators are trained in dual crane lift.

DANGER
FLOATING LOADS! Fig. 5-32
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

20. Pull the pin (Fig. 5-32, Pos. 4) out completely to clear boom (Fig. 5-32, Pos. 3) and stick.

NOTE! Sling the pin as soon as it is possible and support it using a crane to prevent the pin from falling.

REMARKS: Use two puller bolts (Fig. 5-33, Pos. 2) in the

threads at the pin (Fig. 5-33, Pos. 1) to pull the pin
out of the pin bearing.

Fig. 5-33

21. Disassemble the stick assembly using the cranes.

5 - 26 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

22. Lower the stick to the ground and rest it in an appropriate position.

Working steps and checks in the aftermath of disassembling:

23. Disassemble the bucket link rod and the steering rods, refer to section 5.2.5.5 on page 5-64.

24. Disassemble the bucket cylinders from the stick, refer to section 5.2.5.3 on page 5-50.

Fig. 5-34 Bushings at the stick assembly

25. Disassemble the seal rings (Fig. 5-34, Pos. 2 & 3) from inside the bushings (Fig. 5-34, Pos. 4 to 7).
Discard the seal rings.

26. Check all bushings (Fig. 5-34, Pos. 4 to 6) at the stick (Fig. 5-34, Pos. 1) for wear and damage.
Replace the bushings if required, refer to section 5.1.1 on page 5-2.

NOTE! Note the mounting position of the seal ring grooves at the bushings (Fig. 5-34, Pos. 5). The grooves
must face to the outer side of the stick.

REMARKS: The collar bushings (Fig. 5-34, Pos. 7) at the bucket bearing are each equipped with a thrust ring
(Fig. 5-34, Pos. 8) that is shrink-fitted on the collar bushing. Always replace bushings and thrust rings
together at the same time.

27. Check the bushings (Fig. 5-34, Pos. 7) and the rings (Fig. 5-34, Pos. 8) for wear and damage.
Replace the bushings and rings if required, refer to section 5.1.1 on page 5-2.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 27

Backhoe Attachment

5.2.4.2 ASSEMBLING OF THE STICK

Special tools: Thread protector PN 409 329 40

Additional equipment: Safety harness in conformity with EN 361

Swivel hoist ring M20
3 x crane
Mobile elevator working platform
MPG (Multi Purpose Grease)
Paste Aluminium Anti-Seize, PN 509 623 98

Stick: 8715 kg
Stick incl. steering and bucket cylinders: 17500 kg
Pin stick/boom: 711 kg
Nut-cap: 35 kg

Dogman/rigger
Crane operators trained in dual crane lift

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Clean all pins and bushings very carefully and thoroughly. These parts must be completely free of dirt, corro-
sion, or any protective coating.

2. Apply MPG (or roller bearing grease, or grease from the CLS system) on every bushing at the assembly.

3. Insert new seal rings (Fig. 5-35, Pos. 2) into the grooves of all
bushings (Fig. 5-35, Pos. 2) at the assembly.

Fig. 5-35

4. Assemble the bucket cylinders from the stick, refer to section 5.2.5.4 on page 5-57.

5. Assemble the bucket link rod and the steering rod(s), refer to section 5.2.5.5 on page 5-64.

5 - 28 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

6. Attach the stick (Fig. 5-36) to two cranes.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

Fig. 5-36
7. Lift the stick using two cranes.

NOTE! Before lifting the stick, make sure that the crane
operators are trained in dual crane lift.

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from squeezing and sharing due to violent pressure from
sliding parts.

Align the parts with great caution. Never put hands through or into the bushings when aligning parts.

8. Align the stick assembly to the boom using the cranes.

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the stick may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pin, the seals can get sheared between pin and the sharp
groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-37,
Pos. 2) within the collar bushings (Fig. 5-37,
Fig. 5-37
Pos. 1).

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 29

Backhoe Attachment

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

9. Insert the pin (Fig. 5-38, Pos. 4) using a crane and remove
the "Thread Protector" PN 409 329 40 from the pin. Fig. 5-38
10. Insert a swivel hoist ring into the nut-cap (Fig. 5-38, Pos. 2)
and attach it to a crane.

11. Install the nut-cap (Fig. 5-38, Pos. 2) with O-ring (Fig. 5-38,
Pos. 1).

12. Assemble the bolt (Fig. 5-39, Pos. 4) to secure the nut-cap
(Fig. 5-39, Pos. 1).

13. Assemble a new cotter pin (Fig. 5-39, Pos. 2) into the bore
(Fig. 5-39, Pos. 3).

Fig. 5-39

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from squeezing and sharing due to violent pressure from
sliding parts.

Align the parts with great caution. Never put hands through or into the bushings when aligning parts.

14. Align the stick to the stick cylinders. Move the stick with the crane at the front end for aligning.
Precondition: Stick cylinders yet in disassembly position (refer to Fig. 5-29 on page 5-25)!

15. Assemble the stick cylinders at the stick, refer to section 5.2.4.4 on page 5-37.

5 - 30 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

16. Install the SAE-hydraulic hoses (Fig. 5-40, Pos. 1 & 2) at the
bucket cylinders (Fig. 5-40, Pos. 3).

Fig. 5-40

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 5-41 Exemplaric sketch

17. Remove the wire rope securing the bucket cylinder.

18. Assemble the bucket, refer to section 5.2.5.2 on page 5-47.

19. De-isolate the machine according to local regulations.

20. Perform the complete bleeding procedure for the attachment cylinders, refer to the PARTS & SERVICE NEWS
No. "AH06524".

21. Add hydraulic oil up to the specified level.

22. Check for leaks and the cylinders operation.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 31

Backhoe Attachment

5.2.4.3 DISASSEMBLING OF THE STICK CYLINDERS

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

2 x crane
Mobile elevator working platform
2 x Swivel hoist ring M30

Stick Cylinder: 2420 kg

Pin stick cylinder/stick: 82 kg
Pin stick cylinder/boom: 84 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

REMARKS: At first the wear of the bushes in the hydraulic cylinders should be checked, refer to the PARTS &
SERVICE NEWS No. "AH08508".

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area and position the
bucket on the ground with the cylinders in partially extended
position (Fig. 5-42).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to a location with appropriate ground condi-
tion.

3. Isolate the machine to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the

Operation & Maintenance Manual, chapter 3, section Fig. 5-42
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

5. Support the stick cylinder (Fig. 5-43, Pos. 1) to be disassem-

bled with blocks (Fig. 5-43, Pos. 2) between stick cylinder and
boom (Fig. 5-43, Pos. 3).

Fig. 5-43 Exemplaric sketch

5 - 32 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

6. Remove grease feed lines and fittings from the stick cylinder(s) to be removed.

7. Sling the cylinder (Fig. 5-44, Pos. 1) to be removed.

Fig. 5-44

8. Disassemble the bolts (Fig. 5-45, Pos. 2) with washers

(Fig. 5-45, Pos. 3) and disassemble the shackle (Fig. 5-45,
Pos. 4) securing the pin (Fig. 5-45, Pos. 5).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

9. Disassemble the pin (Fig. 5-45, Pos. 5) connecting the stick

cylinder (Fig. 5-45 Pos. 1) to the stick.

NOTE! Sling the pin as soon as it is possible and support it

using a crane to prevent the pin from falling. Fig. 5-45

10. Disassemble the seal rings (Fig. 5-45, Pos. 6) from inside the
bushings. Discard the seal rings.

11. De-isolate the machine according to local regulations.

12. Switch 11S150 to Qmin.

13. Fully retract the stick cylinder at Qmin.

14. Tie the clevis at the piston rod side to the cylinder body using a wire rope to prevent the piston rod from mov-
ing while the hydraulic hoses are disconnected (correspondingly, as shown in Fig. 5-79 on page 5-54).

15. Isolate the machine according to local regulations.

16. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 33

Backhoe Attachment

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

17. Disconnect the SAE-hydraulic hoses (Fig. 5-46, Pos. 1 & 2)

from the stick cylinder (Fig. 5-46, Pos. 4).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

18. Disconnect the grease line of the central lubrication system

from the bore (Fig. 5-46, Pos. 3) at the stick cylinder eye.

Fig. 5-46

19. Insert swivel hoist rings M30 into the threads (Fig. 5-47,
Pos. 1) at the stick cylinder (Fig. 5-47, Pos. 2) and attach a
crane.

20. Swing the stick cylinder into horizontal position using the
crane at the swivel hoist rings.

21. Attach the other end of the stick cylinder to the crane using a
sling.

Fig. 5-47

5 - 34 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

22. Disassemble four bolts (Fig. 5-48, Pos. 1) with washers and
disassemble the shackle (Fig. 5-48, Pos. 2) securing the pin
(Fig. 5-48, Pos. 4).

REMARKS: The catches (Fig. 5-48, Pos. 3) are welded to the

boom.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

23. Pull out the pin (Fig. 5-48, Pos. 4) connecting the stick cylin-
der to the boom (Fig. 5-48, Pos. 5).

NOTE! Sling the pin as soon as possible and support it

using a crane to prevent the pin from falling.

Fig. 5-48

REMARKS: Use two puller bolts (Fig. 5-49, Pos. 2) in the

threads at the pin (Fig. 5-49, Pos. 1) to pull the pin
out of the pin bearing.

Fig. 5-49

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

24. Remove the stick cylinder from the boom, lower the stick cylinder to the ground and place it in an appropriate
position using the crane.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 35

Backhoe Attachment

25. If required, disassemble the other stick cylinder from the boom using the same procedure.

26. If required, remove the hydraulic pipe from the removed cylinder(s). Discard the o-rings, fit caps to the cylin-
der(s) openings to avoid environmental contamination.

Working steps and checks in the aftermath of disassembling:

27. Disassemble the seal rings (Fig. 5-50, Pos. 2) from inside the
collar bushings (Fig. 5-50, Pos. 1). Discard the seal rings.

28. Check the bushings (Fig. 5-50, Pos. 1) of the stick cylinder for
wear and damage.
Replace the bushings if required, refer to section 5.1.1 on
page 5-2.

Fig. 5-50

5 - 36 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

5.2.4.4 ASSEMBLING OF THE STICK CYLINDERS

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

2 x crane
Mobile elevator working platform
2 x Swivel hoist ring M30
MPG (Multi Purpose Grease)
Paste Aluminium Anti-Seize, PN 509 623 98

Stick Cylinder: 2420 kg each

Pin stick cylinder/stick: 82 kg
Pin stick cylinder/boom: 84 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Flush out and clean the hydraulic pipes at the cylinder(s).

2. If required, install the hydraulic pipe at the cylinder(s).

3. Install new seal rings (Fig. 5-51, Pos. 2) into the grooves of
the collar bushings (Fig. 5-51, Pos. 1). Use MPG (or roller
bearing grease, or grease from the CLS system) to center the
seals within the bushings.

REMARKS: For details refer to Fig. 5-53 on page 5-38.

Fig. 5-51

4. Clean all pins and bushings very carefully and thoroughly. These parts must be completely free of dirt, corro-
sion, or any protective coating.

5. Apply MPG (or roller bearing grease, or grease from the CLS system) on every bushing at the assembly.

6. Tie the clevis at the piston rod side to the cylinder body using a wire rope to prevent the piston rod from mov-
ing while the hydraulic hoses are disconnected (correspondingly, as shown in Fig. 5-79 on page 5-54).

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 37

Backhoe Attachment

7. Insert swivel hoist rings M30 into the threads (Fig. 5-52,
Pos. 1) at the stick cylinder (Fig. 5-52, Pos. 2) and attach a
crane.

8. Attach the other end of the stick cylinder to the crane using a
sling.

Fig. 5-52

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from squeezing and sharing due to violent pressure from
sliding parts.

Align the parts with great caution. Never put hands through or into the bushings when aligning parts

9. Lift the stick cylinder and align the stick cylinder to the boom using the crane.

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the stick cylinder may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pin, the seals can get sheared between pin and the sharp
groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-53,
Pos. 2) within the collar bushings (Fig. 5-53,
Fig. 5-53
Pos. 1).

5 - 38 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

10. Insert the pin (Fig. 5-54, Pos. 4) connecting the stick cylinder
(Fig. 5-54, Pos. 6) to the boom. Align the pin’s head to the
catches (Fig. 5-54, Pos. 3) welded to the boom.

REMARKS: Apply paste Aluminium Anti-Seize at the fixed por-

tion of the pin and the pin fixing point of the pin bear-
ing, refer to section 5.1.2 on page 5-4.

11. Assemble the shackle (Fig. 5-54, Pos. 2) and the bolts
(Fig. 5-54, Pos. 1) with washers to secure the pin.

12. Detach the rear end of the stick cylinder from the crane.

Fig. 5-54

13. Install the SAE-hydraulic hoses (Fig. 5-55, Pos. 1 & 2) at the
stick cylinder (Fig. 5-55, Pos. 4).

14. Connect the grease line of the central lubrication system to

the bore (Fig. 5-55, Pos. 3) at the stick cylinder eye.

Fig. 5-55

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 5-56 Exemplaric sketch

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 39

Backhoe Attachment

15. De-isolate the machine according to local regulations.

16. Switch 11S150 to Qmin.

17. Fully retract the stick cylinder at Qmin.

18. Remove the wire rope securing the piston rod to the stick cylinder body.

WARNING
AIR IN THE HYDRAULIC CYLINDER!
May result in personal injury due to slightly jerky movements of the cylinder when it is operated. The jerky
movements are caused by the air in the cylinder which is compressible.

Make sure that nobody is in close range to the cylinder when it is operated with only one end connected to
the attachment.

19. Extend and retract the stick cylinder slowly at Qmin 2...3 times as far as possible to partly bleed the cylinder.

20. Install new seal rings (Fig. 5-57, Pos. 6) into the grooves of
the bushings in the stick. Use MPG (or roller bearing grease,
or grease from the CLS system) to center the seals within the
bushings.

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from
squeezing and sharing due to violent pressure from sliding
parts.

Align the parts with great caution. Never put hands through
or into the bushings when aligning parts.

21. Extend / retract the stick cylinder (Fig. 5-57, Pos. 1) slowly at
Qmin and use the crane to align the clevis of the stick cylinder
into the mounting position for the pin (Fig. 5-57, Pos. 5).
Fig. 5-57

5 - 40 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the stick cylinder may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pin, the seals can get sheared between pin and the sharp
groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-58,
Pos. 2) within the bushing (Fig. 5-58, Pos. 1).
Fig. 5-58

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

22. Insert the pin (Fig. 5-57, Pos. 5) connecting the stick cylinder (Fig. 5-57, Pos. 1) to the stick.

23. Assemble the shackle (Fig. 5-57, Pos. 4) and two bolts (Fig. 5-57, Pos. 2) with washers (Fig. 5-57, Pos. 3)
securing the pin.

24. Detach the crane from the stick cylinder and disassemble the swivel hoist rings from the stick cylinder.

25. Switch 11S150 back to normal condition.

26. De-isolate the machine according to local regulations.

27. Perform the bleeding procedure for the boom cylinders. Refer to the PARTS & SERVICE NEWS "AH06524".

28. Add hydraulic oil up to the specified level.

29. Check for leaks and the cylinders operation.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 41

Backhoe Attachment

Please continue reading on the next page.

5 - 42 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

5.2.5 BUCKET AND STEERING

5.2.5.1 DISASSEMBLING OF THE BUCKET

Special tools: Thread protector PN 409 329 40

Additional equipment: Safety harness in conformity with DIN EN 361

Crane
Mobile elevator working platform
Swivel hoist ring M20

Pin bucket/stick: 532 kg

Pin bucket/bucket link rod: 398 kg
Bucket 15 m³: 15,200 kg
Nut-cap: 35 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area with the boom lifted so that the bucket can move freely
over the ground and the bucket cylinders fully retracted.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to any location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

5. Disassemble the locks of both nut-caps (Fig. 5-59, Pos. 1) at

the pins in the bucket by removing the cotter pin (Fig. 5-59,
Pos. 2) from the bore (Fig. 5-59, Pos. 3) and then removing
the bolt (Fig. 5-59, Pos. 4).

6. Insert a swivel hoist ring M20 into the nut-cap and attach it to
a crane.

Fig. 5-59

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 43

Backhoe Attachment

7. Attach the bucket (Fig. 5-60, Pos. 1) to a crane at the

installed lifting points (Fig. 5-60, Pos. 2).

8. Disassemble the nut-cap (Fig. 5-60, Pos. 6).

9. Fit the "Thread Protector" PN 409 329 40 onto the thread of

the pin.

10. Disassemble the seal fixing rings (Fig. 5-60, Pos. 5) located
on both sides between the stick and the bucket.

11. Safeguard the bucket link rod (Fig. 5-60, Pos. 4) in position
using appropriate supporting blocks and wire ropes to prevent
it from crashing down when the pin is disassembled.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down- Fig. 5-60
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

12. Pull the pin (Fig. 5-60, Pos. 3) out completely to clear the bucket (Fig. 5-60, Pos. 1) from the bucket link rod
(Fig. 5-60, Pos. 4).
(Refer to Fig. 5-61.)

NOTE! Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

REMARKS: Use two puller bolts (Fig. 5-61, Pos. 2) in the

threads at the pin (Fig. 5-61, Pos. 1) to pull the pin
out of the pin bearing.

Fig. 5-61

13. Swivel the bucket down using the crane.

14. Detach the crane.

15. De-isolate the machine according to local regulations.

16. Switch 11S150 to Qmin.

17. Lower the boom at Qmin and position the bucket with its flat side (underside) on the ground.

18. Isolate the machine according to local regulations.

19. Use appropriate blocks to safeguard the bucket on the ground.

5 - 44 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

20. Disassemble the nut-cap (Fig. 5-62, Pos. 5).

21. Fit the "Thread Protector" PN 409 329 40 onto the thread of
the pin.

22. Disassemble the seal fixing rings (Fig. 5-62, Pos. 4) located
on both sides between the stick and the bucket.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.
Fig. 5-62

23. Pull the pin (Fig. 5-62, Pos. 3) out completely to clear the
bucket (Fig. 5-62, Pos. 1) from the stick (Fig. 5-62, Pos. 2).
(Refer to Fig. 5-61.)

NOTE! Sling the pin as soon as possible and support it

using a crane to prevent the pin from falling.

24. Lift the boom at Qmin.

25. Switch 11S150 back to normal condition.

26. Move the excavator away.

27. Isolate the machine according to local regulations.

Working steps and checks in the aftermath of disassembling:

At both sides of the bucket:

28. Remove the seal rings (Fig. 5-63, Pos. 1) from the rings
(Fig. 5-63, Pos. 2) shrink-fitted on the collar bushings.

29. Remove the seal rings (Fig. 5-63, Pos. 4) from the collar
bushings (Fig. 5-63, Pos. 3).

30. Discard the removed seal rings.

Fig. 5-63

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 45

Backhoe Attachment

Fig. 5-64 Bushings to be checked

31. Check the following bushings for wear and damage. Replace the bushings if required, refer to section 5.1.1.1
on page 5-2.

– Collar bushings (Fig. 5-64, Pos. 4) in the bucket (Fig. 5-64, Pos. 1).
– Collar bushings (Fig. 5-64, Pos. 5) in the bucket link rod (Fig. 5-64, Pos. 6).

REMARKS: The collar bushings (Fig. 5-64, Pos. 2) at the bucket (Fig. 5-64, Pos. 1) and the collar bushings
(Fig. 5-64, Pos. 8) at the stick (Fig. 5-64, Pos. 9) are equipped with rings (Fig. 5-64, Pos. 3 & 7) that
are shrink-fitted on the collar bushings. Always replace bushings and thrust rings together at the
same time.

32. Check the bushings (Fig. 5-64, Pos. 2 & 8) and the rings (Fig. 5-64, Pos. 3 & 7) for wear and damage.
Replace the bushings with the rings if required, refer to section 5.1.1.1 on page 5-2.

5 - 46 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

5.2.5.2 ASSEMBLING OF THE BUCKET

Special tools: Thread protector PN 409 329 40

Additional equipment: Safety harness in conformity with DIN EN 361

Crane
Mobile elevator working platform
Swivel hoist ring M20
MPG (Multi Purpose Grease)
Paste Aluminium Anti-Seize, PN 509 623 98

Pin bucket/stick: 532 kg

Pin bucket/bucket link rod: 398 kg
Bucket 15 m³: 15,200 kg
Nut-cap: 35 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Check the grease filling in the chamber of the bucket link rod (Fig. 5-64, Pos. 6), refer to the PARTS & SER-
VICE NEWS No. "AH09522".

2. Clean all pins and bushings very carefully and thoroughly. These parts must be completely free of dirt, corro-
sion, or any protective coating.

At both sides of the bucket:

3. Slip new seal rings (Fig. 5-65, Pos. 1) over the rings
(Fig. 5-65, Pos. 2) shrink-fitted on the collar bushings.

4. Slip new seal rings (Fig. 5-65, Pos. 4) over the collar bush-
ings (Fig. 5-65, Pos. 3).

REMARKS: During assembling there is not enough space to

insert these seal rings.

Fig. 5-65

5. Apply MPG (or roller bearing grease, or grease from the CLS system) on every bushing at the assembly.

6. De-isolate the machine according to local regulations.

7. Move the excavator to the bucket.

8. Switch 11S150 to Qmin.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 47

Backhoe Attachment

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from
squeezing and sharing due to violent pressure from sliding
parts.

Align the parts with great caution. Never put hands through
or into the bushings when aligning parts.

9. Align the stick (Fig. 5-66, Pos. 2) to the bucket (Fig. 5-66,
Pos. 1) by moving the stick at Qmin.

10. Switch 11S150 back to normal condition.

11. Isolate the machine according to local regulations.

Fig. 5-66

12. Insert the pin (Fig. 5-66, Pos. 3) attaching the bucket to the stick.

REMARKS: Apply paste Aluminium Anti-Seize at the fixed portion of the pin and the pin fixing point of the pin
bearing, refer to section 5.1.2 on page 5-4.

13. Assemble the grease feeding line at the bucket mounting pin.

14. Assemble the seal fixing rings (Fig. 5-66, Pos. 4) located on both sides between the stick and the bucket onto
the seal rings (see Fig. 5-65, Pos. 1).
Note the mounting orientation, refer to section 5.2.2 on page 5-8.

REMARKS: Fill the grooves of the seal fixing rings with MPG (or roller bearing grease, or grease from the CLS
system) and place the ring halves over the seal rings.

15. Remove the "Thread Protector" from the pin and assemble the nut-cap (Fig. 5-66, Pos. 5) (with O-ring).

16. Assemble the bolt (Fig. 5-67, Pos. 4) to secure the nut-cap
(Fig. 5-67, Pos. 1).

17. Assemble a new cotter pin (Fig. 5-67, Pos. 2) into the bore
(Fig. 5-67, Pos. 3).

Fig. 5-67

5 - 48 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

18. Attach the bucket (Fig. 5-68, Pos. 1) to a crane at the

installed lifting points (Fig. 5-68, Pos. 2).

19. De-isolate the machine according to local regulations.

20. Lift the boom so that the bucket can swing freely.

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from
squeezing and sharing due to violent pressure from sliding
parts.

Align the parts with great caution. Never put hands through
or into the bushings when aligning parts.

Fig. 5-68
21. Align the bucket to the bucket link rod (Fig. 5-68, Pos. 4)
using the crane. Move the bucket with the crane.
Precondition: Bucket link rod yet in disassembly position rest-
ing on supporting blocks.

22. Isolate the machine according to local regulations.

23. Insert the pin (Fig. 5-68, Pos. 3) attaching the bucket to the bucket link rod.

REMARKS: Apply paste Aluminium Anti-Seize at the fixed portion of the pin and the pin fixing point of the pin
bearing, refer to section 5.1.2 on page 5-4.

24. Assemble the seal fixing rings (Fig. 5-68, Pos. 5) located on both sides between the bucket link rod and the
bucket onto the seal rings (see Fig. 5-65, Pos. 4).
Note the mounting orientation, refer to section 5.2.2 on page 5-8.

REMARKS: Fill the grooves of the seal fixing rings with MPG (or roller bearing grease, or grease from the CLS
system) and place the ring halves over the seal rings.

25. Remove the "Thread Protector" from the pin and assemble the nut-cap (Fig. 5-68, Pos. 6) (with O-ring).

26. Assemble the bolt (Fig. 5-69, Pos. 4) to secure the nut-cap
(Fig. 5-69, Pos. 1).

27. Assemble a new cotter pin (Fig. 5-69, Pos. 2) into the bore
(Fig. 5-69, Pos. 3).

Fig. 5-69

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 49

Backhoe Attachment

5.2.5.3 DISASSEMBLING OF BUCKET CYLINDERS

Special tools: Thread protector PN 409 329 40

Additional equipment: Safety harness in conformity with EN 361

2 x crane
Mobile elevator working platform
Oil drain pan
Swivel hoist ring M20
2 x Swivel hoist ring M30

Bucket Cylinder:1850 kg
Pin bucket cylinder/stick: 61 kg
Pin bucket cylinder/steering rods: 625 kg
Nut-cap: 35 kg
Rod protection cover: 300 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

REMARKS: At first the wear of the bushes in the hydraulic cylinder should be checked, refer to the PARTS &
SERVICE NEWS No."AH08508".

