TS 08199-xD-GB-2

TS 08199-xD-GB-2
Troubleshooting Manual
HYDRAULIC
MINING PC4000-6
SHOVEL
SERIAL NUMBER 08199 and up
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.
Komatsu has Troubleshooting Manuals written

in other languages. If a foreign language man-
ual is required, contact your local distributor for
availability.
COPYRIGHT
This material is property of Komatsu Mining Germany GmbH and is not to be reproduced, used, or
disclosed except in accordance with the written authorization of Komatsu Mining 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.
TABLE OF CONTENTS
1 SAFETY ..................................................................................................... 1-1

1.1 SAFETY INFORMATION ................................................................................................................... 1-2
1.2 OVERVIEW ........................................................................................................................................ 1-3
1.2.1 NORMAL OPERATIONS ....................................................................................................... 1-3
1.2.2 REGULAR MAINTENANCE .................................................................................................. 1-3
1.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR ....................................................... 1-3
1.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING,
DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR.................................. 1-3
1.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB ............................................................... 1-4
1.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR........................... 1-5
1.4.1 UNDERSTANDING THE MACHINE ...................................................................................... 1-5
1.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR ...................... 1-5
1.4.2.1 ENSURING SAFE OPERATION............................................................................ 1-5
1.4.3 PREPARATIONS FOR SAFE OPERATION.......................................................................... 1-5
1.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT ....................... 1-5
1.4.3.2 INSPECTING THE MACHINE ............................................................................... 1-5
1.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT.................. 1-6
1.4.3.4 KEEP MACHINE CLEAN ....................................................................................... 1-6
1.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT................................... 1-6
1.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ........................................ 1-7
1.4.3.7 IF A PROBLEM IS FOUND.................................................................................... 1-7
1.4.4 FIRE PREVENTION .............................................................................................................. 1-7
1.4.4.1 PRECAUTIONS TO PREVENT FIRE .................................................................... 1-7
1.4.4.2 ACTION IF FIRE OCCURS.................................................................................... 1-8
1.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB................................................... 1-9
1.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE ......................................... 1-9
1.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE . 1-9
1.4.5.2 NO JUMPING ON OR OFF THE MACHINE .......................................................... 1-9
1.4.5.3 NO PEOPLE ON THE ATTACHMENT .................................................................. 1-9
1.4.5.4 WORKING IN HIGH PLACES................................................................................ 1-9
1.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK ...................................................... 1-10
1.4.5.6 LEAVING THE MACHINE .................................................................................... 1-10
1.4.6 BURN PREVENTION .......................................................................................................... 1-11
1.4.6.1 HOT COOLANT ................................................................................................... 1-11
1.4.6.2 HOT OIL .............................................................................................................. 1-11
1.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS .............................................................. 1-11
1.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES .......................................... 1-12
1.4.8.1 UNAUTHORIZED MODIFICATION ..................................................................... 1-12
1.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ...................... 1-12
1.4.9 PRECAUTIONS AT JOBSITE ............................................................................................. 1-13
1.4.9.1 VISIBILITY FROM OPERATOR’S SEAT ............................................................. 1-14
1.4.9.2 CAMERA SYSTEM WITH MONITORS ............................................................... 1-14
1.4.9.3 ENSURE GOOD VISIBILITY ............................................................................... 1-14
1.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS ........................................... 1-14
1.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS ................................... 1-15
1.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES .......................................... 1-15
1.4.9.7 WORKING ON LOOSE GROUND ....................................................................... 1-16
TS 08199-upD-GB-2 PC4000-6 TOC - 1

1.4.9.8 GAS, DUST, STEAM AND SMOKE ..................................................................... 1-16
1.4.9.9 VENTILATION OF ENCLOSED AREAS.............................................................. 1-17
1.4.10 STARTING ENGINE ............................................................................................................ 1-18
1.4.10.1 WARNING TAG.................................................................................................... 1-18
1.4.10.2 CHECKS BEFORE STARTING ENGINE............................................................. 1-18
1.4.10.3 PRECAUTION WHEN STARTING ENGINE........................................................ 1-18
1.4.10.4 PRECAUTION IN COLD AREAS ......................................................................... 1-19
1.4.11 OPERATION ........................................................................................................................ 1-19
1.4.11.1 CHECKS BEFORE OPERATION ........................................................................ 1-19
1.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE ............... 1-20
1.4.11.3 PRECAUTIONS WHEN TRAVELLING ................................................................ 1-21
1.4.11.4 TRAVELLING ON SLOPES ................................................................................. 1-22
1.4.11.5 OPERATIONS ON SLOPES ................................................................................ 1-23
1.4.11.6 PROHIBITED OPERATIONS............................................................................... 1-23
1.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES....................... 1-24
1.4.11.8 PARKING THE MACHINE ................................................................................... 1-24
1.4.11.9 TRANSPORTATION ............................................................................................ 1-24
1.5 PRECAUTION FOR MAINTENANCE .............................................................................................. 1-25
1.5.1 GENERAL PRECAUTIONS ................................................................................................. 1-25
1.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL -
BASIC RESPONSIBILITIES................................................................................. 1-26
1.5.1.2 STOP ENGINE FOR MAINTENANCE ................................................................. 1-27
1.5.1.3 WARNING TAG.................................................................................................... 1-28
1.5.1.4 KEEP WORKPLACE CLEAN AND TIDY ............................................................. 1-29
1.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS ..................................... 1-29
1.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING.. 1-30
1.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS ............................... 1-30
1.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 1-31
1.5.1.9 NOISE .................................................................................................................. 1-31
1.5.1.10 WHEN USING A HAMMER.................................................................................. 1-31
1.5.1.11 PROPER TOOLS ................................................................................................. 1-32
1.5.1.12 ACCUMULATOR.................................................................................................. 1-32
1.5.1.13 PERSONNEL ....................................................................................................... 1-32
1.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE................................................ 1-33
1.5.2.1 PRECAUTION WHEN WELDING ........................................................................ 1-33
1.5.2.2 BATTERY HANDLING ......................................................................................... 1-33
1.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID............................................................... 1-34
1.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE ................................................ 1-34
1.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES .......................................... 1-35
1.5.3.3 REPLACEMENT OF HOSE LINES...................................................................... 1-35
1.5.3.4 INSPECTION OF HOSE LINES........................................................................... 1-35
1.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................. 1-36
1.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE............................................................... 1-36
1.5.3.7 AIR CONDITIONING MAINTENANCE................................................................. 1-36
1.5.3.8 COMPRESSED AIR............................................................................................. 1-37
1.5.3.9 WASTE MATERIALS ........................................................................................... 1-37
1.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS ....... 1-38
1.6.1 INSPECTION OF THE HYDRAULIC SYSTEM ................................................................... 1-38
1.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 1-38
1.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...................................... 1-38
TOC - 2 PC4000-6 TS 08199-upD-GB-2

1.7 SPECIAL SAFETY EQUIPMENT..................................................................................................... 1-39
1.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB ................ 1-40
1.7.2 OBJECT HANDLING ........................................................................................................... 1-40
1.7.3 LIGHTING ............................................................................................................................ 1-40
1.7.4 WARNING BEACON ........................................................................................................... 1-40
1.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ........... 1-40
1.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361
(EUROPEAN STANDARD) .................................................................................. 1-40
1.7.5.2 INSTRUCTIONS FOR USE ................................................................................. 1-42
1.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL ......................... 1-44
1.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND
HOLD-BACK HOOKS OF THE SAFETY HARNESS (1) ..................................... 1-44
1.7.5.5 INSTRUCTIONS FOR USE ................................................................................. 1-46
2 INTRODUCTION & GENERAL INFORMATION FOR TROUBLESHOOT. 2-1