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area and posi-
tion the bucket in a hole in the ground as shown in Fig. 5-70,
with the bucket cylinders not fully retracted.

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.

3. Base the stick on the ground.

4. Base the bucket cylinder(s) with appropriate supporting

blocks (Fig. 5-70, Pos. 1). Fig. 5-70 Exemplaric sketch

5. Base the bucket link rod with appropriate blocks (Fig. 5-70,
Pos. 2).

6. Isolate the machine according to local regulations.

7. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

5 - 50 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

8. Disconnect the grease line of the central lubrication system

from the bore (Fig. 5-71, Pos. 1) at the corresponding bucket
cylinder eye.

Fig. 5-71

9. If the L.H. bucket cylinder or both bucket cylinders are to be

disassembled:
Disconnect the grease lines (Fig. 5-72, Pos. 1) of the central
lubrication system from the L.H. steering rod (Fig. 5-72,
Pos. 2).

REMARKS: Also disconnect the grease line from the inner side
of the steering rod.

Fig. 5-72 Exemplaric sketch

10. Carry out the steps 11 and 12 only if the bucket cylinder is
equipped with a rod protection cover.

11. Connect the rod protection cover (Fig. 5-73, Pos. 1) to a

crane using the shackle (Fig. 5-73, arrow).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine Fig. 5-73
part.

12. Disassemble the protection cover (Fig. 5-73, Pos. 1) from the
bucket cylinder (Fig. 5-73, Pos. 2) and remove it using the
crane.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 51

Backhoe Attachment

13. Disassemble the lock of the nut-cap (Fig. 5-74, Pos. 1) at the
pin on the piston rod side of the bucket cylinder by removing
the cotter pin (Fig. 5-74, Pos. 2) from the bore (Fig. 5-74,
Pos. 3) and then removing the bolt (Fig. 5-74, Pos. 4).

14. Insert a swivel hoist ring M20 into the nut-cap and attach it to
a crane.

Fig. 5-74

15. Disassemble the seal fixing rings (Fig. 5-75, Pos. 1) located
on both sides of the cylinder moving rods (Fig. 5-75, Pos. 2).

16. Remove the nut-cap (Fig. 5-75, Pos. 3) from the pin
(Fig. 5-75, Pos. 4), then fit the "Thread Protector"
PN 409 329 40.

Fig. 5-75

17. Sling the steering rod(s) (Fig. 5-76, Pos. 1).

Sling both steering rods if both cylinders or the L.H. cylinder
are to be disassembled.

18. Hold the steering rod in position using the crane.

Fig. 5-76

5 - 52 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

19. Pull out the pin (Fig. 5-77, Pos. 2) connecting the bucket cyl-
inders to the bucket link rod. Fig. 5-77
(Refer to Fig. 5-78.)

REMARKS: If disassembling the R.H. cylinder only, pull the pin

out just enough to clear the cylinder piston rod.
If the L.H. cylinder is to be disassembled pull the pin
out completely.

NOTE! Sling the pin as soon as it is possible and support it

using a second crane to prevent the pin from falling
when pulling out completely.

20. Swivel down the steering rod(s) (Fig. 5-77, Pos. 1) using the
crane.

REMARKS: Use two puller bolts (Fig. 5-78, Pos. 2) in the

threads at the pin (Fig. 5-78, Pos. 1) to pull the pin
out of the pin bearing.

Fig. 5-78

21. Detach the crane from the steering rod(s).

22. De-isolate the machine according to local regulations.

23. Switch 11S150 to Qmin.

24. Fully retract the bucket cylinder(s) at Qmin.

25. Isolate the machine according to local regulations.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 53

Backhoe Attachment

26. Tie the piston rod to the cylinder body with a wire rope
(Fig. 5-79).

Fig. 5-79

27. Isolate the machine according to local regulations.

28. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

29. Disconnect the SAE-hydraulic hoses (Fig. 5-80, Pos. 1 & 2)

from the bucket cylinder (Fig. 5-80, Pos. 3).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

Fig. 5-80

5 - 54 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

30. Insert swivel hoist rings M30 into the threads (Fig. 5-81,
Pos. 1) at the bucket cylinder (Fig. 5-81, Pos. 2) and attach a
crane.

31. Swing the bucket cylinder into horizontal position using the
crane at the swivel hoist rings.

32. Attach the other end of the bucket cylinder to the crane using
a sling.

Fig. 5-81

33. Disassemble two bolts (Fig. 5-82, Pos. 2) with washers and
disassemble the shackle(Fig. 5-82, Pos. 3) securing the pin
(Fig. 5-82, Pos. 4).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

34. Pull out the pin (Fig. 5-82, Pos. 4) connecting the bucket cyl-
inder (Fig. 5-82, Pos. 1) to the stick.

NOTE! Sling the pin as soon as it is possible and support it

using a crane to prevent the pin from falling. Fig. 5-82

35. Remove the two seal rings (Fig. 5-82, Pos. 5) from inside
bushing(s). Discard the seal rings.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

36. Remove the bucket cylinder using the crane. Lower the cylinder to the ground and place it in an appropriate
position.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 55

Backhoe Attachment

Working steps and checks in the aftermath of disassembling:

37. Check the bushings (Fig. 5-83, Pos. 1) of the bucket cylinder
for wear and damage.
Replace the bushings if required, refer to section 5.1.1.1 on
page 5-2.

Fig. 5-83

38. Remove the seal ring(s) (Fig. 5-84, Pos. 1) that are slipped
over the collar bushing(s) (Fig. 5-84, Pos. 2) in the cleared
end of the bucket link rod (Fig. 5-84, Pos. 3).

39. Check the collar bushing(s) (Fig. 5-84, Pos. 2) in the cleared
end of the bucket link rod and the steering rod(s) for wear and
damage.
Replace the bushing(s) if required, refer to section 5.1.1.1 on
page 5-2.

Fig. 5-84

40. Remove the seal ring(s) (Fig. 5-85, Pos. 1) that are slipped
over the collar bushing(s) (Fig. 5-85, Pos. 2) in the cleared
end of the steering rod(s) (Fig. 5-85, Pos. 3).

41. Check the collar bushing(s) (Fig. 5-85, Pos. 2) in the cleared
end of the bucket link rod and the steering rod(s) for wear and
damage.
Replace the bushing(s) if required, refer to section 5.1.1.1 on
page 5-2.

Fig. 5-85

5 - 56 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

5.2.5.4 ASSEMBLING OF BUCKET CYLINDERS

Special tools: Thread protector PN 409 329 40

Additional equipment: Safety harness in conformity with EN 361

2 x crane (3 x crane if L.H. side cylinder is to be assembled)
Mobile elevator working platform
Swivel hoist ring M20
2 x Swivel hoist ring M30
MPG (Multi Purpose Grease)
Paste Aluminium Anti-Seize, PN 509 623 98

Bucket Cylinder:1850 kg
Pin bucket cylinder/stick: 61 kg
Pin bucket cylinder/steering rods: 625 kg
Nut-cap: 35 kg
Rod protection cover: 300 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Clean all pins and bushings very carefully and thoroughly. These parts must be completely free of dirt, corro-
sion, or any protective coating.

2. Apply MPG (or roller bearing grease, or grease from the CLS system) on every bushing at the assembly.

3. Slip a new seal ring (Fig. 5-86, Pos. 1)/new seal rings over
the collar bushing(s) (Fig. 5-86, Pos. 2) in the bucket link rod
(Fig. 5-86, Pos. 3).

REMARKS: During assembling there is not enough space to

insert these seal rings.

4. Before assembling, check the grease filling in the chamber of

the bucket link rod (cylinder side), refer to the PARTS & SER-
VICE NEWS No. "AH09522".

Fig. 5-86

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 57

Backhoe Attachment

5. Slip a new seal ring (Fig. 5-85, Pos. 1)/new seal rings over
the collar bushing(s) (Fig. 5-85, Pos. 2) in the steering rod(s)
(Fig. 5-85, Pos. 3).

REMARKS: During further assembling there is not enough

space to insert these seal rings.

Fig. 5-87

6. Tie the eye at the piston rod side to the cylinder body using a wire rope to prevent the piston rod from moving
while the hydraulic hoses are disconnected (as shown in Fig. 5-79 on page 5-54).

7. Insert swivel hoist rings M30 into the threads (Fig. 5-88,
Pos. 1) at the bucket cylinder (Fig. 5-88, Pos. 2) and attach a
crane.

8. Attach the other end of the bucket cylinder to the crane using
a sling.

Fig. 5-88

9. Install new seals (Fig. 5-89, Pos. 5) into the grooves of the
bushing.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

10. Lift the bucket cylinder (Fig. 5-89, Pos. 1) into mounting posi-
tion using the crane.

NOTE! Make sure that the cylinder is in horizontal position

while lifting and aligning.
Fig. 5-89

5 - 58 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the bucket cylinder may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pin, the seals can get sheared between pin and the sharp
groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-90,
Pos. 2) within the bushing (Fig. 5-90, Pos. 1).
Fig. 5-90

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

11. Insert the pin (Fig. 5-89, Pos. 4) connecting the bucket cylinder (Fig. 5-89, Pos. 1) to the stick.

REMARKS: Apply paste Aluminium Anti-Seize at the fixed portion of the pin and the pin fixing point of the pin
bearing, refer to section 5.1.2 on page 5-4.

12. Assemble the shackle (Fig. 5-89, Pos. 3) and two bolts (Fig. 5-89, Pos. 2) with washers securing the pin.

13. Detach the rear end of the bucket cylinder from the crane.

14. Install the SAE-hydraulic hoses (Fig. 5-91, Pos. 1 & 2) at the
bucket cylinder (Fig. 5-91, Pos. 3).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

Fig. 5-91

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 59

Backhoe Attachment

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 5-92 Exemplaric sketch

15. De-isolate the machine according to local regulations.

16. Switch 11S150 to Qmin.

17. Fully retract the bucket cylinder(s) at Qmin.

18. Remove the wire rope securing the piston rod to the bucket cylinder body.

WARNING
AIR IN THE HYDRAULIC CYLINDER!
May result in personal injury due to slightly jerky movements of the cylinder when it is operated. The jerky
movements are caused by the air in the cylinder which is compressible.

Make sure that nobody is in close range to the cylinder when it is operated with only one end connected to
the attachment.

19. Extend and retract the bucket cylinder slowly at Qmin 2...3 times as far as possible to partly bleed the cylinder.

20. Sling the steering rod(s) (Fig. 5-93, Pos. 1) and attach a sec-
ond crane.

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from
squeezing and sharing due to violent pressure from sliding
parts.

Align the parts with great caution. Never put hands through
or into the bushings when aligning parts.

Fig. 5-93
21. Align steering rod, bucket cylinder, and bucket link rod as fol-
lows:

5 - 60 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

22. Extend / retract the bucket cylinder slowly at Qmin and use the
crane to align the eye of the bucket cylinder into the mounting
position for the pin (Fig. 5-94, Pos. 2).

REMARKS: Use only engine 2 (front) at Qmin.

23. Additionally swivel the steering rod (Fig. 5-94, Pos. 1) into the
mounting position for the pin using the second crane.

For the assembling of the L.H. bucket cylinder carry out the steps
24 to 28.
For the assembling of the R.H. bucket cylinder only continue with
step 29.
Fig. 5-94

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

24. Fit the "thread protector" PN 409 329 40 onto the pin (Fig. 5-94, Pos. 2).

25. Insert the pin connecting bucket cylinder, bucket link rod, and steering rods using a third crane.
Push the pin in, just enough to hold the steering rod and the bucket cylinder in position.

REMARKS: Apply paste Aluminium Anti-Seize at the fixed portion of the pin and the pin fixing point of the pin
bearing, refer to section 5.1.2 on page 5-4.

26. Detach the crane from the L. H. bucket cylinder and disassemble the swivel hoist rings from the bucket cylin-
der.

27. Detach the cranes from the L.H. steering rod and the pin.

28. Repeat the steps 7 on page 5-58 to 23 for the R.H. bucket cylinder.

29. Push the pin through the eye of the bucket cylinder and the steering rod until fully home.

30. Isolate the machine according to local regulations.

31. Detach the crane from the bucket cylinder and disassemble the swivel hoist rings from the bucket cylinder.

32. Detach the crane from the steering rod.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 61

Backhoe Attachment

33. Assemble the nut-cap (Fig. 5-95, Pos. 3) at the pin (Fig. 5-95,
Pos. 4).

34. Assemble the seal fixing rings (Fig. 5-95, Pos. 1) located on
both sides of the cylinder piston rod eyes (Fig. 5-95, Pos. 2).
Note the mounting orientation.

REMARKS: Fill the grooves of the seal fixing rings with MPG (or
roller bearing grease, or grease from the CLS sys-
tem) and place the ring halves over the seal rings.

Fig. 5-95 cross-sectional top view

35. Assemble the bolt (Fig. 5-96, Pos. 4) to secure the nut-cap
(Fig. 5-96, Pos. 1).

36. Assemble a new cotter pin (Fig. 5-96, Pos. 2) into the bore
(Fig. 5-96, Pos. 3).

Fig. 5-96

37. If disconnected:
Install the grease lines (Fig. 5-97, Pos. 1) of the central lubri-
cation system at the L.H. steering rod (Fig. 5-97, Pos. 2).

REMARKS: Also install the grease line at the inner side of the
steering rod.

Fig. 5-97 Exemplaric sketch

5 - 62 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

38. Install the grease line of the central lubrication system into the
bore (Fig. 5-98, Pos. 1) at the bucket cylinder eye(s).

Fig. 5-98

39. Carry out the steps 40 and 41 only if the bucket cylinder is
equipped with a rod protection cover.

40. Connect the rod protection cover (Fig. 5-73, Pos. 1) to a

crane using the shackle (Fig. 5-73, arrow).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine Fig. 5-99
part.

41. Move the protection cover (Fig. 5-73, Pos. 1) into mounting
position using the crane and assemble the protection cover at
the bucket cylinder (Fig. 5-73, Pos. 2).

42. De-isolate the machine according to local regulations.

43. Switch 11S150 back to normal condition.

44. Perform the bleeding procedure for the replacement bucket cylinder(s). Refer to the PARTS & SERVICE
NEWS No. "AH06524".

45. Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

46. Add hydraulic oil up to the specified level.

47. Check for leaks and the cylinders operation.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 63

Backhoe Attachment

5.2.5.5 DISASSEMBLING OF THE BUCKET LINK ROD

Special tools: Thread protector PN 409 329 40

Additional equipment: Safety harness in conformity with DIN EN 361

2 x crane
Mobile elevator working platform

Bucket link rod: 2237 kg

Dogman/rigger

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area with the boom lifted so that the bucket can move freely
over the ground and the bucket cylinders fully retracted.

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the bucket cylinders only, refer to the Operation & Maintenance Manual, chapter 3,
section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

5. Disconnect the grease lines of the central lubrication system

from the bore (Fig. 5-100, Pos. 1) at both bucket cylinder
eyes.

Fig. 5-100

6. Disconnect the grease lines (Fig. 5-101, Pos. 1) of the central

lubrication system from the L.H. steering rod (Fig. 5-101,
Pos. 2).

REMARKS: Also disconnect the grease line from the inner side
of the steering rod.

Fig. 5-101 Exemplaric sketch

5 - 64 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

7. Clear the bucket from the bucket link rod by disassembling the pin connecting bucket and bucket link rod, refer
to section 5.2.5.1 on page 5-43.

8. Safeguard both bucket cylinders (Fig. 5-102, Pos. 2) in posi-

tion using appropriate supporting blocks.

NOTICE
SHARP EDGES!
The lifting equipment may get damaged by sharp edges at
the bushings of the bucket link rod.

In order to avoid damage to the lifting devices, use edge pro-

tection.

Fig. 5-102
9. Attach the bucket link rod (Fig. 5-102, Pos. 1) to a crane.

10. Swivel the bucket link rod into vertical position using the
crane.

11. Disassemble the pin connecting bucket cylinder, bucket link rod, and steering rods, refer to section 5.2.5.3 on
page 5-50.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

12. Remove the bucket link rod using the crane. Lower the bucket link rod to the ground and place it in an appro-
priate position.

Working steps and checks in the aftermath of disassembling:

13. Remove the seal rings (Fig. 5-103, Pos. 1) that are slipped
over the collar bushings (Fig. 5-103, Pos. 2).

14. Discard all removed seal rings.

15. Check all bushings (Fig. 5-103, Pos. 2 & 3) of the bucket link
rod for wear and damage.
Replace the bushings if required, refer to section 5.1.1.1 on
page 5-2.

Fig. 5-103

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 65

Backhoe Attachment

16. Check the bushings (Fig. 5-104, Pos. 1) of the bucket cylin-
ders for wear and damage.
Replace the bushings if required, refer to section 5.1.1 on
page 5-2.

Fig. 5-104

17. Remove the seal rings (Fig. 5-105, Pos. 1) that are slipped
over the collar bushings (Fig. 5-105, Pos. 2) in cleared ends
of both steering rods (Fig. 5-105, Pos. 3).

18. Discard all removed seal rings.

19. Check the collar bushing(s) (Fig. 5-105, Pos. 2) in the cleared
end of the steering rods for damage.
Replace the bushing(s) if required, refer to section 5.1.1 on
page 5-2.

REMARKS: Under normal conditions the collar bushings in the

steering rods are not subject to wear.

Fig. 5-105

20. Remove the seal rings (Fig. 5-106, Pos. 1) that are slipped
over the collar bushings (Fig. 5-106, Pos. 2) in the bucket
(Fig. 5-106, Pos. 3).

21. Discard all removed seal rings.

Fig. 5-106

5 - 66 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

5.2.5.6 ASSEMBLING OF THE BUCKET LINK ROD

Special tools: Thread protector PN 409 329 40

Additional equipment: Safety harness in conformity with DIN EN 361

2 x crane
Mobile elevator working platform
MPG (Multi Purpose Grease)
Paste Aluminium Anti-Seize, PN 509 623 98

Bucket link rod: 2237 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Most of the following operations require the use of men safety cages on elevator working platforms.

1. Clean all pins and bushings very carefully and thoroughly. These parts must be completely free of dirt, corro-
sion, or any protective coating.

2. Apply MPG (or roller bearing grease, or grease from the CLS system) on every bushing at the assembly.

3. At the bucket cylinder end of the bucket link rod (narrow side):
Slip new seal rings (Fig. 5-107, Pos. 1) over the collar bush-
ings (Fig. 5-107, Pos. 2) in the bucket link rod (Fig. 5-107,
Pos. 3).

REMARKS: During assembling there is not enough space to

insert these seal rings.

4. Before assembling, check the grease filling in the chamber of

the bucket link rod, refer to the PARTS & SERVICE NEWS
No. "AH09522".

Fig. 5-107

5. Slip new seal rings (Fig. 5-108, Pos. 1) over both collar bush-
ings (Fig. 5-108, Pos. 2) in both steering rods (Fig. 5-108,
Pos. 3).

Fig. 5-108

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 67

Backhoe Attachment

NOTICE
SHARP EDGES!
The lifting equipment may get damaged by sharp edges at
the bushings of the bucket link rod.

In order to avoid damage to the lifting devices, use edge pro-

tection.

6. Attach the bucket link rod (Fig. 5-109, Pos. 1) to a crane at

the bucket end of the bucket link rod (wide side).
Fig. 5-109

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

7. Move the bucket link rod into mounting position using the crane and align the bucket link rod with the bucket
cylinders (Fig. 5-109, Pos. 2).

8. Assemble the pin connecting bucket cylinder, bucket link rod, and steering rods, refer to section 5.2.5.4 on
page 5-57.

9. Swivel the bucket link rod into horizontal position using the crane and base the bucket link rod with appropriate
blocks.

10. Detach the crane from the bucket link rod.

At both sides of the bucket:

11. Slip new seal rings (Fig. 5-110, Pos. 1) over the collar bush-
ings (Fig. 5-110, Pos. 2) in the bucket (Fig. 5-110, Pos. 3).

REMARKS: During assembling there is not enough space to

insert these seal rings.

Fig. 5-110

12. Connect the bucket with the bucket link rod by assembling the pin connecting bucket and bucket link rod, refer
to section 5.2.5.1 on page 5-43.

5 - 68 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

13. Install the grease lines (Fig. 5-111, Pos. 1) of the central lubri-
cation system at the L.H. steering rod (Fig. 5-111, Pos. 2).

REMARKS: Also install the grease line at the inner side of the
steering rod.

Fig. 5-111 Exemplaric sketch

14. Install the grease line of the central lubrication system into the
bore (Fig. 5-112, Pos. 1) at the bucket cylinder eye(s).

Fig. 5-112

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 69

Backhoe Attachment

5.2.5.7 DISASSEMBLING OF THE STEERING RODS

Special tools: Thread protector PN 409 329 40

Additional equipment: Safety harness in conformity with EN 361

Chain hoist
2 x crane
Mobile elevator working platform
Swivel hoist ring M20

Steering rod: 642 kg

Pin stick/steering rods: 295 kg
Nut-cap: 35 kg

Dogman/rigger

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area and posi-
tion the bucket in a hole in the ground as shown in Fig. 5-113,
with the bucket cylinders not fully retracted.

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.

3. Base the stick on the ground.

4. Base the bucket cylinder(s) with appropriate blocks

(Fig. 5-113, Pos. 1). Fig. 5-113 Exemplaric sketch

5. Base the bucket link rod with appropriate blocks (Fig. 5-113,
Pos. 1).

6. Isolate the machine according to local regulations.

7. Relieve the pressure in the bucket cylinders only, refer to the Operation & Maintenance Manual, chapter 3,
section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

5 - 70 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

8. Disconnect the grease line of the central lubrication system

from the bore (Fig. 5-114, Pos. 1) at the bucket cylinder eye
at the corresponding side.

Fig. 5-114

9. If the L.H. steering rod or both steering rods are to be disas-

sembled:
Disconnect the grease lines (Fig. 5-115, Pos. 1) of the central
lubrication system from the L.H. steering rod (Fig. 5-115,
Pos. 2).

REMARKS: Also disconnect the grease line from the inner side
of the steering rod.

Fig. 5-115 Exemplaric sketch

10. Sling the steering rod(s) (Fig. 5-116, Pos. 1).

Sling both steering rods if both steering rods or the L.H. steer-
ing rod are to be disassembled.

11. Hold the steering rod(s) in position using the crane.

Fig. 5-116

12. Disassemble the upper pin connecting bucket cylinder, bucket link rod, and steering rods, refer to
section 5.2.5.3 on page 5-50.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 71

Backhoe Attachment

13. Disassemble the seal fixing ring(s) (Fig. 5-117, Pos. 1)

located between the steering rod(s) (Fig. 5-117, Pos. 2) and
the stick (Fig. 5-117, Pos. 3).

Fig. 5-117

14. Disassemble the lock of the nut-cap (Fig. 5-118, Pos. 1) by

removing the cotter pin (Fig. 5-118, Pos. 2) from the bore
(Fig. 5-118, Pos. 3) and then removing the bolt (Fig. 5-118,
Pos. 4).

15. Insert a swivel hoist ring M20 into the nut-cap and attach it to
a crane.

Fig. 5-118

16. Disassemble the nut-cap (Fig. 5-119, Pos. 1) from the lower
pin at the steering rod (Fig. 5-119, Pos. 2), then fit the
"Thread Protector" PN 409 329 40.

Fig. 5-119

5 - 72 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

17. Pull out the pin (Fig. 5-120, Pos. 1) connecting the steering
rods to the stick. (Refer to Fig. 5-121.) Fig. 5-120
REMARKS: If disassembling the R.H. steering rod only, pull the
pin out just enough to clear the steering rod.
If the L.H. steering rod (Fig. 5-120, Pos. 2) is to be
disassembled pull the pin out completely.

NOTE! Sling the pin as soon as it is possible and support it

using a crane to prevent the pin from falling.

REMARKS: Use two puller bolts (Fig. 5-121, Pos. 2) in the

threads at the pin (Fig. 5-121, Pos. 1) to pull the pin
out of the pin bearing.

Fig. 5-121

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

18. Remove the steering rod(s) using the crane.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 73

Backhoe Attachment

Working steps and checks in the aftermath of disassembling:

19. Remove the seal rings (Fig. 5-122, Pos. 2) that are slipped
over the collar bushings (Fig. 5-122, Pos. 1) in the steering
rod(s).

20. Discard all removed seal rings.

21. Check the collar bushings (Fig. 5-122, Pos. 1) in the steering
rod(s) for damage.
Replace the bushings if required, refer to section 5.1.1 on
page 5-2.

REMARKS: Under normal conditions the collar bushings in the

steering rods are not subject to wear.

Fig. 5-122

22. Check the bushings (Fig. 5-123, Pos. 1) of the bucket cylin-
ders for wear and damage.
Replace the bushings if required, refer to section 5.1.1 on
page 5-2.

Fig. 5-123

23. Remove the seal rings (Fig. 5-124, Pos. 1) that are slipped
over the collar bushings (Fig. 5-124, Pos. 2).

24. Discard all removed seal rings.

25. Check the collar bushing(s) (Fig. 5-124, Pos. 2) in the cleared
end of the bucket link rod (Fig. 5-124, Pos. 3) for wear and
damage.
Replace the bushing(s) if required, refer to section 5.1.1 on
page 5-2.

REMARKS: If the bushing(s) is/are worn it is recommended to

disassemble the bucket link rod and replace all
bushings in the assembly, refer to section 5.2.5.5 on
page 5-64. Fig. 5-124

5 - 74 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

26. Check the bushing(s) (Fig. 5-125, Pos. 1) of the steering rod
bearing(s) in the stick (Fig. 5-125, Pos. 2) for wear and dam-
age.
Replace the bushing if required, refer to section 5.1.1 on
page 5-2.

Fig. 5-125

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 75

Backhoe Attachment

5.2.5.8 ASSEMBLING OF THE STEERING ROD

Special tools: Thread protector PN 409 329 40

Additional equipment: Safety harness in conformity with EN 361

2 x crane
Mobile elevator working platform
Swivel hoist ring M20
MPG (Multi Purpose Grease)
Paste Aluminium Anti-Seize, PN 509 623 98

Steering rod: 642 kg

Pin stick/steering rods: 295 kg
Nut-cap: 35 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Clean all pins and bushings very carefully and thoroughly. These parts must be completely free of dirt, corro-
sion, or any protective coating.

2. Apply MPG (or roller bearing grease, or grease from the CLS system) on every bushing at the assembly.

3. Slip new seal rings (Fig. 5-126, Pos. 1) over the collar bush-
ings (Fig. 5-126, Pos. 2) in the bucket link rod (Fig. 5-126,
Pos. 3).

REMARKS: During assembling there is not enough space to

insert these seal rings.

4. Before further assembling, check the grease filling in the

chamber of the bucket link rod (cylinder side), refer to the
PARTS & SERVICE NEWS No. "AH09522".

Fig. 5-126

5. Slip new seal rings (Fig. 5-127, Pos. 1) over both collar bush-
ings (Fig. 5-127, Pos. 2) in the steering rod(s) (Fig. 5-127,
Pos. 3).

Fig. 5-127

5 - 76 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

6. Fit the "Thread Protector" PN 409 329 40 onto the pin

(Fig. 5-128, Pos. 1).

7. Attach the steering rod to a crane.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part. Fig. 5-128

8. Move the steering rod into mounting position using a crane.

9. When assembling the L.H. steering rod:

Align the bore in the steering rod to bore in the stick and insert the pin (Fig. 5-128, Pos. 1) completely using a
crane. Make sure that the pin fits into the distortion lock at the steering rod (Fig. 5-128, Pos. 2).

10. When assembling the R.H. steering rod:

Move the steering rod onto the (installed) pin.

11. Remove the "Thread Protector" from the pin (Fig. 5-128, Pos. 1).

12. Assemble the nut-cap (Fig. 5-129, Pos. 1) at the steering rod
(Fig. 5-129, Pos. 2).

Fig. 5-129

13. Assemble the bolt (Fig. 5-130, Pos. 4) to secure the nut-cap
(Fig. 5-130, Pos. 1).

14. Assemble a new cotter pin (Fig. 5-130, Pos. 2) into the bore
(Fig. 5-130, Pos. 3).

Fig. 5-130

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 77

Backhoe Attachment

15. Assemble the seal fixing ring(s) (Fig. 5-131, Pos. 1) located
between the steering rod(s) (Fig. 5-131, Pos. 2) and the stick
(Fig. 5-131, Pos. 3).

Fig. 5-131

16. Sling the steering rod(s) (Fig. 5-132, Pos. 1).

Sling both steering rods if both steering rods or the L.H. steer-
ing rod are to be disassembled.

17. Hold the steering rod(s) in position using the crane.

Fig. 5-132

18. Assemble the upper pin connecting bucket cylinder, bucket link rod, and steering rods, refer to section 5.2.5.4
on page 5-57.

19. If required:
Install the grease lines (Fig. 5-133, Pos. 1) of the central lubri-
cation system at the L.H. steering rod (Fig. 5-133, Pos. 2).

REMARKS: Also install the grease line at the inner side of the
steering rod.

Fig. 5-133 Exemplaric sketch

5 - 78 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

20. Install the grease line of the central lubrication system into the
bore (Fig. 5-112, Pos. 1) at the bucket cylinder eye(s).

Fig. 5-134

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 79

Backhoe Attachment

5.2.6 HYDRAULIC HOSES AT THE BACKHOE ATTACHMENT

5.2.6.1 REPLACE THE BOOM ARC HOSES

Fig. 5-135 Arc hoses at the boom

5 - 80 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

Legend for Fig. 5-135:

(1) Hose clamp (5) Hydraulic tube

(2) Hose clamp (6) Hydraulic hose

(3) Hose clamp (7) Bolt

(4) Manifold (8) Flat seal

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Crane
Oil drain pan

Boom arc hose: 25 kg...38 kg (depending on diameter)

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area and position the
bucket on the ground with the cylinders in partially extended
position (Fig. 5-136).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the

Operation & Maintenance Manual, chapter 3, section Fig. 5-136
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

5. Open the hose clamps (Fig. 5-135, Pos. 1...3) and clear the corresponding hydraulic hose to be disassembled
from the clamp lines.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 81

Backhoe Attachment

Fig. 5-137 Arc hoses at the boom

5 - 82 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

6. Sling the hydraulic hose (Fig. 5-137, Pos. 6) to be disassembled.

7. Disassemble the bolts (Fig. 5-137, Pos. 7) and disconnect the SAE-hydraulic hose from the distributor mani-
fold (Fig. 5-137, Pos. 4) and from the hydraulic tube (Fig. 5-137, Pos. 5) at the boom.
Discard the flat seals (Fig. 5-137, Pos. 8) of the SAE-flange connections.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

8. Remove the hydraulic hose using a crane.

9. Replace the hydraulic hose by a new one and carry out assembling in reverse order of disassembling.

NOTE! Always replace the flat seals (Fig. 5-137, Pos. 8) at SAE-flange connections when installing the
hydraulic lines!
A flat and level sealing surface is essential for proper sealing!

b Tighten the mounting bolts (Fig. 5-137, Pos. 7) of SAE-flange connections according to the
KOMATSU company standard "Torques for SAE-flange connections", refer to section 6.6.5 on
page 6-19.

10. If required replace the other hydraulic hoses using the same procedure.

11. Perform the bleeding procedure for all cylinders. Refer to the PARTS & SERVICE NEWS No. "AH06524".

12. Add hydraulic oil up to the specified level.

13. Check for leaks and the cylinder operation.

14. Check hydraulic oil level again and add oil, if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 83

Backhoe Attachment

5.2.6.2 REPLACE THE BOOM CYLINDER HOSES

Fig. 5-138 Hoses of the boom cylinders

(1) Hydraulic hose (5) Collar ring

(2) Hydraulic hose (6) Boom cylinder

(3) Flat seal (7) Hydraulic tube

(4) Bolt

5 - 84 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Mobile elevator working platform
Oil drain pan

Boom cylinder hoses (depending on type):

13.5 kg...22.5 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate

the machine and the additional working equipment (crane,
mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area and position the
bucket on the ground with the bucket cylinders in fully
extended and the stick cylinders in fully retracted position
(Fig. 5-139).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to a location with appropriate ground condi-
tion. Fig. 5-139

3. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

4. Isolate the machine according to local regulations.

5. Disassemble the guard plate (Fig. 5-138, Pos. 8).

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 85

Backhoe Attachment

Fig. 5-140 Hoses of the boom cylinders

5 - 86 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

6. Remove the bolts (Fig. 5-140, Pos. 4) and disconnect the SAE-flanges of the corresponding hydraulic hose
(Fig. 5-140, Pos. 1 or 2) from the boom cylinder (Fig. 5-140, Pos. 6) and from the hydraulic tube (Fig. 5-140,
Pos. 7) at the boom.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

7. Remove the hydraulic hose.

8. Check the collar ring (Fig. 5-140, Pos. 5) at the hydraulic tube (Fig. 5-140, Pos. 7).
A flat and level sealing surface is essential for proper sealing! Replace if required.

9. Replace the hydraulic hose by a new one and carry out assembling in reverse order of disassembling.

NOTE! Always replace the flat seals (Fig. 5-140, Pos. 3) at SAE-flange connections when installing the
hydraulic lines!
A flat and level sealing surface is essential for proper sealing!

b Tighten the mounting bolts (Fig. 5-140, Pos. 4) of SAE-flange connections according to the
KOMATSU company standard "Torques for SAE-flange connections", refer to section 6.6.5 on
page 6-19.

10. If required replace the other hydraulic hoses using the same procedure.

11. Assemble the guard plate (Fig. 5-140, Pos. 8).

12. Perform the bleeding procedure for the boom cylinder(s). Refer to the PARTS & SERVICE NEWS
No. "AH06524".

13. Add hydraulic oil up to the specified level.

14. Check for leaks and the cylinders operation.

15. Check hydraulic oil level again and add oil if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 87

Backhoe Attachment

5.2.6.3 REPLACE THE STICK CYLINDER HOSES

Fig. 5-141 Hoses of the stick cylinders

(1) Hydraulic hose (4) Flat seal

(2) Hydraulic hose (5) Bolt

(3) Elbow flange (6) Collar ring

5 - 88 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Oil drain pan
Mobile elevator working platform

Stick cylinder hoses: 24.6 kg

Dogman/rigger

f there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate

the machine and the additional working equipment (crane,
mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area and position the
bucket on the ground with the bucket cylinders in fully
extended and the stick cylinders in fully retracted position
(Fig. 5-142).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to a location with appropriate ground condi-
tion. Fig. 5-142

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 89

Backhoe Attachment

Fig. 5-143 Hoses of the stick cylinders

5 - 90 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

5. Remove the bolts (Fig. 5-143, Pos. 5) and disconnect the SAE-flanges of the corresponding hydraulic hose
(Fig. 5-143, Pos. 1 or 2) from the stick cylinder and from the hydraulic tube (Fig. 5-143, Pos. 7) at the boom.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

6. Remove the hydraulic hose.

7. Check the collar ring (Fig. 5-143, Pos. 6) at the hydraulic tube (Fig. 5-143, Pos. 7).
A flat and level sealing surface is essential for proper sealing! Replace if required.

8. Replace the hydraulic hose (Fig. 5-144/Fig. 5-143, Pos. 1 or

2) by a new one and carry out assembling in reverse order of
disassembling.

REMARKS: Note the mounting position of the elbow (Fig. 5-144/

Fig. 5-143, Pos. 3) at the SAE-flange connection.

NOTE! Always replace the flat seals (Fig. 5-143, Pos. 4) at

SAE-flange connections when installing the hydrau-
lic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts (Fig. 5-143, Pos. 5) of

SAE-flange connections according to the Fig. 5-144
KOMATSU company standard "Torques for SAE-
flange connections", refer to section 6.6.5 on
page 6-19.

9. Perform the bleeding procedure for the stick cylinder(s). Refer to the PARTS & SERVICE NEWS
No. "AH06524".

10. Add hydraulic oil up to the specified level.

11. Check for leaks and the cylinders operation.

12. Check hydraulic oil level again and add oil if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 91

Backhoe Attachment

5.2.6.4 REPLACE THE BUCKET CYLINDER HOSES

Fig. 5-145 Hoses of the bucket cylinders

(1) Hydraulic hose (3) O-ring

(2) Bolt (4) Hydraulic tube

5 - 92 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Mobile elevator working platform
Oil drain pan

Bucket cylinder hoses: 27 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate

the machine, boom and two cranes.

2. Park the machine on the prepared flat area and position the
bucket on the ground with the bucket cylinders in fully
extended and the stick cylinders in fully retracted position
(Fig. 5-146).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to a location with appropriate ground condi-
tion.
Fig. 5-146

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 93

Backhoe Attachment

Fig. 5-147 Hoses of the bucket cylinders

5 - 94 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Backhoe

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

5. Remove the bolts (Fig. 5-147, Pos. 2) and disconnect the SAE-flanges of the corresponding hydraulic hose
(Fig. 5-147, Pos. 1) from the bucket cylinder and from the hydraulic tube (Fig. 5-147, Pos. 4) at the boom.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

6. Remove the hydraulic hose.

7. Replace the hydraulic hose by a new one and carry out assembling in reverse order of disassembling.

NOTE! Always replace the flat seals (Fig. 5-147, Pos. 3) at SAE-flange connections when installing the
hydraulic lines!
A flat and level sealing surface is essential for proper sealing!

b Tighten the mounting bolts (Fig. 5-147, Pos. 2) of SAE-flange connections according to the
KOMATSU company standard "Torques for SAE-flange connections", refer to section 6.6.5 on
page 6-19.

8. If required replace the other hydraulic hoses using the same procedure.

9. Perform the bleeding procedure for the bucket cylinder(s). Refer to the PARTS & SERVICE NEWS
No. "AH06524".

10. Add hydraulic oil up to the specified level.

11. Check for leaks and the cylinders operation.

12. Check hydraulic oil level again and add oil if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 95

Face shovel Attachment

5.3 FACE SHOVEL

5.3.1 OVERVIEW

Fig. 5-148 Face shovel attachment overview

(1) Bull clam bucket (clam) (5) Boom cylinder

(2) Bull clam bucket (wall) (6) Stick cylinder

(3) Stick (7) Bucket cylinder

(4) Boom

5 - 96 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

Please continue reading on the next page.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 97

Face shovel Attachment

5.3.2 USING THE CYLINDER MOUNTING DEVICE FOR FRONT SHOVEL

ATTACHMENTS (PN 967 000 40)
REMARKS: For further information refer to the PARTS & SERVICE NEWS No. "AH15840".

Fig. 5-149 Cylinder mounting device

In the following procedures the assembling and disassembling of the stick, boom and bucket cylinders are per-
formed using the cylinder mounting device shown in Fig. 5-149 as the most safest method.

The cylinder mounting device may only be used for the transport and for the assembling and disassembling of the
stick, boom and bucket cylinders for excavators with front shovel.

The cylinder mounting device is constructed according to the latest standards and the current valid safety regula-
tions. It has been tested for safety by Komatsu Germany GmbH and is flawlessly delivered by Komatsu Germany
GmbH to the owner.

A danger is present on the cylinder mounting device, when it has been improperly used or used in non-accordance
to its specifications.

REMARKS: Ask your local KOMATSU dealer for further information.

5 - 98 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

5.3.2.1 DESIGNATED USAGE

The cylinder mounting device is only designated to be used under the owner’s duty and observance of the operat-
ing instructions of the device and the following qualifications. Improper use may present mortal danger and/or
damage to property.

– The cylinder mounting device may only be used for the transport and for the assembling and disassembling of
the stick, boom and bucket cylinders for excavators with front shovel.
– Use together with a lifter with a lifting capacity greater than the sum of the weights of:
– The transport weight
– The own weight of the lifting element
– The weight of the sling gear
– Use of sling gear with a lifting capacity larger than the sum of the weights of:
– The transport weight
– the own weight of the sling gear
– The cylinder mounting device must only be erected, deployed, operated, maintained and disassembled in per-
fect condition by trained personnel in consideration of all valid safety and accident prevention measures. This
also includes the operation and maintenance conditions in these operating instructions.
– Compliance to the safety instructions, as well as all other instructions to functionality, operation, maintenance
and troubleshooting also belongs to designated usage.
– The machine may be used in compliance with the applicable technical data found on in the operating instruc-
tions of the device.
– The cylinder mounting device must be regularly maintained in accordance with stated maintenance intervals
by trained personnel. Worn parts must be regularly exchanged according to the amount and intensity of
usage.

5.3.2.2 NON-DESIGNATED USAGE

Other usage, apart from those stated in the designated usage above, or that go beyond those are classed as non
designated.

– The transporting load must never exceed the maximum permitted load stated on the bearing plate of the lifting
device.
– The machine must never be used for transporting people.
– It must never be used to transport other objects.
– It must never be used for extraction of tight-fitted objects.
– Never diagonal pull or lift loads.
– Never use with an improper lifting element or lifting gear. Lifting element and lifting gear must always adhere to
the maximum permitted load, must always be equipped with an appropriate hook and be in perfect working
condition.
– Never use a defective or damaged machine or use one that has exceeded its designated life-time.
– Unsafe transportation of load (e.g. swinging).
– Lifting loads above people or leaving loads unattended.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 99

Face shovel Attachment

5.3.3 BOOM

5.3.3.1 DISASSEMBLING OF THE BOOM

Special tools: n/a

Additional equipment: Safety harness in conformity with DIN EN 361

Mobile elevator working platform
2 x crane

Boom: 15,985 kg (boom only)

Pin boom/superstructure: 110 kg
Pin boom cylinder/superstructure: 84 kg

Dogman/rigger
Crane operators trained in dual crane lift

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

REMARKS: Before the disassembly of the attachment, the wear of the bushes of the attachment and at the
superstructure should be checked. Refer to the PARTS & SERVICE NEWS No. "AH08508".

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate the machine and the additional working equip-
ment (crane, mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat ground area with the attachment in an appropriate position for stick
removal, refer to section 5.3.4.1 on page 5-116.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to any location with appropriate ground condition.

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

5. Disassemble the stick cylinders from the boom, refer to section 5.3.4.3 on page 5-124.

6. Disassemble the stick, refer to section 5.3.4.1 on page 5-116.

7. Disassemble the bucket cylinders from the boom, refer to section 5.3.5.3 on page 5-140.

5 - 100 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

8. Attach the boom to a crane at the installed lifting points

(Fig. 5-150).

Fig. 5-150 Lifting points FSA boom

9. Disassemble the boom cylinders, refer to section 5.3.3.3 on page 5-106.

10. Disconnect the boom arc hoses and he grease feed lines from the boom, refer to section 5.3.6.1 on
page 5-160.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

11. Unplug and clear all wire harnesses from the boom.

12. Disassemble the two bolts (Fig. 5-151, Pos. 1) and the shack-
les (Fig. 5-151, Pos. 2) securing the pins (Fig. 5-151, Pos. 3)
of both boom foot bearings.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.
Fig. 5-151

13. Disassemble both pins (Fig. 5-151, Pos. 3) from the boom
foot bearings.
Remove the boom using the crane and place it on the ground
in an appropriate position.

14. Check bushings (Fig. 5-5, Pos. 4) for wear and damages.
Replace if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 101

Face shovel Attachment

Working steps and checks in the aftermath of disassembling:

15. Disassemble all provided parts (e.g. ladder, rails, hydraulic pipings, etc.) from the boom if required.

16. Disassemble the seal rings (Fig. 5-152, Pos. 2) from inside
the bushings (Fig. 5-152, Pos. 1). Discard the seal rings.

17. Check the bushings (Fig. 5-152, Pos. 1) of the boom foot
bearing and replace if required, refer to section 5.1.1 on
page 5-2.

Fig. 5-152

5 - 102 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

5.3.3.2 ASSEMBLING OF THE BOOM

Special tools: n/a

Additional equipment: Safety harness in conformity with DIN EN 361

Mobile elevator working platform
Crane
MPG (Multi Purpose Grease)

Boom: 15,985 kg (boom only)

Pin boom/superstructure: 110 kg
Pin boom cylinder/superstructure: 84 kg

Dogman/rigger
Crane operators trained in dual crane lift

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Assemble all provided parts (e.g. ladder, rails, hydraulic pipings, etc.) from the boom.

2. Insert new seal rings (Fig. 5-153, Pos. 2) into the grooves of
the bushings (Fig. 5-153, Pos. 1).

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings within the
bushings.

Fig. 5-153

3. Apply MPG (or roller bearing grease, or grease from the CLS system) on every bushing at the assembly!

4. Attach the boom to a crane at the installed lifting points

(Fig. 5-154).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

Fig. 5-154 Lifting points FSA boom

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 103

Face shovel Attachment

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from squeezing and sharing due to violent pressure from
sliding parts.

Align the parts with great caution. Never put hands through or into the bushings when aligning parts.

5. Align the boom to the boom foot bearings at the superstructure using the crane.

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the boom may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pins, the seals can get sheared between pin and the
sharp groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-155,
Pos. 2) within the bushings (Fig. 5-155, Pos. 1).
Fig. 5-155

6. Assemble both pins (Fig. 5-156, Pos. 3) of the boom foot

bearings.

REMARKS: Apply paste Aluminium Anti-Seize at the fixed por-

tion of the pin and the bushing (Fig. 5-156, Pos. 4)
of the pin bearing, refer to section 5.1.2 on
page 5-4.

7. Assemble the shackles (Fig. 5-156, Pos. 2) and two bolts

(Fig. 5-156, Pos. 1) to secure the pins (Fig. 5-156, Pos. 3) at
both boom foot bearings.

Fig. 5-156

8. Install the boom arc hoses and the grease feed lines from the boom, refer to section 5.3.6.1 on page 5-160.

9. Assemble the boom cylinders, refer to section 5.3.3.4 on page 5-111.

10. Detach the crane from the boom.

11. Assemble the stick cylinders at the boom, refer to section 5.3.4.4 on page 5-128.

12. Assemble the stick at the boom, refer to section 5.3.4.2 on page 5-120.

13. Assemble the bucket cylinders at the boom, refer to section 5.3.5.4 on page 5-144.

5 - 104 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 5-157 Exemplaric sketch

14. Assemble the bucket at the boom, refer to section 5.3.5.2 on page 5-136.

15. Replug and retain all wire harnesses at the boom.

16. De-isolate the machine according to local regulations.

17. Perform the bleeding procedure for the replacement bucket cylinder(s). Refer to the PARTS & SERVICE
NEWS No. "AH06524".

18. Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section
"HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and
to the PARTS & SERVICE NEWS No. "AH06519".

19. Add hydraulic oil up to the specified level.

20. Check for leaks and the cylinders operation.

21. Check the hydraulic oil level again and add oil if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 105

Face shovel Attachment

5.3.3.3 DISASSEMBLING OF THE BOOM CYLINDERS

Special tools: Cylinder mounting device (PN 967 000 40)

Additional equipment: Safety harness in conformity with DIN EN 361

Forklift
2 x crane
Chain hoist
2 x swivel hoist rings M30
Mobile elevator working platform (telescopic or articulated boom lift)
Oil drain pan

Boom cylinder: 2688 kg

Pin boom cylinder/superstructure: 84 kg
Pin boom cylinder/boom: 115 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms

REMARKS: At first the wear of the bushes in the hydraulic cylinder should be checked, refer to the PARTS &
SERVICE NEWS No. "AH08508".

1. Prepare an area of flat ground large enough to accommodate

the machine and the additional working equipment (crane,
mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area with the super-
structure turned by 90° and position the bucket on the ground
as shown (Fig. 5-158).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.
Fig. 5-158

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

5 - 106 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

5. Disconnect the grease lines (Fig. 5-159, Pos. 1) of the central

lubrication system from eyes of the corresponding boom cyl-
inder (Fig. 5-159, Pos. 2).

REMARKS: The eye at the piston rod at the boom cylinder bear-
ing at the superstructure is also connected to the
central lubrication system.

Fig. 5-159 Example:

Upper boom cylinder bearing

6. Insert swivel hoist rings M30 (Fig. 5-160, Pos. 3) into the
threads at the boom cylinder (Fig. 5-160, Pos. 1).

7. Fix the boom cylinder to the fixing eye (Fig. 5-160, Pos. 4) at
the boom using a chain hoist (Fig. 5-160, Pos. 2).

Fig. 5-160

8. Remove the bolt (Fig. 5-161, Pos. 3) and the shackle

(Fig. 5-161, Pos. 4) securing the pin (Fig. 5-161, Pos. 5).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

Fig. 5-161
9. Remove the pin (Fig. 5-161, Pos. 5) attaching the boom cylin-
der to the superstructure supported by a crane.