2.1 OVERVIEW ........................................................................................................................................ 2-2
2.1.1 GENERAL ADVICE WHEN USING TROUBLESHOOTING CHARTS .................................. 2-2
2.2 GENERAL PRECAUTIONS ............................................................................................................... 2-3
2.3 PREPARATIONS FOR WORK .......................................................................................................... 2-4
2.4 PRECAUTIONS DURING WORK ...................................................................................................... 2-4
2.5 PRECAUTIONS WHEN CARRYING OUT ANY OPERATION .......................................................... 2-5
2.5.1 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK.............................................. 2-5
2.5.2 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK...................................... 2-5
2.5.3 PRECAUTIONS WHEN COMPLETING THE OPERATION .................................................. 2-6
2.6 FUNDAMENTAL REQUIREMENTS FOR TROUBLESHOOTING .................................................... 2-7
2.6.1 TECHNICAL DOCUMENTATION .......................................................................................... 2-7
2.6.2 TOOLS................................................................................................................................... 2-7
2.6.2.1 REFERENCE GUIDE FOR DEUTSCH REMOVAL TOOLS ................................ 2-10
2.6.3 PERSONNEL ....................................................................................................................... 2-11
2.7 POINTS TO REMEMBER WHEN TROUBLESHOOTING ............................................................... 2-11
2.8 SEQUENCE OF EVENTS IN TROUBLESHOOTING ...................................................................... 2-13
2.9 CHECKS BEFORE TROUBLESHOOTING ..................................................................................... 2-14
2.10 HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS.............................. 2-15
2.10.1 POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT ........................... 2-15
2.10.2 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT ........................ 2-17
2.11 GENERAL WORKING PROCEDURES ........................................................................................... 2-20
2.11.1 AIR BLEEDING OF VARIOUS HYDRAULIC PARTS .......................................................... 2-20
2.11.2 AIR BLEEDING FROM THE HYDRAULIC PUMPS ............................................................ 2-20
2.11.3 AIR BLEEDING FROM HYDRAULIC CYLINDERS ............................................................. 2-20
2.12 CYLINDER BYPASS TEST ............................................................................................................. 2-21
2.13 INFORMATION ABOUT MTC & NODES ........................................................................................ 2-22
2.13.1 OUTLINE OF THE MTC AND ITS CONNECTOR LOCATIONS ......................................... 2-22
2.13.1.1 VIEW ONTO THE MTC CONNECTORS* LH & RH ............................................ 2-22
2.13.1.2 GENERAL DESCRIPTION OF THE MTC ........................................................... 2-22
2.13.1.3 INFORMATION ABOUT THE LED INDICATIONS AT THE MTC........................ 2-23
TS 08199-upD-GB-2 PC4000-6 TOC - 3

2.13.2 INFORMATION ABOUT THE ICN-D NODE ........................................................................ 2-23
2.13.2.1 VIEW ONTO AN ICN-D NODE WITHOUT WIRING ............................................ 2-24
2.13.2.2 VIEW ONTO THE STATUS LEDS AT THE ICN-D NODE ................................... 2-25
2.13.2.3 GENERAL INFORMATION ON THE LED CONTROL ......................................... 2-25
2.13.3 INFORMATION ABOUT THE ICN-V NODE ........................................................................ 2-27
2.13.3.1 VIEW ONTO AN ICN-V NODE............................................................................. 2-27
2.13.3.2 VIEW ONTO AN OPEN ICN-V NODE AND ITS DIP-SWITCHES ....................... 2-28
2.13.4 DIP SWITCHES AT THE ICN-D AND ICN-V NODES ......................................................... 2-29
2.14 BASICS ABOUT "HOW TO CRIMP"............................................................................................... 2-30
2.14.1 STRIPPING A WIRE FOR USE WITH THE HDT 48 CRIMP TOOL .................................... 2-30
2.14.2 VIEW ONTO THE DEUTSCH CRIMP TOOL HDT 48 ......................................................... 2-30
2.14.3 ADJUSTMENT OF THE WIRE SIZE AT THE DEUTSCH CRIMP TOOL HDT 48 .............. 2-31
2.14.3.1 WIRE CROSS SECTION UNITS IN MM2 AND AWG .......................................... 2-31
2.14.4 CRIMPING INSTRUCTIONS (FOR DEUTSCH CRIMP TOOL HDT 48) ............................. 2-32
2.15 CABLE SHIELDING ......................................................................................................................... 2-33
3 MOUNTING LOCATIONS AND CONNECTOR TYPES ............................ 3-1

3.1 COMPONENT LOCATION................................................................................................................. 3-2
3.1.1 VIEW ONTO THE SUPERSTRUCTURE............................................................................... 3-2
3.1.2 LOCATION OF ENGINE ELECTRICAL PARTS (1) .............................................................. 3-4
3.1.3 LOCATION OF ENGINE ELECTRICAL PARTS (2) .............................................................. 3-6
3.1.4 LOCATION OF HYDRAULIC COMPONENTS (1)................................................................. 3-7
3.1.5 LOCATION OF HYDRAULIC COMPONENTS (2)................................................................. 3-9
3.1.6 LOCATION OF THE REMOTE CONTROL VALVES........................................................... 3-10
3.1.7 LOCATION OF THE HIGH PRESSURE SENSORS ........................................................... 3-12
3.1.8 VIEW ONTO THE SLS AND CLS GREASE BARREL AND
THE LUBRICATION CYCLE COMPONENTS ..................................................................... 3-13
3.1.9 VIEW ONTO THE ELECTRICAL COMPONENTS IN THE CAB BASE............................... 3-15
3.1.10 HYDRAULIC OIL TANK - LOCATION OF ELECTRICAL COMPONENTS ......................... 3-17
3.1.11 HYDRAULICALLY OPERATED ACCESS LADDER ........................................................... 3-19
3.2 CONNECTOR TYPES OVERVIEW.................................................................................................. 3-21
4 STANDARD VALUE TABLE FOR ELECTRICAL COMPONENTS............ 4-1

5 REFERENCES FOR TROUBLESHOOT. (CAN BUS & NODE OUTPUTS) 5-1
5.1 CAN-BUS TROUBLE OR NODE OUTPUT TROUBLE ..................................................................... 5-2
5.1.1 TROUBLE CAN-BUS OR CAN-HARDWARE (G00308) ...................................................... 5-3
5.1.2 TROUBLE OUTPUT SHORT-CIRCUIT (G00043)................................................................. 5-4
5.2 SEQUENCE OF THE CAN NODES AT THE CAN BUS.................................................................... 5-6
5.3 TROUBLESHOOTING FOR RELAY MONITORED NODE OUTPUTS ............................................. 5-7
5.3.1 RELAY CHECK...................................................................................................................... 5-7
G00107 - Trouble slew parking brake control 56K250a...................................................................... 5-8
G00109 - Trouble slew parking brake control 56K250b ..................................................................... 5-8
View onto the CoDeSys HMI Visualization screen for trouble code G00107 .............................. 5-10
Wiring Diagram (56K250a & 56K250b) for trouble code G00107................................................ 5-11
TOC - 4 PC4000-6 TS 08199-upD-GB-2

5.3.2 OUTPUT CHECK................................................................................................................. 5-12
G00108 - Trouble slew parking brake control Output to 56K250a .................................................. 5-13
G00110 - Trouble slew parking brake control Output to 56K250b .................................................. 5-13
View onto the CoDeSys HMI Visualization screen for trouble code G00108 .............................. 5-15
Wiring Diagram (56K250a & 56K250b) for trouble code G00108................................................ 5-16
6 TABLES FOR TESTING AND TROUBLESHOOTING .............................. 6-1

6.1 INDEX OF TABLES IN THIS SECTION............................................................................................. 6-2
6.2 TEST VALUE TABLE FOR TEMPERATURE SENSORS (PT100) CENTIGRADE - VOLT ......... 6-3
6.3 TEST VALUE TABLE FOR TEMPERATURE SENSORS (PT100) CENTIGRADE - OHM .......... 6-4
6.4 TABLE OF TROUBLE CODES (G-CODES) ..................................................................................... 6-5
6.5 TABLE OF INSTRUCTION MESSAGES......................................................................................... 6-11
6.6 TABLE OF BINARY CODES ........................................................................................................... 6-14
6.6.1 TABLE OF ADD-ON BINARY CODES FOR G00308 .......................................................... 6-16
6.7 BINARY OUTPUT SIGNALS ON THE VHMS MONITOR ............................................................... 6-17
6.8 POWER SUPPLY............................................................................................................................. 6-19
6.9 CABLE COLOUR IDENTIFICATION ............................................................................................... 6-20
7 TROUBLESHOOTING BY TROUBLE CODE............................................ 7-1