NOTE! Sling the pin as soon as possible and support it

using a crane to prevent the pin from falling.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 107

Face shovel Attachment

10. De-isolate the machine according to local regulations.

11. Switch 11S150 to Qmin.

12. Fully retract the boom cylinder at Qmin.

13. Tie the eye (Fig. 5-162, Pos. 2) at the piston rod side to the
cylinder body (Fig. 5-162, Pos. 1) using appropriate gear e.g.
stress ribbons (Fig. 5-162, Pos. 3) to prevent the piston rod
from moving while the hydraulic hoses are disconnected.

Fig. 5-162

14. Isolate the machine according to local regulations.

15. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any
hydraulic lines under pressure will result in blindness, seri-
ous injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic

lines will be removed.

16. Disconnect the SAE-hydraulic hoses (Fig. 5-163, Pos. 1 & 2)

from the boom cylinder (Fig. 5-163, Pos. 3).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation. Fig. 5-163

5 - 108 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

17. Lower the boom cylinder into vertical position using the chain hoist and detach the chain hoist.

18. Carry out the following steps at the cylinder mounting device
(PN 967 000 40), refer to the manual of the cylinder mounting
device:

– Secure the supporting rack.

– Preadjust the device.
– Mount the boom cylinder adapter.
– Adjust and erect the counterweight.
– Erect the cylinder mounting device and attach a crane.
19. Mount the cylinder mounting device (Fig. 5-164, Pos. 2) to the
boom cylinder (Fig. 5-164, Pos. 1), refer to the manual of the
cylinder mounting device.

REMARKS: Applying the cylinder mounting device is analo-

gously the same for boom and bucket cylinders.

Fig. 5-164 Use of the cylinder mounting

device (exemplaric sketch)

20. Disassemble the bolts (Fig. 5-165, Pos. 4) with washers

(Fig. 5-165, Pos. 3) and the shackle (Fig. 5-165, Pos. 2).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

Fig. 5-165
21. Pull pin (Fig. 5-165, Pos. 1) out just enough to clear the boom
cylinder from the boom.

REMARKS: The pin remains in the bore of the outer pin bearing.

22. Remove the boom cylinder using the cylinder mounting device.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 109

Face shovel Attachment

Working steps and checks in the aftermath of disassembling:

23. Disassemble the seal rings (Fig. 5-166, Pos. 2) from inside
the bushings (Fig. 5-166, Pos. 3). Discard the seal rings.

24. Check the bushings (Fig. 5-166, Pos. 3) of the boom cylinder
(Fig. 5-166, Pos. 1) for wear and damage.
Replace the bushings if required, refer to section 5.1.1 on
page 5-2.

Fig. 5-166

5 - 110 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

5.3.3.4 ASSEMBLING OF THE BOOM CYLINDERS

Special tools: Cylinder mounting device (PN 967 000 40)

Additional equipment: Safety harness in conformity with DIN EN 361

Crane
Chain hoist
2 x swivel hoist rings M30
Mobile elevator working platform (telescopic or articulated boom lift)
MPG (Multi Purpose Grease)
Paste Aluminium Anti-Seize, PN 509 623 98

Boom cylinder: 2688 kg

Pin boom cylinder/superstructure: 84 kg
Pin boom cylinder/boom: 115 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Clean the pins and bushings very carefully and thoroughly. These parts must be completely free of dirt, corro-
sion, or any protective coating.

2. At first only insert new seal rings (Fig. 5-167, Pos. 2) into the
grooves of the bushings (Fig. 5-167, Pos. 3).

REMARKS: For details refer to Fig. 5-170 on page 5-112 and

Fig. 5-177 on page 5-115.

Fig. 5-167

3. Apply MPG (or roller bearing grease, or grease from the CLS system) on every bushing at the assembly.

4. Insert swivel hoist rings M30 into the threads (Fig. 5-168,
Pos. 1) at the replacement boom cylinder (Fig. 5-168,
Pos. 2).

5. Tie the eye at the piston rod side to the cylinder body using
appropriate gear e.g. stress ribbons to prevent the piston rod
from moving while the hydraulic hoses are disconnected
(refer to Fig. 5-170 on page 5-112).

Fig. 5-168

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 111

Face shovel Attachment

6. Carry out the following steps at the cylinder mounting device

(PN 967 000 40), refer to the manual of the cylinder mounting
device:

– Remove the defective cylinder.

– Mount the replacement cylinder on the v-blocks of the
device.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.
Fig. 5-169 Use of the cylinder mounting
device (exemplaric sketch)
7. Lift the boom cylinder (Fig. 5-169, Pos. 1) into mounting posi-
tion using the cylinder mounting device (Fig. 5-169, Pos. 2).

REMARKS: Applying the cylinder mounting device is analo-

gously the same for boom and bucket cylinders.

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from squeezing and sharing due to violent pressure from
sliding parts.

Align the parts with great caution. Never put hands through or into the bushings when aligning parts.

8. Align the boom cylinder to the boom using the cylinder mounting device, refer to the manual of the cylinder
mounting device.

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the boom cylinder may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pin, the seals can get sheared between pin and the sharp
groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-170,
Pos. 2) within the bushings (Fig. 5-170, Pos. 1).
Fig. 5-170

5 - 112 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

9. Push the pin (Fig. 5-171, Pos. 1) into the cylinder eye.
Fig. 5-171
10. Assemble the shackle (Fig. 5-171, Pos. 2) and secure it with
the bolts (Fig. 5-171, Pos. 4) and washers (Fig. 5-171,
Pos. 3).

11. Detach the cylinder mounting device from the boom cylinder, refer to the manual of the cylinder mounting
device.

12. Attach a chain hoist (Fig. 5-172, Pos. 2) to the fixing eye
(Fig. 5-172, Pos. 4) at the boom and at the swivel hoist ring
(Fig. 5-172, Pos. 3) at the boom cylinder (Fig. 5-172, Pos. 1).

13. Using the chain hoist move the boom cylinder into a position
in which the SAE-hydraulic hoses can be installed at the cyl-
inder.

Fig. 5-172

14. Install the SAE-hydraulic hoses (Fig. 5-173, Pos. 1 & 2) at the
boom cylinder (Fig. 5-173, Pos. 3).

Fig. 5-173

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 113

Face shovel Attachment

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 5-174 Exemplaric sketch

15. De-isolate the machine according to local regulations.

16. Switch 11S150 to Qmin. and fully retract the boom cylinder at Qmin.

17. Remove the gear e.g. stress ribbons (Fig. 5-175, Pos. 3)
securing the eye (Fig. 5-175, Pos. 2) at the piston rod side
from the cylinder body (Fig. 5-175, Pos. 1).

WARNING
AIR IN THE HYDRAULIC CYLINDER!
May result in personal injury due to slightly jerky movements
of the cylinder when it is operated. The jerky movements are
caused by the air in the cylinder which is compressible.

Make sure that nobody is in close range to the cylinder when

it is operated with only one end connected to the attachment.

18. Extend and retract the boom cylinder slowly at Qmin 2...3
times as far as possible to partly bleed the cylinder.
Fig. 5-175

19. Isolate the machine according to local regulations.

20. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from
squeezing and sharing due to violent pressure from sliding
parts.

Align the parts with great caution. Never put hands through
or into the bushings when aligning parts.

21. Extend / retract the boom cylinder (Fig. 5-176, Pos. 1) slowly
at Qmin and use the chain hoist connected to the boom Fig. 5-176
(Fig. 5-176, Pos. 2), to align the piston rod eye of the boom
cylinder to the cylinder foot bearing at the superstructure.

5 - 114 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the boom cylinder may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pins, the seals can get sheared between pin and the
sharp groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-177,
Pos. 2) within the bushing (Fig. 5-177, Pos. 1).
Fig. 5-177

22. Assemble the pin (Fig. 5-176, Pos. 5) and install the shackle (Fig. 5-176, Pos. 4) and the bolt (Fig. 5-176,
Pos. 3) with washers to secure the pin.

23. Isolate the machine according to local regulations.

24. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

25. Detach the chain hoist from the boom cylinder body.

26. Connect the grease lines (Fig. 5-178, Pos. 1) of the central
lubrication system at eyes of the corresponding boom cylin-
der (Fig. 5-178, Pos. 2).

REMARKS: The eye at the piston rod at the boom cylinder bear-
ing at the superstructure is also connected to the
central lubrication system.

Fig. 5-178 Example:

Upper boom cylinder bearing

27. Switch 11S150 back to normal condition.

28. De-isolate the machine according to local regulations.

29. Perform the complete bleeding procedure for the attachment cylinders, refer to the PARTS & SERVICE NEWS
No. "AH06524".

30. Add hydraulic oil up to the specified level.

31. Check for leaks and the cylinders operation.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 115

Face shovel Attachment

5.3.4 STICK ASSEMBLY

5.3.4.1 DISASSEMBLING OF THE STICK

Special tools: n/a

Additional equipment: Safety harness in conformity with DIN EN 361

Crane
Chain hoist
Mobile elevator working platform (telescopic or articulated boom lift)

Stick: 8970 kg
Pin stick/boom: 135 kg
Pin stick cylinder/stick: 52 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate

the machine and the additional working equipment (crane,
mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area with the super-
structure turned by 90° and position the bucket on the ground
as shown (Fig. 5-179).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.
Fig. 5-179

3. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

4. Isolate the machine according to local regulations.

5. Disassemble the bull clam bucket, refer to section 5.3.5.1 on page 5-132.

6. Support the bucket cylinders in not fully retracted position using appropriate supporting stands, to prevent the
cylinder bodies from moving when the hydraulic hoses are disconnected.

7. Disconnect and clear all electric wires from the stick.

5 - 116 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

8. Hook up both stick cylinders (Fig. 5-180, Pos. 1) at the

installed eye (Fig. 5-180, Pos. 3) at the boom using chain
hoists (Fig. 5-180, Pos. 2).

Fig. 5-180

9. Attach the stick to a crane at the installed lifting points

(Fig. 5-181).

Fig. 5-181

10. Clear both stick cylinders from the stick:

– Disassemble the bolts (Fig. 5-182, Pos. 1).

– Disassemble the catches (Fig. 5-182, Pos. 2) securing the
pins.
– Pull the pins (Fig. 5-182, Pos. 3) out just enough to clear
the stick cylinder eyes (Fig. 5-182, Pos. 4) from the stick.
REMARKS: The pins remain in the bore of the stick cylinder eye
(Fig. 5-182, Pos. 4).

11. Lift the stick using the crane, just enough to re-install the pins.

12. For safety reasons re-install the pins (Fig. 5-182, Pos. 3) and
Fig. 5-182
the catches (Fig. 5-182, Pos. 2).

REMARKS: Leave the cylinders in that position for easier align-

ment while assembling.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 117

Face shovel Attachment

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

13. Disconnect the SAE-hydraulic hoses of the bucket and clam cylinders from the stick, refer to section 5.3.6.3
on page 5-168.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

14. Disconnect the hose of the grease line (in the center of the boom) of the central lubrication system leading to
the stick.

15. At both sides of the stick:

Disassemble the bolts (Fig. 5-183, Pos. 3), the washers
(Fig. 5-183, Pos. 4) and the shackles (Fig. 5-183, Pos. 2).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

16. At both sides of the stick:

Pull pins (Fig. 5-183, Pos. 5) out just enough to clear the stick
(Fig. 5-183, Pos. 1).

REMARKS: The pins remain in the bore of the outer pin bearing
at the boom.

Fig. 5-183

17. Remove the stick using the crane and place it on the ground in an appropriate position.

5 - 118 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

Working steps and checks in the aftermath of disassembling:

18. Disassemble all provided parts and hydraulic pipings from the stick if required.

Fig. 5-184 Bushings at the stick assembly

19. Disassemble the seal rings (Fig. 5-184, Pos. 2 & 3) from inside the bushings (Fig. 5-184, Pos. 4 & 5). Discard
the seal rings.

20. Check all bushings (Fig. 5-184, Pos. 4 to 5) at the stick (Fig. 5-184, Pos. 1) for wear and damage.
Replace the bushings if required, refer to section 5.1.1 on page 5-2.

NOTE! Note the mounting position of the seal ring grooves at the bushings (Fig. 5-184, Pos. 4).

REMARKS: The collar bushings (Fig. 5-184, Pos. 6) at the bucket bearing are each equipped with a thrust ring
(Fig. 5-184, Pos. 7) that is shrink-fitted on the collar bushing. Always replace bushings and thrust
rings together at the same time.

21. Check the collar bushings (Fig. 5-184, Pos. 6) and the rings (Fig. 5-184, Pos. 7) for wear and damage.
Replace the collar bushings and the rings if required, refer to section 5.1.1 on page 5-2.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 119

Face shovel Attachment

5.3.4.2 ASSEMBLING OF THE STICK

Special tools: n/a

Additional equipment: Safety harness in conformity with DIN EN 361

Crane
Chain hoist
Mobile elevator working platform (telescopic or articulated boom lift)
MPG (Multi Purpose Grease)
Paste Aluminium Anti-Seize, PN 509 623 98

Stick: 8970 kg
Pin stick/boom: 135 kg
Pin stick cylinder/stick: 52 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Clean all pins and bushings very carefully and thoroughly. These parts must be completely free of dirt, corro-
sion, or any protective coating.

2. Install all provided parts and hydraulic pipings at the stick.

3. Apply MPG (or roller bearing grease, or grease from the CLS system) on every bushing at the assembly.

4. Insert new seal rings (Fig. 5-184, Pos. 2 & 3) into the grooves of the bushings (Fig. 5-184, Pos. 4 to 5) at the
assembly. For details refer to Fig. 5-187 on page 5-121 and Fig. 5-188 on page 5-122.

REMARKS: Use MPG (or roller bearing grease, or grease from the CLS system) to center the seal rings within
the bushings.

5. Attach the stick to a crane at the installed lifting points

(Fig. 5-185).

Fig. 5-185

5 - 120 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

6. Lift the stick (Fig. 5-186, Pos. 1) into mounting position for the
pins connecting the boom with the stick, using the crane.

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from
squeezing and sharing due to violent pressure from sliding
parts.

Align the parts with great caution. Never put hands through
or into the bushings when aligning parts. Fig. 5-186

7. Align the stick to the boom.

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the stick may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pins, the seals can get sheared between pin and the
sharp groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-187,
Pos. 2) within the bushings (Fig. 5-187, Pos. 1).
Fig. 5-187

8. Push the pins (Fig. 5-186, Pos. 5) into the stick bearings.

REMARKS: Apply paste Aluminium Anti-Seize at the fixed portion of the pin and the pin fixing point of the pin
bearing, refer to section 5.1.2 on page 5-4.

9. Assemble the shackles (Fig. 5-186, Pos. 2), the washers (Fig. 5-186, Pos. 4), and the bolts (Fig. 5-186,
Pos. 3) securing the pin.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 121

Face shovel Attachment

10. Swivel the stick into the mounting position for the stick cylinders using the crane.

REMARKS: For safety reasons the pins were re-installed in the stick cylinders. Disassemble the pins as
described beginning with step 10 on page 5-117.

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the stick may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pins, the seals can get sheared between pin and the
sharp groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-188,
Pos. 2) within the bushing (Fig. 5-188, Pos. 1).
Fig. 5-188

11. Install the pins (Fig. 5-189, Pos. 3) at both stick cylinders
(Fig. 5-189, Pos. 4).

REMARKS: Apply paste Aluminium Anti-Seize at the fixed por-

tion of the pin and the pin fixing point of the pin bear-
ing, refer to section 5.1.2 on page 5-4.

12. Mount the catches (Fig. 5-189, Pos. 2) securing the pins and
assemble the bolts (Fig. 5-189, Pos. 1).

13. Detach the crane from the stick.

Fig. 5-189

14. Unchain the stick cylinders from the boom.

15. Connect the SAE-hydraulic hoses of the bucket and clam cylinders at the stick, refer to section 5.3.6.3 on
page 5-168.

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 5-190 Exemplaric sketch

5 - 122 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

16. Connect the hose of the grease line (in the center of the boom) of the central lubrication system leading to the
stick.

17. De-isolate the machine according to local regulations.

18. Switch 11S150 to Qmin.

19. Fully retract the bucket cylinder.

20. Remove the supporting stands that prevented the bucket cylinders from moving while the hydraulic hoses
were disconnected.

WARNING
AIR IN THE HYDRAULIC CYLINDER!
May result in personal injury due to slightly jerky movements of the cylinder when it is operated. The jerky
movements are caused by the air in the cylinder which is compressible.

Make sure that nobody is in close range to the cylinder when it is operated with only one end connected to
the attachment.

21. Extend and retract the bucket cylinder slowly at Qmin 2...3 times as far as possible to partly bleed the cylinder.

22. Isolate the machine according to local regulations.

23. Replug and retain all wire harnesses at the boom.

24. Assemble the bull clam bucket, refer to section 5.3.5.2 on page 5-136.

25. Switch 11S150 back to normal condition.

26. De-isolate the machine according to local regulations.

27. Perform the bleeding procedure for the replacement bucket cylinder(s). Refer to the PARTS & SERVICE
NEWS No. "AH06524".

28. Add hydraulic oil up to the specified level.

29. Check for leaks and the cylinders operation.

30. Check the hydraulic oil level again and add oil if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 123

Face shovel Attachment

5.3.4.3 DISASSEMBLING OF THE STICK CYLINDERS

Special tools: Cylinder mounting device (PN 967 000 40)

Additional equipment: Safety harness in conformity with DIN EN 361

2 x chain hoist
Crane
Forklift
Mobile elevator working platform (telescopic or articulated boom lift)
Oil drain pan

Stick cylinder: 1635 kg

Pin stick cylinder/boom: 60.5 kg
Pin stick cylinder/stick: 52 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

REMARKS: At first the wear of the bushes in the hydraulic cylinders should be checked, refer to the PARTS &
SERVICE NEWS No. "AH08508".

1. Prepare an area of flat ground large enough to accommodate

the machine and the additional working equipment (crane,
mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area with the super-
structure turned by 90° and position the bucket on the ground
as shown (Fig. 5-191).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.
Fig. 5-191

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

5 - 124 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

5. Hook up the corresponding stick cylinder (Fig. 5-192, Pos. 1)

at the installed eye (Fig. 5-192, Pos. 3) at the boom using a
chain hoist (Fig. 5-192, Pos. 2).

Fig. 5-192

6. Disassemble the bolts (Fig. 5-193, Pos. 1).

7. Disassemble the catches (Fig. 5-193, Pos. 2) securing the

pin.

8. Pull the pin (Fig. 5-193, Pos. 3) out just enough to clear the
stick cylinder eye (Fig. 5-193, Pos. 4) from the stick.

REMARKS: The pin remains in the bore of the stick cylinder eye
(Fig. 5-193, Pos. 4).

Fig. 5-193

9. Move the stick cylinder into horizontal position using the chain hoist.

10. De-isolate the machine according to local regulations.

11. Switch 11S150 to Qmin.

12. For safety reasons re-install the pins (Fig. 5-193, Pos. 3) and the catches (Fig. 5-193, Pos. 2) as soon as pos-
sible to prevent the pins from falling down.

13. Fully retract the stick cylinder at Qmin.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 125

Face shovel Attachment

14. Carry out the following steps at the cylinder mounting device
(PN 967 000 40), refer to the manual of the cylinder mounting
device:

– Secure the supporting rack.

– Mount and pre-adjust the stick cylinder adapter.
– Adjust and erect the counterweight.
– Erect the cylinder mounting device and attach a crane.
15. Mount the cylinder mounting device (Fig. 5-194, Pos. 2) to the
stick cylinder (Fig. 5-194, Pos. 1), refer to the manual of the
cylinder mounting device.

Fig. 5-194 Use of the cylinder mounting

device

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

16. Disconnect the hydraulic hoses from the stick cylinder, refer to section 5.3.6.4 on page 5-176.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

5 - 126 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

17. Remove the bolts (Fig. 5-195, Pos. 1), the washers, and the
shackle (Fig. 5-195, Pos. 2), securing the pin (Fig. 5-195,
Pos. 3).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

18. Pull out the pin (Fig. 5-195, Pos. 3) just far enough to clear
the cylinder to be removed.
Fig. 5-195
REMARKS: The pin remains in the bore of the stick cylinder eye.

19. Remove the stick cylinder using the cylinder mounting device.

NOTE! For safety reasons re-install the pin (Fig. 5-195, Pos. 3) and the shackle (Fig. 5-195, Pos. 2) as soon
as possible to prevent the pins from falling down.

Working steps and checks in the aftermath of disassembling:

20. Disassemble the seal rings (Fig. 5-195, Pos. 4) from inside the bushing (Fig. 5-195, Pos. 5) of the stick cylin-
der bearing at the boom.
Discard the seal rings.

21. Check the bushing (Fig. 5-195, Pos. 5) at the boom for wear and damage.
Replace the bushings if required, refer to section 5.1.1 on page 5-2.

22. Refer to Fig. 5-184 on page 5-119:

Disassemble the seal ring (Fig. 5-184, Pos. 3) from inside the bushings (Fig. 5-184, Pos. 5) of the stick cylin-
der bearings at the stick.
Discard the seal rings.

23. Refer to Fig. 5-184 on page 5-119:

Check the bushings (Fig. 5-184, Pos. 5) at the stick for wear and damage.
Replace the bushings if required, refer to section 5.1.1 on page 5-2.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 127

Face shovel Attachment

5.3.4.4 ASSEMBLING OF THE STICK CYLINDERS

Special tools: n/a

Additional equipment: Safety harness in conformity with DIN EN 361

Forklift
Crane
2 x chain hoist
Crane
Mobile elevator working platform (telescopic or articulated boom lift)

Stick cylinder: 1635 kg

Pin stick cylinder/boom: 60.5 kg
Pin stick cylinder/stick: 52 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Clean all pins and bushings very carefully and thoroughly. These parts must be completely free of dirt, corro-
sion, or any protective coating.

2. Refer to Fig. 5-184 on page 5-119:

Insert new seal rings (Fig. 5-184, Pos. 3) into the grooves of the bushings (Fig. 5-184, Pos. 5) of the stick cyl-
inder bearings at the stick.
For details refer to Fig. 5-187 on page 5-121.

3. Insert new seals (Fig. 5-196, Pos. 4) into the grooves of the
bushing (Fig. 5-196, Pos. 5) of the boom.
For details refer to Fig. 5-198 on page 5-129.

Fig. 5-196

5 - 128 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

4. Carry out the following steps at the cylinder mounting device,

refer to the manual of the cylinder mounting device:

– Remove the defective cylinder.

– Mount the replacement cylinder on the v-blocks of the
device.
REMARKS: For safety reasons the pins are re-installed in the
stick cylinders. Disassemble the pins as described
beginning with step 17 on page 5-127.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that Fig. 5-197 Use of the cylinder mounting
nobody steps below or in close range to the lifted machine device
part.

5. Lift the stick cylinder (Fig. 5-197, Pos. 1) into mounting posi-
tion using the cylinder mounting device (Fig. 5-197, Pos. 2).

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the boom may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pins, the seals can get sheared between pin and the
sharp groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-198,
Pos. 2) within the bushing (Fig. 5-198, Pos. 1).
Fig. 5-198

6. Assemble the pin (Fig. 5-196, Pos. 3).

REMARKS: Apply paste Aluminium Anti-Seize at the fixed portion of the pin and the pin fixing point of the pin
bearing, refer to section 5.1.2 on page 5-4.

7. Assemble the shackle (Fig. 5-196, Pos. 2), the washers, and the bolts (Fig. 5-196, Pos. 1) to secure the pin.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 129

Face shovel Attachment

8. Install the SAE-hydraulic hoses at the stick cylinder, refer to section 5.3.6.4 on page 5-176.

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 5-199 Exemplaric sketch

9. Hook up the corresponding stick cylinder (Fig. 5-200, Pos. 1)

at the installed eye (Fig. 5-200, Pos. 3) at the boom using a
chain hoist (Fig. 5-200, Pos. 2).

10. Detach the cylinder mounting device from the stick cylinder,
refer to the manual of the cylinder mounting device.

Fig. 5-200

11. De-isolate the machine according to local regulations.

12. Switch 11S150 to Qmin.

WARNING
AIR IN THE HYDRAULIC CYLINDER!
May result in personal injury due to slightly jerky movements of the cylinder when it is operated. The jerky
movements are caused by the air in the cylinder which is compressible.

Make sure that nobody is in close range to the cylinder when it is operated with only one end connected to
the attachment.

13. Extend and retract the stick cylinder slowly at Qmin 2…3 times as far as possible to partly bleed the cylinder.

5 - 130 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

REMARKS: For safety reasons the pins are re-installed in the stick cylinders. Disassemble the pins as described
beginning with step 6 on page 5-125.