G00001 - Trouble Shut-Off (gate) valve................................................................................................ 7-2
View onto the gap of proximity switch 40B031 .............................................................................. 7-4
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR ................... 7-5
View onto the setting for SHUTDOWN BYPASS on the VHMS monitor ....................................... 7-5
Wiring Diagram (40B031) for trouble code G00001 (Main gate valve open)................................. 7-6
G00002 - Test speed 1800 1/min engine 1 ........................................................................................... 7-7

Wiring Diagram (11S041-1) for trouble code G00002 ................................................................... 7-8
G00003 - Trouble pump controller ....................................................................................................... 7-9
G00005 - Low hydraulic oil level......................................................................................................... 7-13

Wiring Diagram, oil level label, and defined position of the attachment (G00005) ...................... 7-15
G00007 - Trouble hydraulic oil level................................................................................................... 7-16

Wiring Diagram (40B004) and the defined position of the attachment (G00007) ........................ 7-17
G00012 - Central lubrication system grease level too low............................................................... 7-18
G00013 - Slew ring gear lubr. system grease level too low ............................................................. 7-18
Wiring Diagram (62B108 & 62B109) for trouble codes G00012 & G00013................................. 7-22
Wiring Diagram (junction box) for trouble codes G00012 & G00013........................................... 7-23
G00020 - Trouble Shut-Off (gate) valve (Start blocked) ................................................................... 7-24

View onto the gap of proximity switch 40B031 (G00020) ............................................................ 7-26
Wiring Diagram (40B031) for trouble code G00020 (Main gate valve closed) ............................ 7-27
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR ................. 7-28
View onto the setting for SHUTDOWN BYPASS on the VHMS monitor ..................................... 7-28
TS 08199-upD-GB-2 PC4000-6 TOC - 5

G00031 - Set engine to low idle .......................................................................................................... 7-29
Wiring Diagram (20S030) for trouble code G00031 .................................................................... 7-30
Input signal of the engine speed switch 20S030 on the REAL TIME MONITOR ........................ 7-30
G00032 - Trouble starter...................................................................................................................... 7-31

Wiring Diagram (Cold Start Signal) for trouble code G00032 ...................................................... 7-32
Wiring Diagram ("Engine running" signal) for trouble code G00032............................................ 7-33
G00033 - Trouble VHMS-Controller .................................................................................................... 7-34
G00034 - Trouble VHMS-Display ........................................................................................................ 7-35
G00035 - Trouble totally loss gear oil (PTO 1) .................................................................................. 7-36

View onto the location of sensor 57B175-1 at the PTO (G00035)............................................... 7-38
Input signal (analog) of the PTO 1 gear oil sensor 57B175-1 on the REAL TIME MONITOR..... 7-39
View onto the setting for SHUTDOWN BYPASS on the VHMS monitor ..................................... 7-39
Wiring Diagram (57B175-1) for trouble code G00035 ................................................................. 7-40
G00039 - Actuate engine speed selector switch ............................................................................... 7-41
G00043 - Trouble output short-circuit................................................................................................ 7-42
G00048 - Trouble emergency safety circuit....................................................................................... 7-43

Wiring Diagram (11K044a) for trouble code G00048 .................................................................. 7-43
G00053 - Reset emergency safety circuit .......................................................................................... 7-44
G00054 - Monitoring idle position cut off .......................................................................................... 7-45

Wiring Diagram (11K032) for trouble code G00054 .................................................................... 7-46
Input signal (analog) of relay 11K032 on the REAL TIME MONITOR (G00054) ......................... 7-47
Exemplary view onto the VHMS Failure History (G00054) .......................................................... 7-47
G00060 - Fire in the power house....................................................................................................... 7-48

Wiring Diagram (fire alarm) for trouble code G00060 .................................................................. 7-50
Wiring Diagram (10B351 in the safety circuit) for G00060 .......................................................... 7-51
G00061 - Trouble monitoring, engine 1 speed too low .................................................................... 7-52

Input signal (analog) of 51K003b-1 on the REAL TIME MONITOR (G00061) ............................ 7-53
Wrong signal of the engine speed converter on the REAL TIME MONITOR (G00061) .............. 7-54
Wiring Diagram (engine speed) for trouble code G00061 ........................................................... 7-54
G00062 - Trouble monitoring, engine 1 speed too high ................................................................... 7-55

Wiring Diagram (engine speed) for trouble code G00062 ........................................................... 7-56
G00063 - Trouble monitoring hydraulic oil temp .............................................................................. 7-57

Wiring Diagram (59B015) for trouble code G00063 .................................................................... 7-58
G00064 - Trouble monitoring hydraulic oil level ............................................................................... 7-59

Wiring Diagram (40B004) for trouble code G00064 .................................................................... 7-61
G00065 - Very low hydraulic oil level ................................................................................................. 7-62

View onto the hydraulic oil level label .......................................................................................... 7-62
TOC - 6 PC4000-6 TS 08199-upD-GB-2

G00066 - Trouble hydraulic oil temperature...................................................................................... 7-63
Wiring Diagram (57K506a-1 / 57K506b-1) and location for G00066 ........................................... 7-65
Hydraulic oil temperature table .................................................................................................... 7-65
G00067 - Trouble battery voltage too high ........................................................................................ 7-66

Wiring Diagram (11T080) and component location for G00067 .................................................. 7-67
G00067 - Input signal of 11T080 on the REAL TIME MONITOR ................................................ 7-67
G00069 - Trouble monitoring oil temperature gear (PTO 1)............................................................. 7-68

Input of 57B049-1 on the REAL TIME MONITOR (G00069) ....................................................... 7-69
Gear oil temperature (PTO 1) on the Main Gauge Screen (G00069).......................................... 7-69
Wiring Diagram (57B049-1) and component location for G00069............................................... 7-70
G00070 - Trouble oil temperature gear (PTO 1) ................................................................................ 7-71

Location of the PTO 1 gear oil level dipstick and temperature sensor 57B049-1........................ 7-73
G00071 - Trouble gear lubrication (PTO 1) ........................................................................................ 7-74

Wiring Diagram (57B017-1) for trouble code G00071 ................................................................. 7-75
G00081 - Trouble lubrication system ................................................................................................. 7-76

Operation cycles of the lubrication systems ................................................................................ 7-78
Wiring Diagram (11K050) for trouble code G00081 .................................................................... 7-79
Wiring Diagram (pilot control slew & stick) for trouble code G00081........................................... 7-80
G00086 - SHUTDOWN.......................................................................................................................... 7-81
G00087 - Stop all movements for low idle ......................................................................................... 7-82
G00090 - Trouble power supply.......................................................................................................... 7-83
G00099 - Trouble power supply.......................................................................................................... 7-83

Wiring Diagram (stabilized power supply) for G00090 & G00099 ............................................... 7-84
G00091 - Pilot control cut out ............................................................................................................. 7-85

View onto the lock lever and the cover of 20S105 (G00091) ...................................................... 7-86
G00092 - Emergency shut-down at access ladder ........................................................................... 7-87
G00093 - Emergency shut-down at valve block................................................................................ 7-87
G00094 - Emergency shut-down at hydraulic control panel............................................................ 7-87
G00095 - Emergency shut-down in cabin.......................................................................................... 7-87

Wiring Diagram (emergency switches) for G00092~G00095 ...................................................... 7-88
G00096 - Pilot control cut out ............................................................................................................. 7-89

G00100 - Maintenance Safety Switch................................................................................................. 7-91

G00102 - Switch off wiper [S/N 08199 only]....................................................................................... 7-93
TS 08199-upD-GB-2 PC4000-6 TOC - 7

G00103 - Faulty switch 20M004 [S/N 08199 only] ............................................................................. 7-94
Wiring Diagram 1 (wiper) for trouble code G00103 [S/N 08199 only].......................................... 7-96
Wiring Diagram 2 (wiper) for trouble code G00103 [S/N 08199 only].......................................... 7-97
G00104 - Trouble battery current ....................................................................................................... 7-98

Wiring Diagram (battery current) for trouble code G00104........................................................ 7-100
G00105 - Trouble battery charging current too low........................................................................ 7-101

Wiring Diagram (11T080) for trouble code G00105................................................................... 7-102
G00107 - Trouble slew parking brake control 56K250a.................................................................. 7-103
G00109 - Trouble slew parking brake control 56K250b ................................................................. 7-103

View onto the CoDeSys HMI Visualization screen for trouble code G00107 ............................ 7-105
Wiring Diagram (56K250a & 56K250b) for trouble code G00107.............................................. 7-106
G00108 - Trouble slew parking brake control Output to 56K250a ................................................ 7-107
G00110 - Trouble slew parking brake control Output to 56K250b ................................................ 7-107
View onto the CoDeSys HMI Visualization screen for trouble code G00108 ............................ 7-109
Wiring Diagram (56K250a & 56K250b) for trouble code G00108.............................................. 7-110
G00111 - Trouble travel parking brake control 56K251a ................................................................ 7-111
G00113 - Trouble travel parking brake control 56K251b................................................................ 7-111
G00112 - Trouble travel parking brake control Output to 56K251a............................................... 7-112
G00114 - Trouble travel parking brake control Output to 56K251b .............................................. 7-112
G00115 - Trouble slew hydraulic brake control 56K252a............................................................... 7-113
G00117 - Trouble slew hydraulic brake control 56K252b .............................................................. 7-113
G00116 - Trouble slew hydraulic brake control Output to 56K252a ............................................. 7-114
G00118 - Trouble slew hydraulic brake control Output to 56K252b ............................................. 7-114
G00140 - Trouble monitoring X1-1 pressure ................................................................................... 7-115

Wiring Diagram (57B085-1) for trouble code G00140 ............................................................... 7-117
G00141 - Trouble monitoring X2 pressure ...................................................................................... 7-118

Wiring Diagram (57B086) for trouble code G00141 .................................................................. 7-120
G00147 - Trouble monitoring gear lubrication (PTO 1) .................................................................. 7-121

Wiring Diagram (57B017-1) for trouble code G00147 ............................................................... 7-123
G00148 - Trouble monitoring fuel level............................................................................................ 7-124

Wiring Diagram (31B063) and component location for G00148 ................................................ 7-126
G00151 - Trouble monitoring gear (PTO) oil filter 1........................................................................ 7-127

Wiring Diagram (57B027-1) and component location for trouble code G00151 ........................ 7-129
TOC - 8 PC4000-6 TS 08199-upD-GB-2

G00154 - Trouble monitoring return oil filter................................................................................... 7-130
G00155 - Trouble monitoring leak oil filter ...................................................................................... 7-133

G00159 - Trouble monitoring breather filter.................................................................................... 7-136

G00160 - Trouble monitoring engine air cleaner 1 ......................................................................... 7-139

Wiring diagram (52B018-1 & 52B019-1) for trouble code G00160............................................ 7-141
G00161 - Trouble monitoring battery voltage ................................................................................. 7-142

G00162 - Trouble monitoring charging-/discharging current........................................................ 7-145

Wiring Diagram (battery charging current) for trouble code G00162......................................... 7-147
G00164 - Trouble air cleaner 1.......................................................................................................... 7-148

View onto the engine air cleaner (G00164) ............................................................................... 7-149
G00165 - Trouble breather filter hydraulic oil tank ......................................................................... 7-150

Label showing temperature information and defined positions (G00165) ................................. 7-151
G00166 - Trouble oil filter gear (PTO 1) ........................................................................................... 7-152

View onto the PTO 1 gear oil filter with pressure sensor 57B027-1 (G00166) .......................... 7-153
G00169 - Trouble return oil filter hydraulic oil tank........................................................................ 7-154
G00170 - Trouble leak oil filter hydraulic oil tank ........................................................................... 7-155
G00176 - Trouble battery voltage too low........................................................................................ 7-156

Wiring Diagram (batteries) for trouble code G00176 ................................................................. 7-158
G00177 - Trouble battery charging circuit....................................................................................... 7-159

Wiring Diagram (measuring points 1-4) for trouble code G00177 ............................................. 7-160
G00178 - Trouble battery charging current too high ...................................................................... 7-161

G00179 - Trouble control pressure X1-1.......................................................................................... 7-163

View onto the valve cartridge block (G00179) ........................................................................... 7-164
G00180 - Trouble pilot pressure X2 too low .................................................................................... 7-165

Valve cartridge block with X2 pressure sensor 57B086 & M1.2 ................................................ 7-166
G00181 - Trouble pilot pressure X2 too high .................................................................................. 7-167

Valve cartridge block with X2 pressure sensor 57B086 & M1.2 ................................................ 7-168
G00184 - Central lubrication system empty .................................................................................... 7-169
G00187 - Slew ring gear lubrication system empty ........................................................................ 7-169

Grease level (CLS & SLS) on the REAL TIME MONITOR ........................................................ 7-170
TS 08199-upD-GB-2 PC4000-6 TOC - 9

G00185 - Trouble central lubrication system .................................................................................. 7-171
G00188 - Trouble slew ring gear lubrication system ...................................................................... 7-171

Allocation of vent valves and end-of-line switches .................................................................... 7-172
Action chart for lube cycles ........................................................................................................ 7-173
View onto the vent valve (62Q507a/62Q509a) .......................................................................... 7-174
Wiring Diagram (80B043 & 62B046) for trouble codes G00185/G00188 .................................. 7-175
G00186 - Trouble central lubrication system .................................................................................. 7-176
G00189 - Trouble slew ring gear lubrication system ...................................................................... 7-176

Allocation of vent valves ............................................................................................................ 7-176
Action chart for lube cycles ........................................................................................................ 7-177
View onto the vent valve (62Q507a/62Q509a) .......................................................................... 7-178
G00207 - Engine remote oil tank 1 empty ........................................................................................ 7-179
G00216 - Trouble software not compatible ..................................................................................... 7-180
G00218 - Switch off all motors for running transfer pump ............................................................ 7-182
G00220 - Trouble transfer pump motor overheated ....................................................................... 7-183

Wiring Diagram (transfer pump) for trouble code G00220......................................................... 7-184
G00223 - Trouble starter control 51K001a-1.................................................................................... 7-185
G00225 - Trouble starter control 51K001b-1 ................................................................................... 7-185
G00224 - Trouble starter control Output to 51K001a-1 .................................................................. 7-186
G00226 - Trouble starter control Output to 51K001b-1 .................................................................. 7-186
G00231 - Trouble pilot control lever 20S019 ................................................................................... 7-187

Wiring Diagram (20S019) for trouble code G00231 .................................................................. 7-188
G00233 - Trouble pilot control 11Q045 ............................................................................................ 7-190

Wiring Diagram (11Q045) for trouble code G00233 .................................................................. 7-191
G00234 - Trouble pilot control 11K111a .......................................................................................... 7-192
G00236 - Trouble pilot control 11K111b .......................................................................................... 7-192
G00235 - Trouble pilot control Output to 11K111a ......................................................................... 7-193
G00237 - Trouble pilot control Output to 11K111b ......................................................................... 7-193
G00238 - Trouble supply by key switch 11Q044 ............................................................................. 7-194

Input signal of 11Q044 on the REAL TIME MONITOR (G00238) ............................................. 7-194
G00240 - Trouble hydraulic oil temperature .................................................................................... 7-196
G00242 - Engine 1 already running .................................................................................................. 7-197
TOC - 10 PC4000-6 TS 08199-upD-GB-2

G00243 - Fill up fuel tank................................................................................................................... 7-197
G00245 - Engine shutdown from ground......................................................................................... 7-198