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the stick may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pins, the seals can get sheared between pin and the
sharp groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-187,
Pos. 2) within the bushings (Fig. 5-187, Pos. 1).
Fig. 5-201

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from
squeezing and sharing due to violent pressure from sliding
parts.

Align the parts with great caution. Never put hands through
or into the bushings when aligning parts.

14. Extend / retract the stick cylinder slowly at Qmin. Use the
chain hoist (see Fig. 5-200, Pos. 2) to align the piston rod eye Fig. 5-202
of the stick cylinder (Fig. 5-202, Pos. 4) to the cylinder bear-
ing at the stick.

15. Assemble the pin (Fig. 5-202, Pos. 3).

REMARKS: Apply paste Aluminium Anti-Seize at the fixed portion of the pin and the pin fixing point of the pin
bearing, refer to section 5.1.2 on page 5-4.

16. Assemble the catch (Fig. 5-202, Pos. 2) and the bolts (Fig. 5-202, Pos. 1) securing the pin.

17. Switch 11S150 back to normal condition.

18. Perform the bleeding procedure for the replacement bucket cylinder(s). Refer to the PARTS & SERVICE
NEWS No. "AH06524".

19. Add specified hydraulic oil up to the specified level.

20. Check for leaks and the cylinders operation.

21. Check the hydraulic oil level again and add oil if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 131

Face shovel Attachment

5.3.5 BULL CLAM BUCKET

5.3.5.1 DISASSEMBLING OF THE BULL CLAM BUCKET

Special tools: n/a

Additional equipment: Oil drain pan

Bucket 15 m³: 16,565 kg

Pin bucket cylinder/bucket: 83 kg
Pin bucket/stick: 133 kg

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate

the machine and the additional working equipment (crane,
mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area with the super-
structure turned by 90° and position the bucket on the ground
as shown (Fig. 5-203).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.
Fig. 5-203

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

5. Safeguard the bucket using appropriate blocks and wedges.

6. At both sides of the bucket:

Remove the plates (Fig. 5-204, Pos. 2) from the bucket
(Fig. 5-204, Pos. 1) to access the pins.

Fig. 5-204

5 - 132 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any
hydraulic lines under pressure will result in blindness, seri-
ous injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic

lines will be removed.

7. Disconnect the hydraulic hoses (Fig. 5-205, Pos. 1 & 2) of the

clam cylinders from the distributor blocks. Fig. 5-205
REMARKS: When a hydraulic line is disconnected hydraulic oil
will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation.

8. Disconnect the grease line of the central lubrication system from the bucket (not shown in Fig. 5-205 but
located just below the distributor blocks).

9. Disassemble the seal fixing rings (Fig. 5-206, Pos. 1) located

on both sides of the bucket cylinders.

10. Disassemble the covers (Fig. 5-206, Pos. 2) from both bucket
cylinder bearings.

Fig. 5-206

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 133

Face shovel Attachment

11. Tie the bucket cylinders to the stick using appropriate gear
e.g. stress ribbons to prevent the bucket cylinders from
swinging when the pins are disassembled.

12. Disassemble the catches (Fig. 5-207, Pos. 2) securing the

pins of both bucket cylinders.

13. Move the pins (Fig. 5-207, Pos. 1) out just enough to clear the
bucket cylinders.

REMARKS: Both pins remain in the bore of the outer pin bear-
ings at the bucket (Fig. 5-207, Pos. 3).

Fig. 5-207

14. Disassemble the seal fixing rings (Fig. 5-208, Pos. 1) located
on both sides of the sick.

15. Disassemble the covers (Fig. 5-208, Pos. 2) from both stick
bearings.

Fig. 5-208

16. Disassemble the catches (Fig. 5-209, Pos. 2) securing the

pins at the stick.

17. Move the pins (Fig. 5-209, Pos. 1) out just enough to clear the
stick.

REMARKS: Both pins remain in the bores of the outer pin bear-
ings at the bucket (Fig. 5-209, Pos. 3).

Fig. 5-209

18. De-isolate the machine according to local regulations.

19. Lift the boom and move the excavator away.

20. Isolate the machine according to local regulations.

5 - 134 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

Working steps and checks in the aftermath of disassembling:

21. Check the bushings (Fig. 5-210, Pos. 1) of the bucket cylinder
for wear and damage.
Replace the bushings if required, refer to section 5.1.1 on
page 5-2.

Fig. 5-210

REMARKS: The collar bushings (Fig. 5-211, Pos. 1) at the

bucket bearings of the stick (Fig. 5-211, Pos. 3) are
each equipped with a thrust ring (Fig. 5-211, Pos. 2)
that is shrink-fitted on the collar bushing.
Also refer to Fig. 5-184 on page 5-119.
Always replace bushings and thrust rings together
at the same time.

22. Check the collar bushings (Fig. 5-211, Pos. 1) and the rings
(Fig. 5-211, Pos. 2) for wear and damage.
Replace the collar bushings and the rings if required, refer to
section 5.1.1 on page 5-2.

Fig. 5-211

At both sides of the bucket:

23. Remove the seal rings (Fig. 5-212, Pos. 2) that are slipped
over the collar bushings (Fig. 5-212, Pos. 1) in the bucket
(Fig. 5-212, Pos. 3).

24. Remove the seal rings (Fig. 5-212, Pos. 4) that are slipped
over the shrink-fitted rings (Fig. 5-212, Pos. 5) in the bucket.

25. Discard all removed seal rings.

REMARKS: The collar bushings (Fig. 5-212, Pos. 6) at the stick

bearings of the bucket are each equipped with a
thrust ring (Fig. 5-212, Pos. 5) that is shrink-fitted on
the collar bushing.
Always replace bushings and thrust rings together
at the same time.

26. Check the collar bushings (Fig. 5-212, Pos. 6) and the rings Fig. 5-212
(Fig. 5-212, Pos. 5) for wear and damage.
Replace the collar bushings and the rings if required, refer to
section 5.1.1 on page 5-2.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 135

Face shovel Attachment

5.3.5.2 ASSEMBLING OF THE BULL CLAM BUCKET

Special tools: n/a

Additional equipment: MPG (Multi Purpose Grease)

Paste Aluminium Anti-Seize, PN 509 623 98

Bucket 15 m³: 16,565 kg

Pin bucket cylinder/bucket: 83 kg
Pin bucket/stick: 133 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Clean all pins and bushings very carefully and thoroughly. These parts must be completely free of dirt, corro-
sion, or any protective coating.

2. Safeguard the bucket using appropriate blocks and wedges.

3. Apply MPG (or roller bearing grease, or grease from the CLS system) on every bushing at the assembly.

At both sides of the bucket (Fig. 5-213, Pos. 3):

4. Slip new seal rings (Fig. 5-213, Pos. 4) over the rings
(Fig. 5-213, Pos. 5) shrink-fitted on the collar bushings
(Fig. 5-213, Pos. 6).

5. Slip new seal rings (Fig. 5-213, Pos. 2) over the collar bush-
ings (Fig. 5-213, Pos. 1).

REMARKS: During assembling there is not enough space to

insert these seal rings.

Fig. 5-213

6. De-isolate the machine according to local regulations.

7. Switch 11S150 to Qmin.

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from squeezing and sharing due to violent pressure from
sliding parts.

Align the parts with great caution. Never put hands through or into the bushings when aligning parts.

8. Move the excavator to the bucket and align the stick to the bucket at Qmin.

9. Isolate the machine according to local regulations.^

10. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

5 - 136 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

Precondition:
The pin is yet in disassembling position, inserted in the bore of the
outer pin bearing at the bucket (Fig. 5-214, Pos. 3).

11. Push the pin (Fig. 5-214, Pos. 1) in, just enough to insert the
catches (Fig. 5-214, Pos. 2).

REMARKS: Apply paste Aluminium Anti-Seize at the fixed por-

tion of the pin and the pin fixing point of the pin bear-
ing, refer to section 5.1.2 on page 5-4.

12. Assemble the catches (Fig. 5-214, Pos. 2) securing the pin.

Fig. 5-214

13. Assemble the covers (Fig. 5-215, Pos. 2) at both stick bear-
ings.

14. Assemble the seal fixing rings (Fig. 5-215, Pos. 1) located on
both sides of the sick.

Fig. 5-215

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from squeezing and sharing due to violent pressure from
sliding parts.

Align the parts with great caution. Never put hands through or into the bushings when aligning parts.

15. Align the bucket cylinders to the bucket.

Precondition:
Both pins are yet in disassembling position, inserted in the bores
of the outer pin bearings at the bucket (Fig. 5-216, Pos. 3).

16. Push the pins (Fig. 5-216, Pos. 1) at both bucket cylinders in,
just enough to insert the catches (Fig. 5-216, Pos. 2).

REMARKS: Apply paste Aluminium Anti-Seize at the fixed por-

tion of the pin and the pin fixing point of the pin bear-
ing, refer to section 5.1.2 on page 5-4.

17. Assemble the catches (Fig. 5-216, Pos. 2) securing the pins.

Fig. 5-216

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 137

Face shovel Attachment

18. Assemble the covers (Fig. 5-217, Pos. 2) at both bucket cylin-
der bearings.

19. Assemble the seal fixing rings (Fig. 5-217, Pos. 1) located on
both sides of the corresponding bucket cylinder.

Fig. 5-217

20. Connect the grease line of the central lubrication system at

the bucket (not shown in Fig. 5-218 but located just below the
distributor blocks) of the hydraulic hoses.

21. Connect the hydraulic hoses (Fig. 5-218, Pos. 1 & 2) of the
clam cylinders.

Fig. 5-218

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 5-219 Exemplaric sketch

5 - 138 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

22. At both sides of the bucket:

Assemble the plates (Fig. 5-220, Pos. 2) at the bucket
(Fig. 5-220, Pos. 1).

Fig. 5-220

23. De-isolate the machine according to local regulations.

24. Switch 11S150 back to normal condition.

25. Perform the bleeding procedure for the replacement bucket cylinder(s). Refer to the PARTS & SERVICE
NEWS No. "AH06524".

26. Add specified hydraulic oil up to the specified level.

27. Check for leaks and the cylinders operation.

28. Check the hydraulic oil level again and add oil if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 139

Face shovel Attachment

5.3.5.3 DISASSEMBLING OF THE BUCKET CYLINDERS

Special tools: Cylinder mounting device (PN 967 000 40)

Additional equipment: Safety harness in conformity with DIN EN 361

Crane
Forklift
Mobile elevator working platform (telescopic or articulated boom lift)
Oil drain pan

Bucket cylinder: 1787 kg

Pin bucket cylinder/boom: 79 kg
Pin bucket cylinder/bucket: 83 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms

REMARKS: At first the wear of the bushes in the hydraulic cylinder should be checked, refer to the PARTS &
SERVICE NEWS No. "AH08508".

1. Prepare an area of flat ground large enough to accommodate

the machine and the additional working equipment (crane,
mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area with the super-
structure turned by 90° and position the bucket on the ground
as shown (Fig. 5-221).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.
Fig. 5-221

3. Safeguard the bucket using appropriate blocks and wedges.

4. Isolate the machine according to local regulations.

5. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

6. Disconnect the grease line of the central lubrication system from the eye at the bucket cylinder piston rod.

5 - 140 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

7. Disconnect the grease lines (Fig. 5-222, Pos. 2) of the central

lubrication system from the corresponding bucket cylinder
(Fig. 5-222, Pos. 1).

Fig. 5-222

8. Disassemble the seal fixing rings (Fig. 5-223, Pos. 1) located

on both sides of the bucket cylinder to be disassembled.

9. Disassemble the cover (Fig. 5-223, Pos. 2) from the bucket

cylinder bearing.

Fig. 5-223

10. Disassemble the catches (Fig. 5-224, Pos. 2) securing the

pin.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

Fig. 5-224
11. Push the pin (Fig. 5-224, Pos. 1) out just enough to clear the
bucket cylinders.

REMARKS: The pin remains in the bore of the outer pin bearing
at the bucket (Fig. 5-224, Pos. 3).

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 141

Face shovel Attachment

12. De-isolate the machine according to local regulations.

13. Switch 11S150 to Qmin.

14. Fully retract the bucket cylinder at Qmin.

15. Isolate the machine according to local regulations.

16. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

17. Carry out the following steps at the cylinder mounting device
(PN 967 000 40), refer to the manual of the cylinder mounting
device:

– Secure the supporting rack.

– Preadjust the device.
– Mount the boom cylinder adapter.
– Adjust and erect the counterweight.
– Erect the cylinder mounting device and attach a crane.
18. Mount the cylinder mounting device (Fig. 5-225, Pos. 2) to the
bucket cylinder (Fig. 5-225, Pos. 1), refer to the manual of the
cylinder mounting device.

REMARKS: Applying the cylinder mounting device is analo-

gously the same for boom and bucket cylinders.

Fig. 5-225 Use of the cylinder mounting

device (exemplaric sketch)

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any
hydraulic lines under pressure will result in blindness, seri-
ous injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic

lines will be removed.

19. Disconnect the hydraulic lines (Fig. 5-226, Pos. 2 and 3) from
the bucket cylinder (Fig. 5-226, Pos. 1).

REMARKS: When a hydraulic line is disconnected hydraulic oil

will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contami-
nation. Fig. 5-226

5 - 142 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

20. Disassemble the bolts (Fig. 5-227, Pos. 3) with washers

(Fig. 5-227, Pos. 2) and the shackle (Fig. 5-227, Pos. 4).

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

Fig. 5-227
21. Pull pin (Fig. 5-227, Pos. 1) out just enough to clear the
bucket cylinder eye.

REMARKS: The pin remains in the bore of the outer pin bearing.

22. Remove the bucket cylinder using the cylinder mounting device.

Working steps and checks in the aftermath of disassembling:

23. Disassemble the seal rings (Fig. 5-228, Pos. 2) from inside
the collar bushings (Fig. 5-228, Pos. 1). Discard the seal
rings.

24. Check the collar bushings (Fig. 5-228, Pos. 1) of the bucket
cylinder for wear and damage.
Replace the bushings if required, refer to section 5.1.1 on
page 5-2.

Fig. 5-228

25. Remove the seal rings (Fig. 5-229, Pos. 2) that are slipped
over the collar bushings (Fig. 5-229, Pos. 1) in the bucket
(Fig. 5-229, Pos. 3).

26. Discard all removed seal rings.

Fig. 5-229

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 143

Face shovel Attachment

5.3.5.4 ASSEMBLING OF THE BUCKET CYLINDERS

Special tools: Cylinder mounting device (PN 967 000 40)

Additional equipment: Safety harness in conformity with DIN EN 361

Crane
Mobile elevator working platform (telescopic or articulated boom lift)
MPG (Multi Purpose Grease)
Paste Aluminium Anti-Seize, PN 509 623 98

Bucket cylinder: 1787 kg

Pin bucket cylinder/boom: 79 kg
Pin bucket cylinder/bucket: 83 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Clean all pins and bushings very carefully and thoroughly.

These parts must be completely free of dirt, corrosion, or any
protective coating.

2. Install new seals (Fig. 5-230, Pos. 1) into the grooves of the
bushing (Fig. 5-230, Pos. 2). Use MPG (or roller bearing
grease, or grease from the CLS system) to center the seals
within the bushings.

REMARKS: For details refer to Fig. 5-233 on page 5-145.

Fig. 5-230

At both sides of the bucket:

3. Slip new seal rings (Fig. 5-231, Pos. 2) over the collar bush-
ings (Fig. 5-231, Pos. 1) in the bucket (Fig. 5-231, Pos. 3).

REMARKS: During assembling there is not enough space to

insert these seal rings.

Fig. 5-231

4. Apply MPG (or roller bearing grease, or grease from the CLS system) on every bushing at the assembly.

5 - 144 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

5. Carry out the following steps at the cylinder mounting device,

refer to the manual of the cylinder mounting device:

– Remove the defective cylinder.

– Mount the replacement cylinder on the v-blocks of the
device.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or down-
falling of heavy machine parts.

When moving machine parts using a crane, make sure that

nobody steps below or in close range to the lifted machine
part.

Fig. 5-232 Use of the cylinder mounting

6. Lift the bucket cylinder (Fig. 5-232, Pos. 1) into mounting device (exemplaric sketch)
position using the cylinder mounting device (Fig. 5-232,
Pos. 2).

REMARKS: Applying the cylinder mounting device is analo-

gously the same for boom and bucket cylinders.

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from squeezing and sharing due to violent pressure from
sliding parts.

Align the parts with great caution. Never put hands through or into the bushings when aligning parts.

7. Align the bucket cylinder to the boom using the cylinder mounting device, refer to the manual of the cylinder
mounting device.

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the bucket cylinder may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pin, the seals can get sheared between pin and the sharp
groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-233,
Pos. 2) within the bushing (Fig. 5-233, Pos. 1).
Fig. 5-233

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 145

Face shovel Attachment

8. Push the pin (Fig. 5-234, Pos. 1) into the cylinder eye.

REMARKS: Apply paste Aluminium Anti-Seize at the fixed por-

tion of the pin and the pin fixing point of the pin bear-
ing, refer to section 5.1.2 on page 5-4.

9. Assemble the shackle (Fig. 5-234, Pos. 2) and the bolts

(Fig. 5-234, Pos. 4) with washers (Fig. 5-234, Pos. 3) to
secure the pin.

Fig. 5-234

10. Connect the grease line of the central lubrication system at the eye at the bucket cylinder piston rod.

11. Connect the hydraulic lines (Fig. 5-235, Pos. 2 and 3) to the
bucket cylinder (Fig. 5-235, Pos. 1), refer to section 5.3.6.5
on page 5-180.

Fig. 5-235

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 5-236 Exemplaric sketch

12. Detach the cylinder mounting device from the bucket cylinder, refer to the manual of the cylinder mounting
device.

5 - 146 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

13. De-isolate the machine according to local regulations.

14. Switch 11S150 to Qmin.

15. Fully retract the bucket cylinder.

WARNING
AIR IN THE HYDRAULIC CYLINDER!
May result in personal injury due to slightly jerky movements of the cylinder when it is operated. The jerky
movements are caused by the air in the cylinder which is compressible.

Make sure that nobody is in close range to the cylinder when it is operated with only one end connected to
the attachment.

16. Extend and retract the bucket cylinder slowly at Qmin 2...3 times as far as possible to partly bleed the cylinder.

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from squeezing and sharing due to violent pressure from
sliding parts.

Align the parts with great caution. Never put hands through or into the bushings when aligning parts.

17. Extend / retract the bucket cylinder slowly at Qmin and align the bucket cylinder to the cylinder foot bearing at
the bucket.

Precondition:
The pin is yet in disassembling position, inserted in the bore of the
outer pin bearing at the bucket (Fig. 5-237, Pos. 3).

18. Push the pin (Fig. 5-237, Pos. 1) in, just enough to insert the
catches (Fig. 5-237, Pos. 2).

REMARKS: Apply paste Aluminium Anti-Seize at the fixed por-

tion of the pin and the pin fixing point of the pin bear-
ing, refer to section 5.1.2 on page 5-4.

19. Assemble the catches (Fig. 5-237, Pos. 2) securing the pin.

Fig. 5-237

20. Isolate the machine according to local regulations.

21. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 147

Face shovel Attachment

22. Assemble the cover (Fig. 5-238, Pos. 2) at the bucket cylinder
bearing.

23. Assemble the seal fixing rings (Fig. 5-238, Pos. 1) located on
both sides of the corresponding bucket cylinder.

Fig. 5-238

24. Connect the grease lines (Fig. 5-239, Pos. 2) of the central
lubrication system at the bucket cylinder (Fig. 5-239, Pos. 1).

Fig. 5-239

25. De-isolate the machine according to local regulations.

26. Switch 11S150 back to normal condition.

27. Perform the bleeding procedure for the bucket cylinders. Refer to the PARTS & SERVICE NEWS
No. "AH06524".

28. Add hydraulic oil up to the specified level.

29. Check for leaks and the cylinders operation.

30. Check the hydraulic oil level again and add oil if required.

5 - 148 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

5.3.5.5 DISASSEMBLING OF THE CLAM CYLINDERS

Special tools: n/a

Additional equipment: Crane

Oil drain pan

Clam cylinder: 423 kg

Clam cylinder’s upper pin: 28 kg
Clam cylinder’s lower pin: 31 kg

Dogman/rigger

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate

the machine boom and crane.

2. Park the machine on the prepared flat area and position the
bucket into a burrowed hole as shown in Fig. 5-240.

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.

Fig. 5-240

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM"

5. Disconnect the lines of the central lubrication system from the clam cylinder eyes.

6. Disassemble the outer plate (Fig. 5-241, Pos. 1) from the

bucket (Fig. 5-241, Pos. 2) to access the pin connecting the
clam cylinder to the clam.

Fig. 5-241

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 149

Face shovel Attachment

7. Behind the outer plate:

Disassemble the cover (Fig. 5-242, Pos. 1) from the pin in the
clam swinging arm (Fig. 5-242, Pos. 2).

Fig. 5-242

8. Disassemble the inner plate (Fig. 5-243, Pos. 2) from the

bucket (Fig. 5-243, Pos. 1) to access the pin connecting the
clam cylinder to the clam.

Fig. 5-243

9. Behind the inner plate:

Disassemble the cover (Fig. 5-244, Pos. 1) from the pin in the
clam swinging arm (Fig. 5-244, Pos. 2).

Fig. 5-244

10. Sling the clam cylinder to be removed at both ends and attach a crane.

5 - 150 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

11. Pull out the pin (Fig. 5-245, Pos. 1) just enough to clear the
clam cylinder (Fig. 5-245, Pos. 3).
(Refer to Fig. 5-246.)

REMARKS: The pin remains in the bore of the clam swinging

arm (Fig. 5-245, Pos. 2).

Fig. 5-245

REMARKS: Use two puller bolts (Fig. 5-246, Pos. 2) in the

threads at the pin (Fig. 5-246, Pos. 1) to pull the pin
out of the pin bearing.

Fig. 5-246

12. De-isolate the machine according to local regulations.

13. Switch 11S150 to Qmin and retract the clam cylinder to be removed fully.

NOTE! Both clam cylinders are connected to the same hydraulic line, so when the cleared cylinder is fully
retracted, the clam will start to open. Do not open the clam.

14. Isolate the machine according to local regulations.

15. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 151

Face shovel Attachment

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

16. Disconnect the hydraulic hoses from the clam cylinder, refer to section 5.3.6.6 on page 5-184.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

17. Disassemble the bolt (Fig. 5-247, Pos. 1) and the plate
(Fig. 5-247, Pos. 2).

18. Pull out the pin (Fig. 5-247, Pos. 3).

(Refer to Fig. 5-248.)

Fig. 5-247

REMARKS: Use two puller bolts (Fig. 5-248, Pos. 2) in the

threads at the pin (Fig. 5-248, Pos. 1) to pull the pin
out of the pin bearing.

Fig. 5-248

5 - 152 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

19. Remove the clam cylinder from the bucket using a crane.

Working steps and checks in the aftermath of disassembling:

20. Disassemble the seal rings (Fig. 5-249, Pos. 1) from inside
the bushings (Fig. 5-249, Pos. 2). Discard the seal rings.

21. Check the bushings (Fig. 5-249, Pos. 2) of the clam cylinder
(Fig. 5-249, Pos. 3) for wear and damage.
Replace the bushings if required, refer to section 5.1.1.1 on
page 5-2.

Fig. 5-249

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 153

Face shovel Attachment

5.3.5.6 ASSEMBLING OF THE CLAM CYLINDERS

Special tools: n/a

Additional equipment: Crane

MPG (Multi Purpose Grease)
Paste Aluminium Anti-Seize, PN 509 623 98

Clam cylinder: 423 kg

Clam cylinder’s upper pin: 28 kg
Clam cylinder’s lower pin: 31 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Clean all pins and bushings very carefully and thoroughly. These parts must be completely free of dirt, corro-
sion, or any protective coating.

2. Install new seals (Fig. 5-250, Pos. 1) into the grooves of the
bushings (Fig. 5-250, Pos. 2) in the clam cylinder (Fig. 5-250,
Pos. 3).
Use MPG (or roller bearing grease, or grease from the CLS
system) to center the seals within the bushings.

REMARKS: For details refer to Fig. 5-251 on page 5-155.

Fig. 5-250

3. Apply MPG (or roller bearing grease, or grease from the CLS system) on every bushing at the assembly.

DANGER
FLOATING LOADS!
Death or serious injury will result due to swinging or downfalling of heavy machine parts.

When moving machine parts using a crane, make sure that nobody steps below or in close range to the
lifted machine part.

5 - 154 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from squeezing and sharing due to violent pressure from
sliding parts.

Align the parts with great caution. Never put hands through or into the bushings when aligning parts.