Input signal of 54S007 & 54S008 on the REAL TIME MONITOR (G00245) ............................. 7-199
G00246 - Hydraulic oil temperature.................................................................................................. 7-200
G00252 - Emergency shut-down at access ladder ......................................................................... 7-201
G00253 - Emergency shut-down at valve block.............................................................................. 7-201
G00254 - Emergency shut-down at hydraulic control panel.......................................................... 7-201
G00255 - Emergency shut-down in cabin........................................................................................ 7-201

Wiring Diagram (emergency switches) for trouble codes G00252~G00255 ............................. 7-202
G00257 - Hydraulic oil temperature.................................................................................................. 7-203
G00261 - Maintenance Safety Switch............................................................................................... 7-204

G00262 - Trouble screen at hydr. cooler entry clogged................................................................. 7-206

40B166 and 40B165 on the REAL TIME MONITOR 03 Hydraulic (G00262)............................ 7-206
Location of 40B166 and 40B165 at the hydraulic oil tank (G00262) ......................................... 7-207
Wiring Diagram (40B166 & 40B165) for trouble code G00262.................................................. 7-208
G00308 - Trouble CAN-Bus or CAN-Hardware ................................................................................ 7-209
G00309 - Trouble ladder up 56K253a ............................................................................................... 7-212
G00311 - Trouble ladder up redundant 56K253b ............................................................................ 7-212
G00310 - Trouble ladder up Output to 56K253a.............................................................................. 7-213
G00312 - Trouble ladder up redundant Output to 56K253b ........................................................... 7-213
G00313 - Trouble ladder down 56K254a .......................................................................................... 7-214
G00315 - Trouble ladder down redundant 56K254b ....................................................................... 7-214
G00314 - Trouble ladder down Output to 56K254a......................................................................... 7-215
G00316 - Trouble ladder down redundant Output to 56K254b ...................................................... 7-215
G00317 - Trouble service arm up 56K255a...................................................................................... 7-216
G00319 - Trouble service arm up redundant 56K255b ................................................................... 7-216
G00318 - Trouble service arm up Output to 56K255a..................................................................... 7-217
G00320 - Trouble service arm up redundant Output to 56K255b.................................................. 7-217
G00321 - Trouble service arm down 56K256a................................................................................. 7-218
G00323 - Trouble service arm down redundant 56K256b .............................................................. 7-218
G00322 - Trouble service arm down Output to 56K256a................................................................ 7-219
TS 08199-upD-GB-2 PC4000-6 TOC - 11

G00324 - Trouble service arm down redundant Output to 56K256b ............................................. 7-219
G00325 - Trouble service arm Input ................................................................................................. 7-220
G00326 - Trouble ladder Input .......................................................................................................... 7-220
G00327 - Trouble parking brake Input ............................................................................................. 7-220
G00328 - Trouble start Input ............................................................................................................. 7-220
G00330 - Trouble pilot control 11Q111 ............................................................................................ 7-223

Wiring Diagram (11Q111/11K126) for trouble code G00330..................................................... 7-225
G00331 - Automatic after_running engine 1.................................................................................... 7-226
G00333 - Trouble battery charger relay ........................................................................................... 7-227

G00351 - Engine 1 running................................................................................................................ 7-229
G00352 - Engine 1 standstill ............................................................................................................. 7-229
G00417 - Communication failure PLC [MTC] <=> VHMS-controller .............................................. 7-230
G00420 - Connector sel error............................................................................................................ 7-231
G00421 - Farm sys error.................................................................................................................... 7-232
G00422 - Can-net sys (J1939) ........................................................................................................... 7-233
G00423 - Application sys error ......................................................................................................... 7-234
G00425 - Settings impossible to take over into the PLC................................................................ 7-235

Wiring Diagram overview for G00425: VHMS monitor → VHMS controller → MTC ................. 7-236
G00491 - Communication failure MH800 <=> VHMS-Controller .................................................... 7-237

Wiring Diagram overview for G00491: VHMS monitor (MH801) → VHMS controller................ 7-238
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 ............................................................. 8-4
Wiring Diagram 2 (engine start) for trouble code SEL001 ............................................................. 8-6
SEL002 - Engine stops while in operation........................................................................................... 8-7

View onto the fuel system water separator (SEL002).................................................................... 8-9
SEL003 - Engine speed is hunting during boom-up movement...................................................... 8-10
SEL004 - Engine does not stop .......................................................................................................... 8-11
SEL005 - Engine lacks output (no power) ......................................................................................... 8-12

Judgment Table for SEL005 ..................................................................................................... 8-13
TOC - 12 PC4000-6 TS 08199-upD-GB-2

SEL006 - Exhaust smoke is black ...................................................................................................... 8-14
Judgment Table for SEL006 ........................................................................................................ 8-15
SEL007 - Oil consumption is excessive ............................................................................................ 8-16

Judgment Table for SEL007 ....................................................................................................... 8-17
SEL008 - Oil becomes contaminated quickly.................................................................................... 8-18

SEL009 - Fuel consumption is excessive.......................................................................................... 8-20

SEL010 - Oil is in engine coolant ....................................................................................................... 8-22

SEL011 - Oil level rises........................................................................................................................ 8-24

SEL012 - Coolant temperature becomes too high (overheating) .................................................... 8-26

8.2 SYMPTOMS OF THE HYDRAULIC SYSTEM ................................................................................. 8-28
SHY001 - All the work equipment shows lack of power or slow movement
(especially the "boom up" function) ........................................................................................ 8-28
SHY002 - Engine speed sharply drops or engine stalls too much.................................................. 8-30
SHY003 - No work equipment, travel or swing movement............................................................... 8-32
SHY004 - Work equipment has too much hydraulic drift................................................................. 8-33
SHY005 - Work equipment has big time lag ...................................................................................... 8-35
SHY006 - Machine deviates during travel movement....................................................................... 8-36
SHY007 - Hydraulic system has lack of power (Energy Efficiency)................................................ 8-37
SHY008 - Machine does not swing..................................................................................................... 8-39
SHY009 - Swing acceleration is poor................................................................................................. 8-40
SHY010 - Excessive overrun when stopping swing ......................................................................... 8-42
SHY011 - Floating system without function ...................................................................................... 8-44
SHY012 - Abnormal noise coming from SRV or MRV ...................................................................... 8-45
SHY013 - Track tensioning system without function ....................................................................... 8-46
SHY014 - Ladder does not move, or slow movement ...................................................................... 8-47
SHY015 - Refilling arm does not move, or slow movement............................................................. 8-49
SHY016 - The hydraulic driven grease pump does not move ......................................................... 8-51
SHY017 - Trouble pump bearing lubrication ..................................................................................... 8-53
TS 08199-upD-GB-2 PC4000-6 TOC - 13

SHY018 - Abnormal track chain movement during digging ............................................................ 8-54
SHY019 - Swing parking brake without function .............................................................................. 8-55
SHY020 - Travel parking brake without function .............................................................................. 8-56
8.3 SYMPTOMS OF THE MECHANICAL SYSTEM .............................................................................. 8-57
SME001 - Abnormal noise is made .................................................................................................... 8-57

Judgment Table for SME001 ....................................................................................................... 8-58
SME002 - Abnormal noise around the PTO / hydraulic pumps ....................................................... 8-59
SME003 - Vibration is excessive (engine mountings) ...................................................................... 8-61

Judgment Table for SME003 ....................................................................................................... 8-62
SME004 - Vibration is excessive (engine torsion) ............................................................................ 8-63
SME005 - There is a big shock when stopping swing ...................................................................... 8-64
SME006 - There is a big abnormal noise when moving/stopping swing ........................................ 8-65
SME007 - Fan hub bearing noise is abnormal .................................................................................. 8-67
SME008 - Abnormal noise coming from a travel gearbox ............................................................... 8-68
SME009 - Abnormal noise coming from the work equipment (lack of grease).............................. 8-70
SME010 - Abnormal idler movement.................................................................................................. 8-72
SME011 - Leak at the PTO shaft seal ................................................................................................. 8-73
8.4 SYMPTOMS OF ADDITIONAL SYSTEMS ...................................................................................... 8-75
SAD001 - Air conditioner does not work ........................................................................................... 8-75

View onto the A/C unit (SAD001) ................................................................................................ 8-76
SAD002 - Air conditioner compressor clutch is burnt ..................................................................... 8-77

View onto the A/C compressor and its mounting (SAD002) ........................................................ 8-78
SAD003 - Air conditioning system defective (pipes and hoses full of moisture) .......................... 8-79
SAD004 - Travel alarm does not sound ............................................................................................. 8-80

Wiring Diagram (60P140) for trouble code SAD004 .................................................................... 8-81
TOC - 14 PC4000-6 TS 08199-upD-GB-2

SAFETY
1 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.
TS 08199-xD-GB-2 PC4000-6 1 -1
SAFETY INFORMATION SAFETY
1.1 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.
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.
1 -2 PC4000-6 TS 08199-xD-GB-2
SAFETY OVERVIEW
1.2 OVERVIEW
The appropriate safety information for specific working modes on the excavator can be found in the following:
1.2.1 NORMAL OPERATIONS

– For normal operating procedures, refer to the OPERATION section of the Operation and Maintenance Manual.
– For operational safety information, refer to section 1.4 on page 1-5.
– For on site safety information, refer to section 1.4.9 on page 1-13.
1.2.2 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 1.5 on page 1-25.
1.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR

– For additional safety information for troubleshooting and adjustments refer to section 1.6 on page 1-38.
– For maintenance solutions, refer to the separate manuals TROUBLESHOOTING manual. Available through
Komatsu Mining Germany.
– For servicing information and adjustments, refer to the separate SERVICE MANUAL. Available through
Komatsu Mining Germany.
1.2.4 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.
TS 08199-xD-GB-2 PC4000-6 1 -3
SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB SAFETY
1.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S

CAB
Fig. 1-1 Sound Pressure Level in the Operator’s Cab
The sound pressure level in the operator’s cab is measured according to ISO 6396 (Dynamic test method).
The sound pressure value is also shown on the decal attached to the wall inside the operator’s cab, see Fig. 1-1.
1 -4 PC4000-6 TS 08199-xD-GB-2
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
1.4 GENERAL PRECAUTIONS COMMON TO OPERATION

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.
1.4.1 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.
1.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE

EXCAVATOR
1.4.2.1 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 severly 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.
1.4.3 PREPARATIONS FOR SAFE OPERATION
1.4.3.1 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.
1.4.3.2 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.
TS 08199-xD-GB-2 PC4000-6 1 -5
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR SAFETY
1.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT

Refer to Fig. 1-2:
– 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. 1-2
using it.
1.4.3.4 KEEP MACHINE CLEAN

Refer to Fig. 1-3:
– 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. 1-3
1.4.3.5 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.
1 -6 PC4000-6 TS 08199-xD-GB-2
1.4.3.6 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. 1-4.
– 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. 1-4
1.4.3.7 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.
1.4.4 FIRE PREVENTION
1.4.4.1 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. 1-5:
– Do not smoke or use any flame near fuel or other flamma-

ble substances.
– Stop the engines 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. 1-5
– 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.
NOTICE: Before carrying out grinding or welding work on the machine, remove any flammable materials.
TS 08199-xD-GB-2 PC4000-6 1 -7
– 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 engines, 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.
1.4.4.2 ACTION IF FIRE OCCURS

– Activate the STOP switch to stop the engine.
– Use the access ladders and steps to get off the machine.
– If it is impossible to escape from the rear of the cab, use the
rope ladder provided for emergency escape to escape from
the side of the cab, refer to Fig. 1-6.
Fig. 1-6
– After escaping with the emergency escape ladder, activate

the engine stop chains ( Fig. 1-7 Pos. 1) to shut down the
engine if they are equipped on your shovel.
Fig. 1-7
1 -8 PC4000-6 TS 08199-xD-GB-2
1.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB

If the cab door does not open, use the sliding window for an emergency escape. On machines without a sliding
window, use the emergency escape hammer to break the window glass and use the window as an emergency
escape.
1.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE
1.4.5.1 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. 1-8). with the handrails and steps to
ensure that you support yourself.
– When walking around the machine, where possible, move
only in areas that have non-slip padded walkways and non-
slip gratings. Extra care is to be taken when moving around
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. Fig. 1-8
Repair any damage and tighten any loose bolts.
1.4.5.2 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.
1.4.5.3 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 1.7 on
page 1-39.
1.4.5.4 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 1.7 on page 1-39.
TS 08199-xD-GB-2 PC4000-6 1 -9
1.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK

Refer to Fig. 1-9:
– 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 engine, 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. 1-9
1.4.5.6 LEAVING THE MACHINE

– When leaving the machine, always lower the work equipment
completely to the ground, turn off the engine, relieve the pres-
sure in the hydraulic system and set lock lever (1) securely to
the LOCK position (L), then stop the engine. Use the key to
lock all the equipment. Always remove the key, take it with
you, and keep it in the specified place (Fig. 1-10). For infor-
mation on relieving the pressure in the hydraulic system, refer
to chapter ’RELIEVING THE PRESSURE IN THE HYDRAU-
LIC SYSTEM’ in the ’OPERATION’ part of this manual.
Fig. 1-10
1 - 10 PC4000-6 TS 08199-xD-GB-2
1.4.6 BURN PREVENTION
1.4.6.1 HOT COOLANT

Refer to Fig. 1-11:
– 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. 1-12) 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. 1-11
1.4.6.2 HOT OIL

Refer to Fig. 1-12:
– 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. 1-12
1.4.7 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.
TS 08199-xD-GB-2 PC4000-6 1 - 11
1.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

On jobsites where there is a hazard that falling objects (Fig. 1-13),
flying objects (Fig. 1-14), 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.
– 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- Fig. 1-13
site. Always contact your Komatsu distributor for advice.
Fig. 1-14
1.4.8.1 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.
1.4.8.2 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.
1 - 12 PC4000-6 TS 08199-xD-GB-2
1.4.9 PRECAUTIONS AT JOBSITE
Fig. 1-15
TS 08199-xD-GB-2 PC4000-6 1 - 13
1.4.9.1 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. 1-15 shows an example of general blind areas of large Komatsu hydraulic mining shovels.
The grey 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
outside 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.
1.4.9.2 CAMERA SYSTEM WITH MONITORS

Komatsu Mining Germany offers optionally camera systems and monitors to improve the overall visibility. See lat-
est version 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.
1.4.9.3 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.
1.4.9.4 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.
1 - 14 PC4000-6 TS 08199-xD-GB-2
1.4.9.5 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. 1-16).
– 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. 1-16
– 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.
1.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES
DANGER
HIGH VOLTAGE!
Do not travel or operate the machine near electric cables
(Fig. 1-17). 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. 1-17
TS 08199-xD-GB-2 PC4000-6 1 - 15
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.
1.4.9.7 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.
1.4.9.8 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.
Follow the instructions given in PARTS & SERVICE NEWS No. AH04518 for expelling the gases from the
counterweight chambers. (See Volume 2 binder)
1 - 16 PC4000-6 TS 08199-xD-GB-2
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.
1.4.9.9 VENTILATION OF ENCLOSED AREAS
WARNING
POISONOUS FUMES!
Unventilated areas where poisonous fumes can accumulate can kill.
Always ensure adequate ventilation.
Refer to Fig. 1-18:
– Operate internal combustion engines 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 engine 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. 1-18
TS 08199-xD-GB-2 PC4000-6 1 - 17
1.4.10 STARTING ENGINE
1.4.10.1 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. 1-19). 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 engine or touch the
levers.
Fig. 1-19
1.4.10.2 CHECKS BEFORE STARTING ENGINE

Carry out the following checks before starting the engine 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 engine 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. 1-20
all at the Neutral position.
– Before starting the engine, check that lock lever (Fig. 1-20) 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.
1.4.10.3 PRECAUTION WHEN STARTING ENGINE