4. Insert the clam cylinder into the bucket using a crane and align the cylinder with the bucket to insert the lower
pin.

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the clam cylinder may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pin, the seals can get sheared between pin and the sharp
groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-251,
Pos. 2) within the bushing (Fig. 5-251, Pos. 1).
Fig. 5-251

5. Assemble the pin (Fig. 5-252, Pos. 3).

REMARKS: Apply paste Aluminium Anti-Seize at the fixed por-

tion of the pin and the pin fixing point of the pin bear-
ing, refer to section 5.1.2 on page 5-4.

6. Fix the pin with the plate (Fig. 5-252, Pos. 2).

7. Secure the plate with the bolt (Fig. 5-252, Pos. 1).

Fig. 5-252

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 155

Face shovel Attachment

8. Install the hydraulic hoses at the clam cylinder, refer to section 5.3.6.6 on page 5-184.

NOTE! Always replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 5-253 Exemplaric sketch

9. De-isolate the machine according to local regulations.

10. Switch 11S150 to Qmin.

11. Fully retract the clam cylinder.

NOTE! Both clam cylinders are connected to the same hydraulic line, so when the cleared cylinder is fully
retracted, the clam will start to open. Do not open the clam.

WARNING
AIR IN THE HYDRAULIC CYLINDER!
May result in personal injury due to slightly jerky movements of the cylinder when it is operated. The jerky
movements are caused by the air in the cylinder which is compressible.

Make sure that nobody is in close range to the cylinder when it is operated with only one end connected to
the attachment.

12. Extend and retract the clam cylinder slowly at Qmin 2…3 times as far as possible to partly bleed the cylinder.

NOTE! Both clam cylinders are connected to the same hydraulic line, so when the cleared cylinder is fully
retracted, the clam will start to open. Do not open the clam.

DANGER
HAZARD OF SQUEEZING AND SHEARING!
Will result in serious injury to hands and fingers from squeezing and sharing due to violent pressure from
sliding parts.

Align the parts with great caution. Never put hands through or into the bushings when aligning parts.

13. Operate the clam cylinder slowly at Qmin to align the cylinder piston rod to the swinging arm of the clam.

5 - 156 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

NOTICE
SHARP-EDGED GROOVE!
Damages to the seals in the clam cylinder may result.
There is a tolerance gap between bushing and seal, so that
the seal can move freely within the groove. When installing
the pin, the seals can get sheared between pin and the sharp
groove edge.

In order to avoid damage to the seals make sure that the

seals are centered in their mounting position within the
bushings.

REMARKS: Use MPG (or roller bearing grease, or grease from

the CLS system) to center the seal rings (Fig. 5-254,
Pos. 2) within the bushing (Fig. 5-254, Pos. 1).
Fig. 5-254

14. Push the pin (Fig. 5-255, Pos. 1) into the cylinder eye
(Fig. 5-255, Pos. 3) until fully home.

REMARKS: Apply paste Aluminium Anti-Seize at the fixed por-

tion of the pin and the pin fixing point of the pin bear-
ing, refer to section 5.1.2 on page 5-4.

Fig. 5-255

15. Isolate the machine according to local regulations.

16. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

17. Assemble the cover (Fig. 5-256, Pos. 1) at the clam swinging
arm (Fig. 5-256, Pos. 2).

Fig. 5-256

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 157

Face shovel Attachment

18. Assemble the cover (Fig. 5-257, Pos. 1) at the clam swinging
arm (Fig. 5-257, Pos. 2).

Fig. 5-257

19. Detach the crane from the clam cylinder.

20. Assemble the inner plate (Fig. 5-258, Pos. 2) at the bucket
(Fig. 5-258, Pos. 1).

Fig. 5-258

21. Assemble the outer plate (Fig. 5-259, Pos. 1) from the bucket
(Fig. 5-259, Pos. 2) to access the pin connecting the clam cyl-
inder to the clam.

Fig. 5-259

22. De-isolate the machine according to local regulations.

23. Switch 11S150 back to normal condition.

24. Perform the bleeding procedure for the clam cylinders. Refer to the PARTS & SERVICE NEWS
No. "AH06524".

25. Add specified hydraulic oil up to the specified level.

26. Check for leaks and the cylinders operation and heck the hydraulic oil level again. Add oil if required.

5 - 158 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

Please continue reading on the next page.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 159

Face shovel Attachment

5.3.6 HYDRAULIC HOSES AT THE FACE SHOVEL ATTACHMENT

5.3.6.1 REPLACE THE BOOM ARC HOSES

Fig. 5-260 Arc hoses at the boom

5 - 160 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

Legend for Fig. 5-260:

(1) Hose clamp (5) Hydraulic tube

(2) Hose clamp (6) Hydraulic hose

(3) Hose clamp (7) Bolt

(4) Manifold (8) Flat seal

Special tools: n/a

Additional equipment: Safety harness in conformity with DIN EN 361

Crane
Oil drain pan

Boom arc hose: 25 kg...38 kg (depending on diameter)

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.

1. Prepare an area of flat ground large enough to accommodate

the machine and the additional working equipment (crane,
mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area with the stick cyl-
inder fully retracted and position the bucket horizontally on
the ground (Fig. 5-261).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.
Fig. 5-261

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

5. Open the hose clamps (Fig. 5-260, Pos. 1...3) and clear the corresponding hydraulic hose to be disassembled
from the clamp lines.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 161

Face shovel Attachment

Fig. 5-262 Arc hoses at the boom

5 - 162 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

6. Sling the hydraulic hose (Fig. 5-262, Pos. 6) to be disassembled.

7. Disassemble the bolts (Fig. 5-262, Pos. 7) and disconnect the SAE-hydraulic hose from the distributor mani-
fold (Fig. 5-262, Pos. 4) and from the hydraulic tube (Fig. 5-262, Pos. 5) at the boom.
Discard the flat seals (Fig. 5-262, Pos. 8) of the SAE-flange connections.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

8. Remove the hydraulic hose using a crane.

9. Replace the hydraulic hose by a new one and carry out assembling in reverse order of disassembling.

NOTE! Always replace the flat seals (Fig. 5-262, Pos. 8) at SAE-flange connections when installing the
hydraulic lines!
A flat and level sealing surface is essential for proper sealing!

b Tighten the mounting bolts (Fig. 5-262, Pos. 7) of SAE-flange connections according to the
KOMATSU company standard "Torques for SAE-flange connections", refer to section 6.6.5 on
page 6-19.

10. If required replace the other hydraulic hoses using the same procedure.

11. Perform the bleeding procedure for all cylinders. Refer to the PARTS & SERVICE NEWS No. "AH06524".

12. Add hydraulic oil up to the specified level.

13. Check for leaks and the cylinder operation.

14. Check hydraulic oil level again and add oil, if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 163

Face shovel Attachment

5.3.6.2 REPLACE THE BOOM CYLINDER HOSES

Fig. 5-263 Boom cylinder hoses

(1) Boom (6) Bolt

(2) Hydraulic hose (7) Bolt

(3) Hydraulic hose (8) Flat seal

(4) Guard plate (9) Hydraulic tube

(5) Boom cylinder (10) Guard plate

5 - 164 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

Special tools: n/a

Additional equipment: Safety harness in conformity with DIN EN 361

Mobile elevator working platform (telescopic or articulated boom lift)
Oil drain pan

Boom cylinder hose: 18 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate

the machine and the additional working equipment (crane,
mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area with the super-
structure turned by 90° and position the bucket on the ground
as shown (Fig. 5-264).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.
Fig. 5-264

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

5. Disassemble the guard plates (Fig. 5-263, Pos. 4 and 10).

REMARKS: Disassembling the guard plates at the boom (Fig. 5-265, Pos. 10) is not absolutely necessary but
recommended.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 165

Face shovel Attachment

Fig. 5-265 Boom cylinder hoses

5 - 166 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

6. Remove the bolts (Fig. 5-265, Pos. 6 & 7) and disconnect the SAE-hydraulic hose (Fig. 5-265, Pos. 2 or 3)
from the boom cylinder (Fig. 5-265, Pos. 5) and from the hydraulic tube (Fig. 5-265, Pos. 9) at the boom.
Discard the flat seals (Fig. 5-265, Pos. 8) of the SAE-flange connections.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

7. Remove the hydraulic hose.

8. Check the collar ring at the hydraulic tube (Fig. 5-265, Pos. 9).
A flat and level sealing surface is essential for proper sealing! Replace if required.

9. Replace the hydraulic hose by a new one and carry out assembling in reverse order of disassembling.

NOTE! Always replace the flat seals (Fig. 5-265, Pos. 8) at SAE-flange connections when installing the
hydraulic lines!
A flat and level sealing surface is essential for proper sealing!

b Tighten the mounting bolts (Fig. 5-265, Pos. 6 & 7) of SAE-flange connections according to
the KOMATSU company standard "Torques for SAE-flange connections", refer to
section 6.6.5 on page 6-19.

10. If required replace the other hydraulic hoses using the same procedure.

11. Perform the bleeding procedure for the boom cylinder(s). Refer to the PARTS & SERVICE NEWS
No. "AH06524".

12. Add specified hydraulic oil up to the specified level.

13. Check for leaks and the cylinders operation.

14. Check hydraulic oil level and add oil if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 167

Face shovel Attachment

5.3.6.3 REPLACE THE STICK ARC HOSES

The machine may be equipped with two different versions of stick related hydraulic line routing:

Hydraulic line routing type A

Fig. 5-266 Stick arc hoses - routing type A

5 - 168 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

Legend for Fig. 5-266:

(1) Hose clamp line (5) Hydraulic hose

(2) Boom (6) Collar ring

(3) Bolt (7) Flat seal

(4) Hydraulic pipe

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 169

Face shovel Attachment

Hydraulic line routing type B

Fig. 5-267 Stick arc hoses - routing type B

(1) Boom (5) Hydraulic tube at boom

(2) Hydraulic hose (6) Hydraulic tube at stick

(3) Flat seal (7) Bolt

(4) Collar ring

5 - 170 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

Preparatory work (for routing types A and B)

Special tools: n/a

Additional equipment: Safety harness in conformity with DIN EN 361

Mobile elevator working platform (telescopic or articulated boom lift)
Oil drain pan

Stick arc hose: 17 kg...25 kg (depending on diameter and type)

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate

the machine and the additional working equipment (crane,
mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area with the super-
structure turned by 90° and position the bucket on the ground
as shown (Fig. 5-268).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.
Fig. 5-268

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 171

Face shovel Attachment

Replace the stick arc hoses, routing type A

Fig. 5-269 Stick arc hoses - routing type A

5 - 172 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

1. Disassemble the hose clamp line(s) (Fig. 5-269, Pos. 1).

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

2. Disassemble the bolts (Fig. 5-269, Pos. 3) and disconnect the SAE-hydraulic hose (Fig. 5-269, Pos. 5) from
the hydraulic tube (Fig. 5-269, Pos. 4) at the boom and from the hydraulic tube at the stick.
Discard the flat seals (Fig. 5-269, Pos. 7) of the SAE-flange connections.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

3. Remove the hydraulic hose.

4. Check the collar rings (Fig. 5-269, Pos. 6) at the hydraulic tubes (Fig. 5-269, Pos. 4) at boom and stick.
A flat and level sealing surface is essential for proper sealing! Replace if required.

5. Replace the hydraulic hose by a new one and carry out assembling in reverse order of disassembling.

NOTE! Always replace the flat seals (Fig. 5-269, Pos. 7) at SAE-flange connections when installing the
hydraulic lines!
A flat and level sealing surface is essential for proper sealing!

b Tighten the mounting bolts (Fig. 5-269, Pos. 3) of SAE-flange connections according to the
KOMATSU company standard "Torques for SAE-flange connections", refer to section 6.6.5 on
page 6-19.

6. If required replace the other hydraulic hoses using the same procedure.

7. Perform the bleeding procedure for the bucket and clam cylinders. Refer to the PARTS & SERVICE NEWS
No. "AH06524".

8. Add hydraulic oil up to the specified level.

9. Check for leaks and the cylinders operation.

10. Check hydraulic oil level again and add oil if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 173

Face shovel Attachment

Replace the stick arc hoses, routing type B

Fig. 5-270 Stick arc hoses - routing type B

5 - 174 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

1. Disassemble the bolts (Fig. 5-270, Pos. 7) and disconnect the SAE-hydraulic hose (Fig. 5-270, Pos. 2) from
the hydraulic tube (Fig. 5-270, Pos. 5) at the boom and from the hydraulic tube at the stick (Fig. 5-270, Pos. 6).
Discard the flat seals (Fig. 5-270, Pos. 3) of the SAE-flange connections.

REMARKS: When a hydraulic line is disconnected hydraulic oil will flow out. Catch it in an oil pan.
Cap the openings with blind plugs to avoid contamination.

2. Remove the hydraulic hose.

3. Check the collar rings (Fig. 5-270, Pos. 4) at the hydraulic tubes.
A flat and level sealing surface is essential for proper sealing! Replace if required.

4. Replace the hydraulic hose by a new one and carry out assembling in reverse order of disassembling.

NOTE! Always replace the flat seals (Fig. 5-270, Pos. 3) at SAE-flange connections when installing the
hydraulic lines!
A flat and level sealing surface is essential for proper sealing!

b Tighten the mounting bolts (Fig. 5-270, Pos. 7) of SAE-flange connections according to the
KOMATSU company standard "Torques for SAE-flange connections", refer to section 6.6.5 on
page 6-19.

5. If required replace the other hydraulic hoses using the same procedure.

6. Perform the bleeding procedure for the bucket and clam cylinders. Refer to the PARTS & SERVICE NEWS
No. "AH06524".

7. Add hydraulic oil up to the specified level.

8. Check for leaks and the cylinders operation.

9. Check hydraulic oil level again and add oil if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 175

Face shovel Attachment

5.3.6.4 REPLACE THE STICK CYLINDER HOSES

Fig. 5-271 Stick cylinder hoses

(1) Boom (5) Bolt

(2) Hydraulic hose (6) Collar ring

(3) Hydraulic hose (7) Flat seal

(4) Hydraulic pipe (8) Nut

5 - 176 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

Special tools: n/a

Additional equipment: Safety harness in conformity with DIN EN 361

Mobile elevator working platform (telescopic or articulated boom lift)
Oil drain pan

Stick cylinder hose: 17 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate

the machine and the additional working equipment (crane,
mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area with the super-
structure turned by 90° and position the bucket on the ground
as shown (Fig. 5-272).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.
Fig. 5-272

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 177

Face shovel Attachment

Fig. 5-273 Stick cylinder hoses

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

5 - 178 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

1. Disassemble the bolts (Fig. 5-273, Pos. 5) and disconnect the SAE-hydraulic hose (Fig. 5-273, Pos. 2 or 3)
from the hydraulic tube (Fig. 5-273, Pos. 4) at the stick and from the cylinder.
Discard the flat seals (Fig. 5-273, Pos. 7) of the SAE-flange connections.

2. Remove the hydraulic hose.

3. Check the collar ring (Fig. 5-273, Pos. 6) at the hydraulic tube.
A flat and level sealing surface is essential for proper sealing! Replace if required.

4. Replace the hydraulic hose by a new one and carry out assembling in reverse order of disassembling.

NOTE! Always replace the flat seals (Fig. 5-273, Pos. 7) at SAE-flange connections when installing the
hydraulic lines!
A flat and level sealing surface is essential for proper sealing!

b Tighten the mounting bolts (Fig. 5-273, Pos. 5) of SAE-flange connections according to the
KOMATSU company standard "Torques for SAE-flange connections", refer to section 6.6.5 on
page 6-19.

5. If required replace the other hydraulic hoses using the same procedure.

6. Perform the bleeding procedure for the stick cylinder(s). Refer to the PARTS & SERVICE NEWS
No. "AH06524".

7. Add hydraulic oil up to the specified level.

8. Check for leaks and the cylinders operation.

9. Check hydraulic oil level again and add oil if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 179

Face shovel Attachment

5.3.6.5 REPLACE THE BUCKET CYLINDER HOSES

Fig. 5-274 Bucket cylinder hoses

(1) Hydraulic hose (5) Collar ring

(2) Hydraulic hose (6) Intermediate flange

(3) Bolt (7) Bucket cylinder

(4) Flat seal (8) Stick

5 - 180 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

Special tools: n/a

Additional equipment: Safety harness in conformity with DIN EN 361

Mobile elevator working platform (telescopic or articulated boom lift)
Oil drain pan

Bucket cylinder hose (depending on type): 19 kg / 25kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate

the machine and the additional working equipment (crane,
mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area with the super-
structure turned by 90° and position the bucket on the ground
as shown (Fig. 5-275).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.
Fig. 5-275

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 181

Face shovel Attachment

Fig. 5-276 Bucket cylinder hoses

5 - 182 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

5. Disassemble the bolts (Fig. 5-274, Pos. 3) and disconnect the SAE-hydraulic hose (Fig. 5-274, Pos. 1 or 3)
from the hydraulic tube at the stick and from the bucket cylinder (Fig. 5-274, Pos. 7).

– Remove the intermediate flange (Fig. 5-276, Pos. 6) from the cylinder when disconnecting the bucket cylin-
der hose (Fig. 5-276, Pos. 1) on the piston rod side of the bucket cylinder.
– Discard the flat seals (Fig. 5-274, Pos. 4) of the SAE-flange connections.
6. Remove the hydraulic hose.

7. Check the collar ring (Fig. 5-276, Pos. 5) at the hydraulic tube.
A flat and level sealing surface is essential for proper sealing! Replace if required.

8. Replace the hydraulic hose by a new one and carry out assembling in reverse order of disassembling.

NOTE! Always replace the flat seals (Fig. 5-276, Pos. 4) at SAE-flange connections when installing the
hydraulic lines!
A flat and level sealing surface is essential for proper sealing!

b Tighten the mounting bolts (Fig. 5-276, Pos. 3) of SAE-flange connections according to the
KOMATSU company standard "Torques for SAE-flange connections", refer to section 6.6.5 on
page 6-19.

9. If required replace the other hydraulic hoses using the same procedure.

10. Perform the bleeding procedure for the bucket cylinder(s). Refer to the PARTS & SERVICE NEWS
No. "AH06524".

11. Add specified hydraulic oil up to the specified level.

12. Check for leaks and the cylinders operation.

13. Check hydraulic oil level again and add oil if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 183

Face shovel Attachment

5.3.6.6 REPLACE THE CLAM CYLINDER HOSES

The clam cylinder hose set contains two hydraulic hoses at the stick and four (two for each cylinder) hydraulic
hoses at the clam cylinders.

Fig. 5-277 Clam cylinder hoses at stick,

(1) Hydraulic hose (3) Flat seal

(2) Bolt (4) Collar ring

5 - 184 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

Replace the clam cylinder hoses at the stick

Special tools: n/a

Additional equipment: Safety harness in conformity with DIN EN 361

Oil drain pan
Mobile elevator working platform (telescopic or articulated boom lift)

Clam cylinder hose at stick: 26 kg

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
Most of the following operations require the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate

the machine and the additional working equipment (crane,
mobile working platforms, forklift, etc.).

2. Park the machine on the prepared flat area with the super-
structure turned by 90° and position the bucket on the ground
as shown (Fig. 5-278).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.
Fig. 5-278

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 185

Face shovel Attachment

Fig. 5-279 Clam cylinder hoses at stick

5 - 186 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

5. Disassemble the bolts (Fig. 5-279, Pos. 2) and disconnect the SAE-hydraulic hose (Fig. 5-279, Pos. 1) from
the hydraulic tube at the stick and from the distributor block (see Fig. 5-282, Pos. 7 on page 5-190) at the
bucket back wall.
Discard the flat seals (Fig. 5-279, Pos. 3) of the SAE-flange connections.

6. Remove the hydraulic hose.

7. Check the collar ring (Fig. 5-279, Pos. 4) at the hydraulic tube.
A flat and level sealing surface is essential for proper sealing! Replace if required.

8. Replace the hydraulic hose by a new one and carry out assembling in reverse order of disassembling.

NOTE! Always replace the flat seals (Fig. 5-279, Pos. 3) at SAE-flange connections when installing the
hydraulic lines!
A flat and level sealing surface is essential for proper sealing!

b Tighten the mounting bolts (Fig. 5-279, Pos. 2) of SAE-flange connections according to the
KOMATSU company standard "Torques for SAE-flange connections", refer to section 6.6.5 on
page 6-19.

9. If required replace the other hydraulic hoses using the same procedure.

10. Perform the bleeding procedure for the clam cylinders. Refer to the PARTS & SERVICE NEWS
No. "AH06524".

11. Add specified hydraulic oil up to the specified level.

12. Check for leaks and the cylinders operation.

13. Check hydraulic oil level again and add oil if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 187

Face shovel Attachment

Replace the clam cylinder hoses at the cylinders

Fig. 5-280 Clam cylinder hoses

5 - 188 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

Legend for Fig. 5-280:

(1) Hydraulic hose (6) Flat seal

(2) Hydraulic hose (7) Distributor block

(3) Hydraulic hose (8) Clam cylinder

(4) Hydraulic hose (9) Flange half

(5) Bolt (6) Flat seal

Special tools: n/a

Additional equipment: Oil drain pan

Clam cylinder hose at cylinder: 6 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

For further information about the needed blind plugs, refer to

section 6.7 on page 6-20.

1. Prepare an area of flat ground large enough to accommodate

the machine.

2. Park the machine on the prepared flat area with the super-
structure turned by 90° and position the bucket on the ground
as shown (Fig. 5-281).

REMARKS: If the ground condition is too poor to guarantee safe

and stable stand of the machine and the additional
working equipment (crane, mobile working plat-
forms, forklift, etc.), make sure that the machine is
moved to any location with appropriate ground con-
dition.
Fig. 5-281

3. Isolate the machine according to local regulations.

4. Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section
"RELIEVE THE PRESSURE IN THE HYDRAULIC SYSTEM".

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 189

Face shovel Attachment

Fig. 5-282 Clam cylinder hoses

5 - 190 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Face shovel

WARNING
HOT HYDRAULIC OIL!
May result in personal injury from heated oil.

Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is
below 50 °C.

DANGER
HYDRAULIC PRESSURE!
The hydraulic system may be pressurized. Opening any hydraulic lines under pressure will result in blind-
ness, serious injury or permanent disfigurement.

Make sure that the pressure is relieved before any hydraulic lines will be removed.

5. Disassemble the bolts (Fig. 5-282, Pos. 5) from the flange halves (Fig. 5-282, Pos. 9) to disconnect the
SAE-hydraulic hoses from the distributor block(s) (Fig. 5-282, Pos. 7) / from the clam cylinder (Fig. 5-282,
Pos. 8).
Discard the flat seals (Fig. 5-282, Pos. 6) of the SAE-flange connections.

6. Remove the hydraulic hose.

7. Replace the hydraulic hose by a new one and carry out assembling in reverse order of disassembling.

NOTE! Always replace the flat seals (Fig. 5-282, Pos. 6) at SAE-flange connections when installing the
hydraulic lines!
A flat and level sealing surface is essential for proper sealing!

b Tighten the mounting bolts (Fig. 5-282, Pos. 5) of SAE-flange connections according to the
KOMATSU company standard "Torques for SAE-flange connections", refer to section 6.6.5 on
page 6-19.

8. If required replace the other hydraulic hoses using the same procedure.

9. Perform the bleeding procedure for the clam cylinder(s). Refer to the PARTS & SERVICE NEWS
No. "AH06524".

10. Add hydraulic oil up to the specified level.

11. Check for leaks and the cylinders operation.

12. Check hydraulic oil level again and add oil if required.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 191

Metering valves (grease injectors) at the attachment Attachment

5.4 METERING VALVES (GREASE INJECTORS) AT

THE ATTACHMENT
Refer to part 10 STRUCTURE & FUNCTION, chapter 17 in the SHOP MANUAL for further information concerning
the metering valves.

5.4.1 DISASSEMBLING OF THE METERING VALVES (GREASE

INJECTORS)
Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Mobile elevator working platform

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
The work requires the use of men safety cages on elevator working platforms.

1. Prepare an area of flat ground large enough to accommodate the machine, boom and mobile elevator working
platform.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to a location with appropriate ground condition.

2. For machines with face shovel attachment (FSA) only:

Park the machine on the prepared flat area and position the
attachment in the "defined position" (see Fig. 5-283).

Fig. 5-283

3. For machines with backhoe attachment (BHA) only:

Park the machine on the prepared flat area and position the
bucket on the ground with the bucket cylinders in fully
extended and the stick cylinders in fully retracted position
(Fig. 5-284).

Fig. 5-284

4. Isolate the machine according to local regulations.

REMARKS: In the following, it is described how to remove the metering valves at the FSA boom exemplarily. All
other metering valves at the attachment (BHA included) are removed analogously.

5 - 192 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Metering valves (grease injectors) at the attachment

5. Disconnect all grease lines (Fig. 5-285, Pos. 2) from the

metering valve assemblies (Fig. 5-285, Pos. 5).

6. Disconnect the grease feeding line at the union (Fig. 5-285,

Pos. 3).

7. Disassemble the bolts (Fig. 5-285, Pos. 4), and remove the
metering valve assemblies (Fig. 5-285, Pos. 5) from the
boom (Fig. 5-285, Pos. 1).

Fig. 5-285

8. Disassemble the adapter bolt (Fig. 5-286, Pos. 2) and

remove the valve housing (Fig. 5-286, Pos. 1) from the meter-
ing valve assembly (Fig. 5-286, Pos. 4).

Fig. 5-286

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 193

Metering valves (grease injectors) at the attachment Attachment

5.4.2 ASSEMBLING OF THE METERING VALVES (GREASE

INJECTORS)
Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Mobile elevator working platform

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

NOTE! Always wear the safety harness when working on high-lying or elevated working positions.
The work requires the use of men safety cages on elevator working platforms.

1. Install the valve housing (Fig. 5-287, Pos. 1) to the metering

valve assembly (Fig. 5-287, Pos. 4) by assembling the
adapter bolt (Fig. 5-287, Pos. 2).

REMARKS: Use new seals (Fig. 5-287, Pos. 3) at the valve

housing (Fig. 5-287, Pos. 1).

2. Tighten the mounting bolts to the specified torque.

b Tightening torque for adapter bolt: 223.7 Nm

Fig. 5-287

3. Mount the metering valve assemblies (Fig. 5-288, Pos. 5) at

the boom (Fig. 5-288, Pos. 1) using the mounting bolts
(Fig. 5-288, Pos. 4).

4. Connect the grease feeding line at the union (Fig. 5-288,

Pos. 3).

5. Connect all grease lines (Fig. 5-288, Pos. 2) at the metering

valve assemblies (Fig. 5-288, Pos. 5) and tighten their grease
nipple fittings to the specified torque.

b Tightening torque for grease nipple fittings:

Refer to the PARTS & SERVICE NEWS
No. "AH10532".
Fig. 5-288

6. Check metering valves at the attachment for proper operation, refer to the OPERATION & MAINTENANCE
Manual, chapter 4, section "WALK-AROUND INSPECTION".

5 - 194 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Ground engaging tools (GET)

5.5 GROUND ENGAGING TOOLS (GET)

As ground engaging tools (Fig. 5-289, Pos. 1), one of the follow-
ing systems is used:

– Hensley Tooth System XS252, 120 mm lip (standard)

– ESCO POSILOK System 85SV2 (option available on custom-
ers request)

REMARKS: The ESCO POSILOK System V81 is no longer the

standard tooth system, but is furthermore available
on customers request.

Fig. 5-289 Example

5.5.1 DISASSEMBLING AND ASSEMBLING OF THE GET

Special tools: POSILOK Pin removal tool PN 795 997 73
Hensley Pin removal tool (ask local dealer)

Additional equipment: Forklift

Point (tooth): 81.2 kg (Hensley), 73 kg (ESCO)

Shroud: 182 kg (Hensley), 205 kg (ESCO)
Wear cap 21 kg (Hensley), 25 kg (ESCO)

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to

KOMATSU company standard, refer to section 6.6 on page 6-16.

1. Prepare an area of flat ground large enough to accommodate the machine, bucket and a forklift.

2. Park the machine on the prepared flat ground area and position the bucket in an appropriate height for work.

REMARKS: If the ground condition is too poor to guarantee safe and stable stand of the machine and the addi-
tional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine
is moved to any location with appropriate ground condition.

3. Isolate the machine according to local regulations.

Disassembling and assembling of the ESCO-GET

1. Remove and replace the ESCO Tooth System according to the PARTS & SERVICE NEWS No. "AH03510".

REMARKS: An enhanced version of the PARTS & SERVICE NEWS including PC3000 is in development.
Use a forklift to remove and install the GET.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 195

Ground engaging tools (GET) Attachment

Disassembling and assembling the Hensley-GET

1. Sling the Hensley-point (Fig. 5-290, Pos. 1) and attach it to a

forklift.

2. Unlock the fastener of the pin (Fig. 5-290, Pos. 3) by turning

the lock pin (Fig. 5-290, Pos. 2) by 90°.

3. Pull out the fastener (Fig. 5-290, Pos. 3).

4. Pull the Hensley-point (Fig. 5-290, Pos. 1) off using the fork-
lift.

5. If required, remove the wear cap (Fig. 5-290, Pos. 4).

Fig. 5-290

6. Sling the shroud (Fig. 5-291, Pos. 2) and attach it to a forklift.

7. Unlock the J-bolt assembly (Fig. 5-291, Pos. 1) and pull the
shroud off using the forklift.

REMARKS: The J-bolt lock remains in the lip.

Fig. 5-291

For further information about the disassembling and assembling of the HENSLEY tooth system refer to the manual
delivered with the tooth system or ask your local dealer.

5 - 196 PC3000-6 SHOP-50 06279-xD-GB-1

Attachment Cylinder bypass test

5.6 CYLINDER BYPASS TEST

Special tools: n/a

Additional equipment: Safety harness in conformity with EN 361

Mobile elevator working platform
Infrared thermometer, PN 232 665 40

The cylinder bypass test can be performed to check if a hydraulic cylinder has an internal leakage. A cylinder with
an internal leakage also has a higher temperature (at working temperature of the machine) than a hydraulic cylin-
der which has no internal leakage.

REMARKS: Before starting the bypass test, always make sure that the hydraulic circuit which is to be tested, has
reached the operating temperature (T3).

1. Bring the concerning cylinders in their end position  rod end completely moved in or out.

2. Keep up the system pressure in the concerning hydraulic circuit for approx. 10 minutes.

3. During these 10 minutes, measure and monitor the cylinder temperature in the piston area of both cylinders,
using an infrared thermometer.

If any cylinder seal package is leaking, hydraulic oil is now pressed through this leakage, which causes the
temperature to increase (90°C and higher) within a few minutes.

Case 1 Case 2

Seal package is leaking in 1 cylinder only Seal package is leaking in both cylinders

Defective cylinder: Both defective cylinders:

Temperature increase during the test, Temperature increase during the test,
increased temperature approx. 90°C increased temperature approx. 90°C

Proper cylinder:
No temperature increase during the test, -
normal temperature approx. 70°C

Remark: Remark:
The hydraulic oil will heat up at the MRV, A strong drift occurs.
not in the proper cylinder.

SHOP-50 06279-xD-GB-1 PC3000-6 5 - 197

Cylinder bypass test Attachment

Please continue reading on the next page.

5 - 198 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information

6 SERVICE INFORMATION

SHOP-50 06279-xD-GB-1 PC3000-6 6 -1

Fluids and lubricants Service Information

6.1 FLUIDS AND LUBRICANTS

Due to extremely different environmental and working conditions for the excavator as well as special customized
approvals for lubricants, it is not possible to get a general conclusion about the used fluids and lubricants.
Therefore, no lubrication or other fluids are listed at this point in this Disassembly & Assembly Manual.

REMARKS: For proper fluids and lubricants refer to the Operation & Maintenance Manual of your machine.

6.2 LIFTING GEARS

– Heavy parts (25 kg or more) must be lifted with a hoist etc.
– If any part cannot be smoothly removed from the machine by hoisting, the following checks should be made:
– Check for removal of all bolts fastening the part to the relative parts.
– Check for existence of another part causing interference with the part to be removed.

WIRE ROPES

– Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:

Wire popes
(Standard "Z" or "S" twist ropes without galvanizing)

Rope diameter
10,0 11,2 12,5 14,0 16,0 18,0 20,0 22,4 30,0 40,0 50,0 60,0
[mm]

Allowable load
1,0 1,4 1,6 2,2 2,8 3,6 4,4 5,6 10,0 18,0 28,0 40,0
[tons]

Table 6-1 Rope diameter/allowable bend

NOTE! The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used.

– Sling wire ropes from the middle portion of the hook. Slinging
near the edge of the hook may cause the rope to slip off the
hook during hoisting, and a serious accident can result.
Hooks have maximum strength at the middle portion.

Fig. 6-1

– Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the
load.
NOTE! Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slip-
ping of the rope from its original winding position on the load, which can result in a dangerous acci-
dent.

6 -2 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Lifting Gears

– Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with
two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below
shows the variation of allowable load (kg) where hoisting g is made with two ropes, each of which is allowed to
sling up to 1000kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000kg of
total weight can be suspended. This weight becomes 1000kg when two ropes make a 120° hanging angle. On
the other hand two ropes are subject to an excessive force as large as 4000kg if they sling a 2000kg load at a
lifting angle of 150°.

Fig. 6-2 Allowable load at various hanging angles

SHOP-50 06279-xD-GB-1 PC3000-6 6 -3

Safety hints for sling accessory Service Information

6.3 SAFETY HINTS FOR SLING ACCESSORY

– Always attend to local standards when using sling accessory.
NOTE! Eye bolts or sling accessory which is not suitable can result in serious accidents.

– Do not use rigid eye bolts from steel C 15 for lifting (e.g. ISO 580). These eye bolts may only be loaded verti-
cally or with a maximum permissible angle of 45° to the ring.
– Always use suitable swivel hoist rings according to local standards or Vario-Starpoint hoist rings recom-
mended by Komatsu, see following table:

Thread Komatsu Part Number Tightening Torque

M8 941 650 40 10 Nm

M10 941 651 40 10 Nm

M12 906 519 40 25 Nm

M16 906 780 40 60 Nm

M20 906 782 40 115 Nm

M24 906 783 40 190 Nm

M30 906 421 40 330 Nm

M36 906 233 40 590 Nm

Table 6-2 Vario-Starpoint hoist rings

NOTE! Vario-Starpoint hoist rings are not suited for turning under load.
After installing a Starpoint hoist ring disengage the star key.
Adjust the ring plane in direction of pull before attaching any sling accessory.

– Check that the wire rope, chains, and hooks are free from damage.
– Always use lifting equipment which has ample capacity.Install the lifting equipment at the correct places.
– Use a hoist or crane and operate slowly to prevent the component from hitting any other part.
Do not work with any part still raised by the hoist or crane.

6 -4 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Work instructions

6.4 WORK INSTRUCTIONS

6.4.1 SURFACE COATING WITH INTERZINC 697

Coating compound "INTERZINC 697", PN 674 997 40
Additional equipment: Thinner, PN 907 886 40
Dust bonding cloths, PN 932 911 40

NOTE! All working procedures in coherency with the coating compound "INTERZINC 697" must be carried
out according to local regulations and standards concerning occupational health and safety.

All working procedures in coherency with the coating compound "INTERZINC 697" must be carried
out by authorized specialists only.

WARNING
HARMFUL DUSTING AND GASSING!
Welding or cutting on parts which have been coated with the coating compound "INTERZINC 697" may
result in illness due to harmful dusting and gassing.

Carry out welding or cutting work with personal protective equipment only.
Dust and gases must be lead away from the workplace.

1. Clean the surface to be coated according to ISO 8504, purity level 3 with thinner, PN 907 886 40.
The surface to be coated must be completely free of dirt, grease, or oil.

REMARKS: Do not use compressed air because it contains oil.

2. Plug all threads.

3. Set up the surface to be coated with sand paper (grain 60) or a grinder, according to ISO 8504-1:1998.

4. Cover the area around the surface to be coated (e. g. with plastic film).

5. Use dust bonding cloths, PN 932 911 40 to clean the surface to be coated from grinding swarf.

NOTE! Do not use compressed air because it contains oil.

If a rust film has formed at the surface to be coated before INTERZINC can be applied, repeat the
cleaning procedure.

6. INTERZINC contains of two parts, a liquid binder and powder. Pour the powder into the liquid binder while agi-
tating.

Mixing ratio:
1 part liquid binder: 0.7 parts powder (volume)
1 part liquid binder: 4 parts powder (weight)

NOTE! Don not add liquid to the powder.

Do not water down the powder or the final coating compound.
Do not use brushes or paint rollers.

SHOP-50 06279-xD-GB-1 PC3000-6 6 -5

Work instructions Service Information

7. Apply the INTERZINC compound with a clean spraygun equipped with a 2.5 mm flat spray nozzle. Apply inter-
zinc in one pass only to obtain the permissible film thickness.

NOTE! Only use a compressed air supply without air line lubricator.

8. The specified dry paint film thickness (DFT) must be 75 µm (3.0 Mil) or 125 µm (5.0 Mil) wet paint film thick-
ness (WFT).

9. Let the surface coating harden, observe the hints below:

– The temperature of the surface to be coated must be at least 10 °C (50 °F).

– The humidity should be 50% to 60%, otherwise the hardening time will increase considerably.
– The coated parts must be ventilated well while drying. The air speed must be at least 0.1 m/s (4 in/sec).
Otherwise the coating will be cracked.
– If the coating is cracked, the coating must be removed, and the coating procedure has to be repeated.
– Pay attention to the hardening time. The hardening time depends on ambient temperature, humidity and
dry paint film thickness (DFT). At an ambient temperature of 20 °C (68 °F), the hardening takes about five
days.

6 -6 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Work instructions

6.4.2 HINTS FOR HYDRAULIC HOSE INSTALLATION

NOTICE
The hydraulic hoses undergo natural aging.
Hence, as they are safety critical parts, their usable lifetime is limited to a maximum of 6 years (including
storage time).

For further information refer to the Operation and Maintenance Manual, chapter 4, section "SAFETY CRIT-
ICAL PARTS".

To avoid damage to the hydraulic hose lines, follow the installation procedures listed below:

NOTE! Allways replace the flat seals at SAE-flange connec-

tions when installing used hydraulic lines!
A flat and level sealing surface is essential for
proper sealing!

b Tighten the mounting bolts of SAE-flange con-

nections according to the KOMATSU company
standard "Torques for SAE-flange connections",
refer to section 6.6.5 on page 6-19.

Fig. 6-3 Exemplaric scetch

NOTE! Pay attention to the Natural curvature of the hose!

Fig. 6-4

SHOP-50 06279-xD-GB-1 PC3000-6 6 -7

Work instructions Service Information

NOTE! Do not twist the hoses during installation!

Fig. 6-5

NOTE! Mount angled flanges at first!

Fig. 6-6

NOTE! Pay attention to the changing in hose length,

depending on the pressure inside the hose!

Fig. 6-7

6 -8 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Work instructions

NOTE! Pay attention to the bending radius!

Fig. 6-8

NOTE! Pay attention to the bending radius!

Fig. 6-9

SHOP-50 06279-xD-GB-1 PC3000-6 6 -9

Work instructions Service Information

6.4.3 REMOVE / INSTALL THE CRAWLER CARRIER

Hydraulic torque wrench, PN 793 374 73 + PN 793 376 73
Special tools:
Electro-hydraulic pump set, PN 793 375 73

Fig. Fig. 6-1 shows the following:

(1) Hydraulic wrench PN 793 374 73.

(2) Special wrench socket PN 793 376 73.

(3) Electro-hydraulic pump set PN 793 375 73.

REMARKS: For information about using the electro-hydraulic

pump set an the torque wrench, refer to the sepa-
rate documentations delivere with these tools.

Fig. 6-1 Hydraulic torque wrench

6 - 10 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Weight tables

6.5 WEIGHT TABLES

6.5.1 SUPERSTRUCTURE
Part or assembly Weight Remark

Complete roof incl. roof frame 2500 kg

Roof cover plate 1 engine 162 kg

Roof cover plate 2 engine 164 kg Single roof
Roof cover plate radiator 119 kg cover plates
Roof cover plate PTO 173 kg

Diesel engine 7000 kg

Alternator 39 kg

Starter motor 26 kg

Battery 62 kg

Geislinger coupling 165 kg

CentaFlex coupling 80 kg Compl. assy.

Radiator fan 35 kg

Radiator 748 kg

Main pump 1 assembly 475 kg

Main pump 2 assembly 547 kg
Main pump 3 assembly 481 kg

PTO 3400 kg

PTO oil circulation pump < 25 kg

Hydraulic cooler fan drive pump 106 kg

Hydraulic cooler fan assembly 71.5 kg

Hydraulic cooler fan motor: 19 kg

Fan motor carrier 20.5 kg

Fan hub 13 kg

Hydraulic oil cooler 240 kg

2508 kg Standard type

Hydraulic oil cooler assembly
3353kg 55°C type

Sound silencer 1400 kg Optional

Pilot oil pump < 25 kg

Main shut off valve 22 kg

Hydraulic oil reservoir incl. Back pressure valve 2341 kg Empty

Main control valve block I and II 400 kg

Main control valve block III 310 kg

MRV at main control valve blocks < 10 kg

SRV at main control valve blocks < 10 kg

SHOP-50 06279-xD-GB-1 PC3000-6 6 - 11

Weight tables Service Information

Part or assembly Weight Remark

Anti cavitation valve on manifold 10 kg

Anti cavitation valve on control valve block < 10 kg

Throttle check valve on manifold 18 kg

Diffuser on manifold 14 kg FSA only

Distributor manifold assembly 700 kg Aprox.

Slew gear box (L&S) 1880 kg

Slew gear box (Siebenhaar) 1700 kg

Slew motor with attached slew service brake valve 260 kg

Slew motor 110 kg

Bearing ring of the slew parking brake (L&S) 112 kg

Slew parking brake assembly (Siebenhaar) 115 kg

Slew service brake valve 110 kg

Pinion cover 37.5 kg

Lubrication pinion assembly 14.5 kg

Slew circle 3500 kg

Lubrication pump 28 kg

Operator's cab 3000 kg

Viscous mount 4.6 kg

Absorber plate 1 incl. viscous mount 9 kg

Absorber plate 2 incl. viscous mounts 12 kg

Absorber plate 3 incl. viscous mounts 19.5 kg

Front window 95 kg

Operator's seat 62 kg

Access ladder 130 kg

Access ladder cylinder 13 kg

Cab base 3059 kg

Emergency ladder 47 kg

Counterweight 27,650 kg

Fuel tank 2300 kg Empty

Superstructure incl. Diesel engine without counterweight 61,000 kg Aprox.

Table 6-3 Weights of superstructure components and assemblies

6 - 12 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Weight tables

6.5.2 UNDERCARRIAGE
Part or assembly Weight Remark

Crawler track 800 mm 12,880 kg

Crawler track 1000 mm 15,280 kg

Pin between track shoes 9.2 kg

Sprocket 1280 kg

Guide wheel assembly 1590 kg

Low pressure accumulator 13 kg

High pressure accumulator 23 kg

Track tensioning valve block 40 kg

Track tensioning cylinders 188 kg

Hydraulic hoses of the track tensioning system 23 kg Max.

Travel brake valve block 95 kg

Travel motor 155 kg

Travel parking brake 75 kg

Travel gear box 2600 kg

Lower drive motor protection 298 kg

Carrier roller assembly 205 kg

Track roller assembly 296 kg

Car body 19,500 kg

Crawler carrier assembly (incl. 800 mm track group) 31,900 kg

Crawler carrier assembly (incl. 1000 mm track group) 36,150 kg

Rotary joint 215 kg

Table 6-4 Weights of undercarriage components and assemblies

SHOP-50 06279-xD-GB-1 PC3000-6 6 - 13

Weight tables Service Information

6.5.3 BACKHOE ATTACHMENT (BHA)

Part or assembly Weight Remark

Boom 22,760 kg

Pin boom/superstructure 110 kg

Boom cylinder 2660 kg

Pin boom cylinder/boom 84 kg

Pin boom cylinder/superstructure 85 kg

Stick incl. steering and bucket cylinders 17500 kg

Stick 8715 kg

Pin stick/boom 711 kg

Nut-cap 35 kg

Stick cylinder 2420 kg

Pin stick cylinder/stick 82 kg

Pin stick cylinder/boom 84 kg

Bucket 15,200 kg 15 m³

Pin bucket/stick 532 kg

Pin bucket/bucket link rod 398 kg

Bucket cylinder 1850 kg

Pin bucket cylinder/stick 61 kg

Pin bucket cylinder/steering rod 625 kg

Rod protection cover 300 kg Optional

Bucket link rod 2237 kg

Steering rod 642 kg

Pin stick/steering rods 295 kg

Point (Hensley) 81.2 kg

Shroud (Hensley) 182 kg

Wear caps (Hensley) 21 kg

Point (ESCO) 73 kg

Shroud (ESCO) 205 kg

Wear caps (ESCO) 25 kg

Boom arc hose 38 kg

Boom cylinder hoses 22.5 kg

Stick cylinder hoses 24.6 kg

Bucket cylinder hoses 27 kg

Table 6-5 Weights of BHA components and assemblies

6 - 14 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Weight tables

6.5.4 FACE SHOVEL ATTACHMENT (FSA)

Part or assembly Weight Remark

Boom with attached stick and boom cylinders 24,800 kg

Boom 15985 kg

Pin boom/superstructure 110 kg

Pin boom cylinder/boom 115 kg

Pin boom cylinder/superstructure 84 kg

Boom cylinder 2688 kg

Stick 8970 kg

Pin stick/boom 135 kg

Stick cylinder 1635 kg

Pin stick cylinder/stick 52 kg

Pin stick cylinder/boom 60.5 kg

Bucket 16,565 kg 15 m³

Pin bucket cylinder/bucket 83 kg

Pin bucket/stick 133 kg

Bucket cylinder 1787 kg

Pin bucket cylinder/boom 79 kg

Clam cylinder 423 kg

Upper pin at clam cylinder 28 kg

Lower pin at clam cylinder 31 kg

Point (Hensley) 81.2 kg

Shroud (Hensley) 182 kg

Wear caps (Hensley) 21 kg

Point (ESCO) 73 kg

Shroud (ESCO) 205 kg

Wear caps (ESCO) 25 kg

Boom arc hose 38 kg

Boom cylinder hose 18 kg

Stick arc hose 25 kg

Stick cylinder hose 17 kg

Bucket cylinder hose 27 kg

Clam cylinder hose at stick 26 kg

Clam cylinder hose at clam cylinder < 10 kg

Table 6-6 Weights of FSA components and assemblies

SHOP-50 06279-xD-GB-1 PC3000-6 6 - 15

Torque charts according to KOMATSU company standard Service Information

6.6 TORQUE CHARTS ACCORDING TO KOMATSU

COMPANY STANDARD

6.6.1 METRIC STANDARD THREAD

Bolt Wrench size Tightening torque

diameter [mm] [Nm]

Metric regular Bolt quality grades

8.8 10.9 12.9

M 8 13 6 21 31 36

M 10 17 8 43 63 73

M 12 19 10 74 108 127

M 14 22 12 118 173 202

M 16 24 14 179 265 310

M 18 27 14 255 360 425

M 20 30 17 360 510 600

M 22 32 17 485 690 810

M 24 36 19 620 880 1030

M 27 41 19 920 1310 1530

M 30 46 22 1250 1770 2080

M 33 50 24 1690 2400 2800

M 36 55 27 2170 3100 3600

M 39 60 2800 4000 4700

M 42 65 32 3500 4950 5800

M 45 70 4350 6200 7200

M 48 75 35 5200 7500 8700

M 52 80 6700 9600 11200

M 56 85 41 8400 12000 14000

M 60 90 10400 14800 17400

M 64 95 46 12600 17900 20900

M 68 100 15200 21600 25500

Table 6-7 Torque chart standard thread

REMARKS: (1 kgm = 9.806 Nm)

6 - 16 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Torque charts according to KOMATSU company standard

6.6.2 METRIC FINE THREAD

Bolt Wrench size Tightening torque

diameter [mm] [Nm]

Metric fine Bolt quality grades

8.8 10.9 12.9

M 8 x 1.0 13 6 23 33 39

M 10 x 1.0 17 8 48 70 82

M 12 x 1.25 19 10 81 119 139

M 14x1.5 22 12 127 187 219

M 16 x 1.5 24 14 191 280 330

M 18 x 2.0 27 14 270 385 450

M 20 x 2.0 30 17 380 540 630

M 22 x 2.0 32 17 510 720 850

M 24 x 2.0 36 19 680 960 1130

M 27 x 2.0 41 19 990 1410 1650

M 30 x 2.0 46 22 1380 1960 2300

M 33 x 2.0 50 24 1850 2650 3100

M 36 x 3.0 55 27 2300 3250 3850

M 39 x 3.0 60 3000 4200 4950

M 42 x 3.0 65 32 3750 5300 6200

M 45 x 3.0 70 4600 6600 7700

M 48 x 3.0 75 35 5700 8100 9500

M 52 x 3.0 80 7300 10400 12100

M 56 x 4.0 85 41 8900 12600 14800

M 60 x 4.0 90 11000 15600 18300

M 64 x 4.0 95 46 13300 19000 22200

M 68 x 4.0 100 16100 22900 27000

Table 6-8 Torque chart fine thread

REMARKS: Threads and bolts must be greased carefully with MPG (or roller bearing grease, or grease from the
CLS system) . Contact surfaces which should be screwed together must be free of grease.

NOTE! Bolts at the slew rings have different torques, refer to the Parts & Service News "AH00511" latest edi-
tion!

SHOP-50 06279-xD-GB-1 PC3000-6 6 - 17

Torque charts according to KOMATSU company standard Service Information

6.6.3 CUMMINS MOTOR TORQUES - METRIC

Grade 8.8 10.9 12.9

Body size Torque Torque Torque

Diameter Cast iron Aluminium Cast iron Aluminium Cast iron Aluminium
[mm]
[Nm] [ft-lb] [Nm] [ft-lb] [Nm] [ft-lb] [Nm] [ft-lb] [Nm] [ft-lb] [Nm] [ft-lb]

6 9 5 7 4 13 10 7 4 14 9 7 4

7 14 9 11 7 18 14 11 7 23 18 11 7

8 23 17 18 14 33 25 18 14 40 29 18 14

10 45 33 30 25 65 50 30 25 70 50 30 25

12 80 60 55 40 115 85 55 40 125 95 55 40

14 125 90 90 65 180 133 90 65 195 145 90 65

16 195 140 140 100 280 200 140 100 290 210 140 100

18 280 200 180 135 390 285 180 135 400 290 180 135

20 400 290 - - 550 400 - - - - - -

Table 6-9 Torque chart standard metric

6.6.4 CUMMINS MOTOR TORQUES - U.S. CUSTOMARY

Grade 5 (three radial lines on cap) 8 (six radial lines on cap)

Body size Torque Torque

Diameter - threads Cast iron Aluminium Cast iron Aluminium

[Nm] [ft-lb] [Nm] [ft-lb] [Nm] [ft-lb] [Nm] [ft-lb]

1/4 - 20 9 7 8 6 15 11 8 6

1/4 - 28 12 9 9 7 18 13 9 7

5/16 - 18 20 15 16 12 30 22 16 12

5/16 - 24 23 17 19 14 33 24 19 14

3/8 - 16 40 30 25 20 55 40 25 20

3/8 - 24 40 30 35 25 60 45 35 25

7/16 - 14 60 45 45 35 90 65 45 35

7/16 - 20 65 50 55 40 95 70 55 40

1/2 - 13 95 70 75 55 130 95 75 55

1/2 - 20 100 75 80 60 150 110 80 60

9/16 - 12 135 100 110 80 190 140 110 80

Table 6-10 Torque chart U.S. customary

6 - 18 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Torque charts according to KOMATSU company standard

6.6.5 SAE-FLANGE CONNECTIONS

Fig. 6-2 Torques for SAE-flange connections

Reference in Fig. Connection type Connecting parts Tightening Torque Bolt quality
6-2 grades

A Tube to tube 4 x Bolt and nut M12 = 108 Nm

M14 = 173 Nm
Tube to connector 4 x Cylinder head 10.9
B M16 = 265 Nm
plate screw M20 = 510 Nm

4 x Cylinder head M12 = 074 Nm

C Hose to tube
screw and nut M14 = 118 Nm
8.8
Hose to connector 4 x Cylinder head M16 = 179 Nm
D M20 = 360 Nm
plate screw

Table 6-11 Torques for SAE-flange connections

REMARKS: The torque values given in these charts are only valid for bolts manufactured according to DIN (Ger-
man Standard).

NOTE! Tightening torques for SAE-flange connections at oil pumps with aluminium housing: Refer to the
PARTS & SERVICE NEWS No. "AH00521".

SHOP-50 06279-xD-GB-1 PC3000-6 6 - 19

Blind plugs Service Information

6.7 BLIND PLUGS

6.7.1 DUMMY PLATES FOR SAE–FLANGES

Fig. 6-3 Forms / types of dummy plates for SAE–flanges

Up to 3000 PSI

Form / type
DN
SAE size according to PN
(hose / pipe)
Fig. Fig. 6-3

1/2" A 506 521 98 12

3/4" A 506 583 98 20

1 1/4" A 506 584 98 32

1 1/2" A 506 522 98 40

2" A 506 523 98 50

2 1/2" A 506 585 98 65

3" A 512 570 98 80

3/4" B 516 826 98 20

1 1/4 B 517 479 98 32

1 1/2" B 506 528 98 40

2" B 506 529 98 50

2 1/2" B 506 530 98 65

3" B 512 571 98 80

Table 6-12 Dummy plates for SAE-flanges up to 3000 PSI

6 - 20 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Blind plugs

Up to 6000 PSI

Form / type
DN
SAE size according to PN
(hose / pipe)
Fig. Fig. 6-3

3/4" A 506 580 98 20

1" A 506 519 98 25

1 1/4" A 506 520 98 32

1 1/2" A 506 581 98 40

2" A 506 582 98 50

1" B 506 524 98 25

1 1/4" B 506 525 98 32

1 1/2" B 506 526 98 40

2" B 506 527 98 50

1 1/4" C 516 499 98 32

1 1/2" C 509 375 98 40

2" C 509 376 98 50

Table 6-13 Dummy plates for SAE-flanges up to 6000 PSI

SHOP-50 06279-xD-GB-1 PC3000-6 6 - 21

Blind plugs Service Information

6.7.2 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH

Heavy class Light class
(up to 6000 PSI) (up to 3000 PSI)

Size Ra DN Ra DN

M 12 x 1.5 - - 6 5

M 14 x 1.5 - - 8 6

M 16 x 1.5 8 5 10 8

M 18 x 1.5 10 6 12 10

M 20 x 1.5 12 8 - -

M 22 x 1.5 14 10 15 12

M 24 x 1.5 16 12 - -

M 26 x 1.5 - - 18 16

M 30 x 1.5 - - - -

M 30 x 2 20 16 22 20

M 36 x 2 25 20 28 25

M 38 x 1.5 - - - -

M 42 x 2 30 25 - -

M 45 x 1.5 - - - -

M 45 x 2 - - 35 32

M 52 x 1.5 - - - -

M 52 x 2 38 32 42 40

M 65 x 2 - - - -

Table 6-14 Thread / nominal width

Method of using the above table to find appropriate plugs and fittings according to DIN 2353, refer to section 6.7.3
on page 6-23:

EXAMPLE:

To cover up a hose / tube with a diameter of 25 mm, for a pressure up to 3000 PSI perform the following steps:

1. Locate the 25 in the column "DN" in the category "up to 3000 PSI".

2. Check the digit in the column "Ra" next to DN 25 in the same row and category. For this example the proper
plug and fitting is BUZ 28-L and ROV 28-L

3. Choose the proper plugs and fittings from the following table, refer to section 6.7.3 on page 6-23.

REMARKS: The column "Size" indicates the thread-size for the ROV-fittings.

6 - 22 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Blind plugs

6.7.3 PLUGS AND FITTINGS ACCORDING TO DIN 2353

Up to 3000 PSI

BUZ (plugs) PN ROV (fittings) PN

8-L 501 692 98 8-L 518 113 98

10-L 371 852 99 10-PL 513 789 98

12-L 371 854 99 12-PL 513 547 98

15-L 371 855 99 15-PL 507 051 98

18-L 371 856 99 18-PL 513 787 98

22-L 371 857 99 22-PL 513 788 98

28-L 371 858 99 28-PL 509 377 98

35-L 371 859 99 35-PL 516 770 98

42-L 371 860 99 42-PL 513 790 98

Up to 6000 PSI

BUZ (plugs) PN ROV (fittings) PN

- - 8-PS 515 921 98

- - 10-PS 507 023 98

- - 12-PS 507 022 98

16-S 371 866 99 - -

20-S 371 853 99 20-PS 512 005 98

25-S 371 867 99 25-PS 508 033 98

30-S 371 868 99 30-PS 507 021 98

38-S 371 869 99 38-PS 507 020 98

Table 6-15 Plugs and fittings according to DIN 2353

SHOP-50 06279-xD-GB-1 PC3000-6 6 - 23

Conversion table Service Information

6.8 CONVERSION TABLE

6.8.1 METHOD OF USING THE CONVERSATION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method
of using the Conversion Table, see the example given below.

EXAMPLES:

Method of using the Conversion Table to convert from millimeters to inches.

Convert 55 mm into inches:

1. Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from
(A).

2. Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B).

3. Take the point where the two lines cross as (C). This point (C) gives the value when converting from millime-
ters to inches.
Therefore, 55 millimeters = 2.165 inches.

Convert 550 mm into inches:

1. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to con-
vert it to 55 mm.

2. Carry out the same procedure as above to convert 55 mm to 2.165 inches.

3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to
the right) to return to the original value. This gives 550 mm = 21.65 inches.

6 - 24 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Conversion table

6.8.2 MILLIMETER - INCH & KILOGRAM - POUND

Table 6-16 Conversion table mm - inch / kg - pound

SHOP-50 06279-xD-GB-1 PC3000-6 6 - 25

Conversion table Service Information

6.8.3 LITER - U.S. GALLON & LITER - U.K. GALLON

Table 6-17 Conversion table Liter - Gallon

6 - 26 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Conversion table

6.8.4 NM- FT.LB

0 1 2 3 4 5 6 7 8 9
0 0 0.74 1.47 2.21 2.95 3.69 4.42 5.16 5.90 6.63
10 7.37 8.11 8.84 9.58 10.32 11.06 11.79 12.53 13.27 14.00
20 14.74 15.48 16.21 16.95 17.69 18.43 19.16 19.90 20.64 21.37
30 22.11 22.85 23.58 24.32 25.06 25.80 26.53 27.27 28.01 28.74
40 29.48 30.22 30.95 31.69 32.43 33.17 33.90 34.64 35.38 36.11
50 36.85 37.59 38.32 39.06 39.80 40.54 41.27 42.01 42.75 43.48
60 44.22 44.96 45.69 46.43 47.17 47.91 48.64 49.38 50.12 50.85
70 51.59 52.33 53.06 53.08 54.54 55.28 56.01 56.75 57.49 58.22
80 58.96 59.07 60.43 61.17 61.91 62.65 63.38 64.12 64.86 65.59
90 66.33 67.07 67.80 68.54 69.28 70.02 70.75 71.49 72.23 72.96
100 73.70 74.44 75.17 75.91 76.65 77.39 78.12 78.86 79.60 80.33
110 81.07 81.81 82.54 83.28 84.02 84.76 85.49 86.23 86.97 87.70
120 88.44 89.18 89.91 90.65 91.39 92.13 92.86 93.60 94.34 95.07
130 95.81 96.55 97.28 98.02 98.76 99.50 100.23 100.97 101.71 102.44
140 103.18 103.92 104.65 105.39 106.13 106.87 107.60 108.34 109.08 109.81
150 110.55 111.29 112.02 112.76 113.50 114.24 114.97 115.71 116.45 117.18
160 117.92 118.66 119.39 120.13 120.87 121.61 122.34 123.08 123.82 124.55
170 125.29 126.03 126.76 127.50 128.24 128.98 129.71 130.45 131.19 131.92
180 132.66 133.40 134.13 134.87 135.61 136.35 137.08 137.82 138.56 139.29
190 140.03 140.77 141.50 142.24 142.98 143.72 144.45 145.19 145.93 146.66
200 147.40 148.14 148.87 149.61 150.35 151.09 151.82 152.56 153.30 154.03

Table 6-18 Conversion table Nm - ft.lb

1 Nm = 0.737 FT.LB

SHOP-50 06279-xD-GB-1 PC3000-6 6 - 27

Conversion table Service Information

6.8.5 BAR - PSI - KPA - MPA

1...200 Bar 205...400 Bar

Bar PSI kPa MPa Bar PSI kPa MPa
1 14.5037 100 0.1 205 2973.18 20500 20.5
5 72.52 500 0.5 210 3045.69 21000 21
10 145.03 1000 1 215 3118.21 21500 21.5
15 217.55 1500 1.5 220 3190.73 22000 22
20 290.07 2000 2 225 3263.24 22500 22.5
25 362.58 2500 2.5 230 3335.76 23000 23
30 435.1 3000 3 235 3408.28 23500 23.5
35 507.62 3500 3.5 240 3480.79 24000 24
40 580.13 4000 4 245 3553.31 24500 24.5
45 652.65 4500 4.5 250 3625.83 25000 25
50 725.17 5000 5 255 3698.34 25500 25.5
55 797.68 5500 5.5 260 3770.86 26000 26
60 870.2 6000 6 265 3843.37 26500 26.5
65 942.71 6500 6.5 270 3915.89 27000 27
70 1015.23 7000 7 275 3988.41 27500 27.5
75 1087.75 7500 7.5 280 4060.92 28000 28
80 1160.26 8000 8 285 4133.44 28500 28.5
85 1232.78 8500 8.5 290 4205.96 29000 29
90 1305.3 9000 9 295 4278.47 29500 29.5
95 1377.81 9500 9.5 300 4350.99 30000 30
100 1450.33 10000 10 305 4423.51 30500 30.5
105 1522.85 10500 10.5 310 4496.02 31000 31
110 1595.36 11000 11 315 4568.54 31500 31.5
115 1667.88 11500 11.5 320 4641.06 32000 32
120 1740.4 12000 12 325 4713.57 32500 32.5
125 1812.91 12500 12.5 330 4786.09 33000 33
130 1885.43 13000 13 335 4858.61 33500 33.5
135 1957.95 13500 13.5 340 4931.12 34000 34
140 2030.46 14000 14 345 5003.64 34500 34.5
145 2102.98 14500 14.5 350 5076.16 35000 35
150 2175.5 15000 15 355 5148.67 35500 35.5
155 2248.01 15500 15.5 360 5221.19 36000 36
160 2320.53 16000 16 365 5293.7 36500 36.5
165 2393.04 16500 16.5 370 5366.22 37000 37
170 2465.56 17000 17 375 5438.74 37500 37.5
175 2538.08 17500 17.5 380 5511.25 38000 38
180 2610.59 18000 18 385 5583.77 38500 38.5
185 2683.11 18500 18.5 390 5656.29 39000 39
190 2755.63 19000 19 395 5728.8 39500 39.5
195 2828.14 19500 19.5 400 5801.32 40000 40
200 2900.66 20000 20

Table 6-19 Conversion table bar - PSI / PSI - bar

1 Bar = 14.5037 PSI

6 - 28 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Conversion table

6.8.6 TEMPERATURE
The figures in the table below refer to the temperature in either Fahrenheit or Centigrade degrees.

If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.

If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.

Table 6-20 Conversion table °C - °F / °F - °C

SHOP-50 06279-xD-GB-1 PC3000-6 6 - 29

Tools Service Information

6.9 TOOLS
All tools can be found in the Komatsu Tools Catalogue which can be ordered for free at your local dealer for
Komatsu Germany mining equipment.

6.9.1 STANDARD TOOL CASE

Komatsu provides a standard tool case, PN 232 709 40.

Q‘ty Part name Part number

1 Measuring tape 3 m long 470 615 40
1 Hammer 500 g 232 130 40
1 Sliding caliper, 200 mm long 232 107 40
1 Reamer (countersink, stem diameter 10 mm; reamer diameter 20 mm 232 690 40
1 Socket wrench ½“ - set (WS 10 - 32) 232 691 40
1 Internal hexagon socket, 1/2“ - set, (WS 5 - 17) 232 570 40
1 Double ended open wrench - set (WS 6 - 32) 232 692 40
1 Combination wrenches - set (WS 10 - 32) 232 693 40
1 Twist drill - set (1 - 13 mm) 232 207 40
1 Needle files - set 232 199 40
1 Tool bag 232 694 40
1 Toolbox L= 460; B= 170; L= 310 232 695 40
1 Socket wrench ¼“ - set (WS 3 - 13) 232 696 40
1 Drift punch 3 - 8 mm 232 697 40
1 Socket wrench with ball head - set (1.5 - 10 mm) 232 698 40
1 Side cutter insulated up to 1000 Volt, 190 mm 232 401 40
1 Combination pliers insulated up to 1000 Volt, 185 mm 232 400 40
1 Bent nose pliers, Knipex 232 403 40
1 Water pump pliers 250 mm long 232 139 40
1 Cable stripping knife 4 - 16 mm 232 699 40
1 Screwdriver for slotted screws 11 x 300 mm 232 120 40
1 Screwdriver for slotted screws 13 x 390 mm 232 121 40
1 Crosstip screwdriver size 0 232 111 40
1 Crosstip screwdriver size 1 232 112 40
1 Crosstip screwdriver size 2 232 113 40
1 Infrared thermometer IR 1 232 665 40
1 LCD-Digital Multimeter VC 444 232 688 40
1 VDE Screwdriver, WERA 232 689 40
1 Hydraulic mini testing kit 232 591 40
2 Pressure gauge 400 bar 793 363 73
3 Measuring hose 2.5 m 896 483 40
2 Pressure gauge fitting G¼ 232 501 40
1 Set – Screwdriver 907 696 40
1 Side cutting pliers, Knipex 232 700 40
1 Stripping- and cutting tool Stripax for PVC-isolation up to 6 mm², 20 mm 232 663 40
1 Crimp pliers, rimp capacity 0.5 - 4 mm² 232 661 40
1 Crimp pliers HTN 21 232 701 40
2 Testing wire 4mm Type 410 (red) 232 702 40
2 Testing wire 4mm Type 410 (black) 232 703 40
1 Testing tip "Hirschmann Prüf 2" (red) 232 704 40
1 Testing tip "Hirschmann Prüf 2" (black) 232 705 40

6 - 30 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Tools

1 Clip terminal "Hirschmann Ak 2 S" (red) 232 706 40

Q‘ty Part name Part number

1 Clip terminal "Hirschmann Ak 2 S" (black) 232 707 40
1 Fluke 179 Digital-Multimeter 232 708 40
1 Rollbox K 412 (740 x 365 x 375) 232 711 40
1 Tachometer Moviport 232 551 40
1 Magnet-stick 232 712 40
1 Electric set with pliers 793 265 73
1 Software (Bodem 24) 796 726 73
1 Bodem connection cable 896 791 40
1 Crimp-pliers for revolved contacts 793 729 73
1 Cable set 796 443 73
1 Prostat Cable VL 3 (X27 -PC) 659 820 40
1 Prosyd Cable VL 12 (PLC-PC) 926 503 40
1 TazETM Cable VL 10 (ETM-PC) 891 175 40
1 Cable VL 9a 891 176 40
1 Cable VL 9b 891 177 40
1 PC4000-6 VHMS download-cable (new for 08156 and up) 894 580 40
1 Converter, cable, and software as set 796 442 73
1 Converter 796 439 73
1 USB extension wire 796 440 73
1 UMG diagnostic software (CD) 796 441 73

Table 6-21 KOMATSU Standard tool case

SHOP-50 06279-xD-GB-1 PC3000-6 6 - 31

Tools Service Information

6.9.2 USED SPECIAL TOOLS (OVERVIEW)

Component Part number Part name Q‘ty Nature of work, remarks

Swing circle mounting kit

PN 768 222 73 (normal condition) 1
PN 768 928 73 (cold weather) Installation of the swing circle
Assembly of superstructure onto
46 mm hexagon
undercarriage
PN 232 265 40 impact socket 1
Swing circle wrench (1")
mounting REMARKS: *1 May differ from the
Electro-hydraulic given part number.
PN 793 375 73 1
pump set Refer to the spare part
catalogue of the spe-
Hydraulic torque
PN 232 614 40 1 cific machine.
wrench

PN 379 383 40 Mounting cross 1

Safety unit for

PN 921 166 40 changing track 1
rollers Disassembling and assembling of
Track rollers
Tool for changing the track rollers
n/a track rollers 1
Ask local dealer!

Pressure accumu-
Testing- and refilling
lators of the track PN 761 520 73 1 Refilling pressure accumulators
device
tensioning system

Wrench socket with

PN 793 376 73 1
supporting bar

Hydraulic torque Disassembling and assembling of

Car body/crawler PN 793 374 73 1
wrenchr the car body/crawler carrier
carrier
Electro-hydraulic
PN 793 375 73 1
pump set

PN 928 476 40 Measuring device 1 Installation of the crawler carriers

Hydraulic system Measurements of hydraulic pres-

PN 232 315 40 Hydraulic testing kit 1
(general) sures

Power Torque Multi-

Sprocket PN 232 511 40 1 Installation of the sprocket
plier & socket size

Rotational speed
Cooling fans PN 793 788 73 infrared probe 1 Measurements of rotation speed
DS03

Hydraulic torque
PN 232 759 40 wrench & aggre- 1
Hydraulic oil cooler gate set Disassembling and assembling of
assembly 46 mm hexagon the hydraulic oil cooler assembly
PN 232 265 40 impact socket 1
wrench (1")

6 - 32 PC3000-6 SHOP-50 06279-xD-GB-1

Service Information Tools

Component Part number Part name Q‘ty Nature of work, remarks

Hydraulic torque
PN 232 759 40 wrench & aggre- 1
Hydraulic oil tank gate set Disassembling and assembling of
assembly 46 mm hexagon the hydraulic oil tank assembly
PN 232 265 40 impact socket 1
wrench (1")

65 mm hexagon
PN 232 521 40 impact socket 1
wrench (1 1/2") Disassembling and assembling of
Counterweight
Hydraulic torque the counterweight
PN 232 758 40 wrench & aggre- 1
gate set

Hydraulic torque
PN 232 759 40 wrench & aggre- 1
gate set Disassembling and assembling of
Fuel tank assembly
46 mm hexagon the fuel tank assembly
PN 232 265 40 impact socket 1
wrench (1")

46 mm hexagon
PN 232 265 40 impact socket 1
wrench (1")
Disassembling and assembling of
Superstructure Hydraulic torque
PN 232 614 40 1 the superstructure
wrench

Electro-hydraulic
PN 793 375 73 1
pump set

Disassembling and assembling of

the bucket
Disassembling and assembling of
the bucket cylinders
Attachment BHA PN 409 329 40 Thread protector 1
Disassembling and assembling of
the steering rods
Disassembling and assembling of
the stick

Disassembling and assembling of

the boom cylinders
Cylinder mounting Disassembling and assembling of
Attachment FSA PN 967 000 40 1
device the bucket cylinders
Disassembling and assembling of
the stick cylinders

POSILOK pin
PN 795 997 73 1
removal tool
Disassembling and assembling of
GET HENSLEY pin the GET
n/a removal tool 1
Ask local dealer!

Table 6-22 Used special tools

SHOP-50 06279-xD-GB-1 PC3000-6 6 - 33

Tools Service Information

Please continue reading on the next page.

6 - 34 PC3000-6 SHOP-50 06279-xD-GB-1

Parts & Service News

7 PARTS & SERVICE NEWS

SHOP-50 06279-xD-GB-1 PC3000-6 7 -1

List of The PARTS AND SERVICE NEWS Parts & Service News

7.1 LIST OF THE PARTS AND SERVICE NEWS

SB-No. Subject

AH00511 Installation procedure for the swing circle / slew ring (SR)

AH00519 Adhesive lubricants for the slew ring gear

AH00521 Tightening torques for bolts

AH01521 Diesel engine suspension

AH01531 Hydraulic accumulators – testing and refilling

AH02513 Testing wear and tear of swing circle bearing

AH02521 Track group – wear measurement

AH03510 ESCO bucket tooth system

AH03528 Pilot control safety line

AH04518 Welding procedure for welded counterweight

AH05511 Dual cone seal ring mounting

AH05518 Wear check – Swing circle pinion

AH05535 Hints for replacing a slew gear of an other manufacturer

AH06519 Main hydraulic pumps – hints for venting

AH06521 Air Condition System

AH06524 Hydraulic cylinder

AH06544 Hydraulic track tensioning system – Pressure increasing valve

AH06545 Installation hints for hydraulic cylinder bushings

AH08507 Repair welding procedure

AH08508 Bushings of the attachment and at the undercarriage

AH09522 Wishbone and rod

AH10530 Tightening torque for grease injectors (SL1 and SL11)

AH10532 Operation Manual for the hydraulic oil transfer pump

AH11511 Bearing bushes

AH12503 Komatsu Main pumps HPV 375+375

AH11507 Bolted undercarriage

AH13423 Windshield

AH15824 User Manual Lubrication Pump (PN 798 884 73)

AH15840 Exchange of Hydraulic cylinders

REMARKS: The numbers of the PARTS & SERVICE NEWS do not label the latest edition. Ensure that the latest
edition is always filed to the binder of this manual.

7 -2 PC3000-6 SHOP-50 06279-xD-GB-1