– Start and operate the machine only while seated.
– Do not short circuit the starting motor circuit to start the engine. Short circuiting can cause fire.
– When starting the engine, sound the horn as a warning.
1 - 18 PC4000-6 TS 08199-xD-GB-2
– 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.
1.4.10.4 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 engine 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 engine with a different power source, melt the battery electrolyte and check that
there is no leakage of electrolyte before starting.
1.4.11 OPERATION
1.4.11.1 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.
TS 08199-xD-GB-2 PC4000-6 1 - 19
1.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE

– Before travelling, set the machine so that sprocket (1) is
behind the operator's seat (Fig. 1-21).
– 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. 1-21
– Before travelling, check again that there is no one in the sur-

rounding area, and that there are no obstacles (Fig. 1-22).
– 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. 1-22
– 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. 1-23)
Fig. 1-23
NOTE! Always be sure to carry out the above precautions even when the machine is equipped with mirrors
or camera systems.
1 - 20 PC4000-6 TS 08199-xD-GB-2
1.4.11.3 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. 1-24).
– 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. 1-24
– 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. 1-25).
– 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. 1-25
TS 08199-xD-GB-2 PC4000-6 1 - 21
1.4.11.4 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. 1-26).
– 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. 1-26
– 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. 1-27).
Fig. 1-27
– 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. 1-28).
– Travel on slippery ground with low speed. Even with slight
slopes there is a hazard that the machine may slip
Fig. 1-28
1 - 22 PC4000-6 TS 08199-xD-GB-2
1.4.11.5 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. 1-29) that will keep the machine as hori-
zontal as possible.
Fig. 1-29
1.4.11.6 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. 1-30).
Fig. 1-30
– 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. 1-31).
Fig. 1-31
TS 08199-xD-GB-2 PC4000-6 1 - 23
– 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. 1-32).
– 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. 1-32
and cause serious injury or property damage.
1.4.11.7 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.
1.4.11.8 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. 1-33, Pos 1) to
the LOCK position (L), then stop the engine.
– 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. 1-33
1.4.11.9 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.
1 - 24 PC4000-6 TS 08199-xD-GB-2
SAFETY PRECAUTION FOR MAINTENANCE
1.5 PRECAUTION FOR MAINTENANCE
1.5.1 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 1-1.
– 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 engines and move all control levers through their shift positions to relieve the pressure in the hydrau-
lic system. Refer to ”Stopping the Engines” 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 1.5.1.3 on page 1-28. 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.
– 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
TS 08199-xD-GB-2 PC4000-6 1 - 25
PRECAUTION FOR MAINTENANCE SAFETY
– 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.
– 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.
1.5.1.1 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 engineering 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.
1 - 26 PC4000-6 TS 08199-xD-GB-2
1.5.1.2 STOP ENGINE FOR MAINTENANCE

Refer to Fig. 1-34:
– 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 engine.
Fig. 1-34
– 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. 1-35, 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 engine STOP switch and press the horn switch. If the
horn does not sound, it is not activated.)
Fig. 1-35
TS 08199-xD-GB-2 PC4000-6 1 - 27
1.5.1.3 WARNING TAG

– Always attach the “DO NOT OPERATE“ warning tag
(Fig. 1-36) 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 engine, or touches or operates
the control levers or control pedals while you are performing
service or maintenance, you may suffer serious injury.
Fig. 1-36
– Before entering the machinery house, switch off maintenance

safety switch (Fig. 1-37)
– The maintenance safety switch is located in the machinery
house, next to the entrance door (Pos. 1 on Fig. 1-38).
– Before beginning maintenance operations, set the safety
switch to "0" to prevent a starting of the engines. Secure this
position by inserting a padlock into the holes of the safety
switch. Up to ten padlocks can be attached.
Fig. 1-37
Fig. 1-38
1 - 28 PC4000-6 TS 08199-xD-GB-2
1.5.1.4 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
1.5.1.5 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.
TS 08199-xD-GB-2 PC4000-6 1 - 29
1.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING

– To prevent injury, do not perform maintenance or adjustments
while the engine runs. If work must be carried out with the
engine 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 engine 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 1.6 on page 1-38.
– 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. 1-39). Fig. 1-39
– 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.
1.5.1.7 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. 1-40). And
take steps to prevent unauthorized persons from entering the
storage area.
Fig. 1-40
1 - 30 PC4000-6 TS 08199-xD-GB-2
1.5.1.8 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. 1-41),
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. 1-41
1.5.1.9 NOISE
When carrying out maintenance of the engine 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.
1.5.1.10 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. 1-42).
– 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. 1-42
TS 08199-xD-GB-2 PC4000-6 1 - 31
1.5.1.11 PROPER TOOLS

Refer to Fig. 1-43:
– 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. 1-43
1.5.1.12 ACCUMULATOR
Refer to Fig. 1-44:
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. 1-44
this work performed.
1.5.1.13 PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
If necessary, employ an observer.
1 - 32 PC4000-6 TS 08199-xD-GB-2
1.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE
1.5.2.1 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.
1.5.2.2 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. 1-45).
Fig. 1-45
– 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. 1-46), 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. 1-46
TS 08199-xD-GB-2 PC4000-6 1 - 33
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 engine 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.
1.5.3 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.
1.5.3.1 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. 1-47). If you are hit by a jet of
high-pressure oil and suffer injury to your skin or eyes, wash Fig. 1-47
the place with clean water, and consult a doctor immediately
for medical attention.
High pressure is generated inside the engine fuel piping when the engine is running. When carrying out inspection
or maintenance of the fuel piping system, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before starting inspection or maintenance.
1 - 34 PC4000-6 TS 08199-xD-GB-2
1.5.3.2 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. 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.
1.5.3.3 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 Mining Germany replacement
hose lines.
1.5.3.4 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.
TS 08199-xD-GB-2 PC4000-6 1 - 35
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.
1.5.3.5 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.
1.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE
DANGER
HIGH VOLTAGE!
High voltage appliances cause serious injury or death.
Authorized staff only.
– When the engine is running and immediately after it is stopped, high voltage is generated inside the engine
controller and the engine 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 engine 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.
1.5.3.7 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.
1 - 36 PC4000-6 TS 08199-xD-GB-2
1.5.3.8 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.
1.5.3.9 WASTE MATERIALS

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 Fig. 1-48

– 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. 1-48).
– Dispose of harmful material, such as oil, fuel, coolant, sol-
vent, filters and batteries in accordance with local environ-
mental regulations and laws.
TS 08199-xD-GB-2 PC4000-6 1 - 37
ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS SAFETY
1.6 ADDITIONAL SAFETY INFORMATION FOR

TROUBLESHOOTING AND ADJUSTMENTS
1.6.1 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 engine 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 1-6, 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 Mining 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
engine 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).
1.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING

ADJUSTMENTS
To prevent injury, do not carry out adjustments with the engine running. If work must be carried out with the engine
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 engine at any time. All workers must maintain con-
tact 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. 1-49).
– 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. 1-49
1.6.3 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.
1 - 38 PC4000-6 TS 08199-xD-GB-2
SAFETY SPECIAL SAFETY EQUIPMENT
1.7 SPECIAL SAFETY EQUIPMENT
Fig. 1-50
TS 08199-xD-GB-2 PC4000-6 1 - 39
SPECIAL SAFETY EQUIPMENT SAFETY
1.7.1 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.
1.7.2 OBJECT HANDLING

Object handling operations are not allowed.
1.7.3 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.
1.7.4 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.
1.7.5 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.
1.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361

(EUROPEAN STANDARD)
WARNING
RISK OF FALLING!
Injuries can occur when working in high areas. Always use a Safety Harness (1) in conjunction with a
strap type Fall Absorber (2), illust. (Fig. 1-50) 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. 1-50) shows the standard use of the safety harness with a strap type fall absorber.
1 - 40 PC4000-6 TS 08199-xD-GB-2
Fig. 1-51
TS 08199-xD-GB-2 PC4000-6 1 - 41
Legend for Fig. 1-50:
(1) Safety Harness according to EN 361
(2) Strap-Type Fall Absorber according to DIN EN 355
(3) Railings (attachment points)
(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
1.7.5.2 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. 1-50).
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 attachment point for the safety harness should be above the wearer, and the carrying capacity of the attach-
ment point should be sufficient to correspond with the minimum carrying capacity acc. to EN 795.
1 - 42 PC4000-6 TS 08199-xD-GB-2
Fig. 1-52
TS 08199-xD-GB-2 PC4000-6 1 - 43
1.7.5.3 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.
At least every 12 months, the safety harness and its components have to be inspected by a competent person
authorized by the manufacturer and maintained, if the manufacturer considers it necessary.
1.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK

HOOKS OF THE SAFETY HARNESS (1)
During the holding function, the connectors may only be placed around a mast or other construction between the
two holding hooks, so that free fall is limited to max. 0.5 m.
It should be strictly seen to it that the connector be not slung around constructions with too small diameter or sharp
edges.
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.
1 - 44 PC4000-6 TS 08199-xD-GB-2
Fig. 1-53
TS 08199-xD-GB-2 PC4000-6 1 - 45
1.7.5.5 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 attachment point should be above the wearer and its minimum carrying capacity should be 10
KN, acc. to DIN EN 795.
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.
1 - 46 PC4000-6 TS 08199-xD-GB-2
Introduction & General Information for Troubleshooting
2 INTRODUCTION &
GENERAL INFORMATION
FOR TROUBLESHOOTING
TS 08199-xD-GB-2 PC4000-6 2 -1
Overview Introduction & General Information for Troubleshooting
2.1 OVERVIEW
In this manual you find troubleshooting information which should assist you when troubleshooting.
Chapter 1 Safety
Chapter 2 Introduction and General Information for Troubleshooting
Chapter 3 Mounting Locations and Connector Types
Chapter 4 Standard Value Table for Electrical Components
Chapter 5 References for Troubleshooting in the CAN Bus System
Chapter 6 Tables for Testing and Troubleshooting
Chapter 7 Troubleshooting by Trouble Code
Chapter 8 Troubleshooting by Symptoms
Chapter 1 Contains the global Safety Notes which always have to be followed!
Chapter 2 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.
Chapter 3 Provides you with troubleshooting and monitoring features for checks of the CAN bus system.
Chapter 4 Provides you with information about mounting locations of components and illustrations of different
connector types as they are used on your machine.
Chapter 5 Provides you with charts of standard values for electrical components as a quick reference guide.
Chapter 6 Contains various assistant Tables for Testing and Troubleshooting.
Chapter 7 In this chapter troubleshooting charts for G-Codes are listed in the numerical sequence of the trouble
codes as they are stored in the VHMS system.
Chapter 8 Troubleshooting charts for various engine electrical, mechanical, and hydraulic problems according to
symptoms 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 VHMS.
2.1.1 GENERAL ADVICE WHEN USING TROUBLESHOOTING CHARTS

Even as many troubles and troubleshooting procedures as possible are detailed in this manual, the troubleshoot-
ing charts in chapter 7 and chapter 8 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.
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.
2 -2 PC4000-6 TS 08199-xD-GB-2
Introduction & General Information for Troubleshooting General Precautions
2.2 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
TS 08199-xD-GB-2 PC4000-6 2 -3
Preparations For Work Introduction & General Information for Troubleshooting
2.3 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.
2.4 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 -4 PC4000-6 TS 08199-xD-GB-2
Introduction & 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.
2.5 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.
2.5.1 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.
2.5.2 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.
TS 08199-xD-GB-2 PC4000-6 2 -5
Precautions When Carrying Out Any Operation Introduction & 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.
2.5.3 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 2.11 on page 2-20 (General Working Procedures/Air bleeding).
- Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
2 -6 PC4000-6 TS 08199-xD-GB-2
Introduction & General Information for Troubleshooting Fundamental Requirements for Troubleshooting
2.6 FUNDAMENTAL REQUIREMENTS FOR TROUBLE-

SHOOTING
2.6.1 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
- Service Manual
- 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!
2.6.2 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
TS 08199-xD-GB-2 PC4000-6 2 -7
Fundamental Requirements for Troubleshooting Introduction & 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 2.6.2.1 on page 2-10: Reference Guide for Deutsch Removal Tools
2 -8 PC4000-6 TS 08199-xD-GB-2
Introduction & 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 CoDeSys HMI Software Standard LAN Cable
CoDeSys HMI
VHMS Download Cable Standard LAN Cable (2 m)
Basis Software Tool
(serial connection) for CoDeSys HMI
& Visualization
P/N 894 580 40 P/N 941 825 40 Standard
TS 08199-xD-GB-2 PC4000-6 2 -9
Fundamental Requirements for Troubleshooting Introduction & General Information for Troubleshooting
2.6.2.1 REFERENCE GUIDE FOR DEUTSCH REMOVAL TOOLS
Fig. 2-1 Reference Guide for Deutsch Removal Tools
2 - 10 PC4000-6 TS 08199-xD-GB-2
Introduction & General Information for Troubleshooting Points To Remember When Troubleshooting
2.6.3 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.
2.7 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?
TS 08199-xD-GB-2 PC4000-6 2 - 11
Points To Remember When Troubleshooting Introduction & 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 - 12 PC4000-6 TS 08199-xD-GB-2
Introduction & General Information for Troubleshooting Sequence Of Events In Troubleshooting
2.8 SEQUENCE OF EVENTS IN TROUBLESHOOTING
Fig. 2-2 Sequence Of Events In Troubleshooting
TS 08199-xD-GB-2 PC4000-6 2 - 13
Checks Before Troubleshooting Introduction & General Information for Troubleshooting
2.9 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 swing 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 - 14 PC4000-6 TS 08199-xD-GB-2
Introduction & General Information for Troubleshooting Handling Of Electric Equipment And Hydraulic Components
2.10 HANDLING OF ELECTRIC EQUIPMENT AND

HYDRAULIC COMPONENTS
2.10.1 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
TS 08199-xD-GB-2 PC4000-6 2 - 15
Handling Of Electric Equipment And Hydraulic Components Introduction & 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 - 16 PC4000-6 TS 08199-xD-GB-2
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
2.10.2 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
TS 08199-xD-GB-2 PC4000-6 2 - 17
Handling Of Electric Equipment And Hydraulic Components Introduction & 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 - 18 PC4000-6 TS 08199-xD-GB-2
– 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
TS 08199-xD-GB-2 PC4000-6 2 - 19
General working procedures Introduction & General Information for Troubleshooting
2.11 GENERAL WORKING PROCEDURES
2.11.1 AIR BLEEDING OF VARIOUS HYDRAULIC PARTS
Fig. 2-18 Air Bleeding of Various Hydraulic Parts
2.11.2 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.
2.11.3 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 - 20 PC4000-6 TS 08199-xD-GB-2
Introduction & General Information for Troubleshooting Cylinder bypass test
2.12 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 2-7 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 clinder:
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.
TS 08199-xD-GB-2 PC4000-6 2 - 21
Information about MTC & Nodes Introduction & General Information for Troubleshooting
2.13 INFORMATION ABOUT MTC & NODES
2.13.1 OUTLINE OF THE MTC AND ITS CONNECTOR LOCATIONS

During troubleshooting always make sure to use your Wiring Diagrams which are assigned to your machine.
Due to variable requirements in many aspects, the samples of Wiring Diagrams, MTC & nodes shown in this
manual can not meet the actual state of each machine in every case. Inputs and outputs of MTC & nodes are
not identical in construction.
2.13.1.1 VIEW ONTO THE MTC CONNECTORS* LH & RH
Fig. 2-19 View onto the MTC connectors LH & RH
*The shown connector locations in the above illustration are exemplarily.
2.13.1.2 GENERAL DESCRIPTION OF THE MTC

For a general description of the MTC refer to your SERVICE MANUAL, section 14.7 GLOBAL LAYOUT OF THE
MTC CONTROL SYSTEM.
2 - 22 PC4000-6 TS 08199-xD-GB-2
Introduction & General Information for Troubleshooting Information about MTC & Nodes
2.13.1.3 INFORMATION ABOUT THE LED INDICATIONS AT THE MTC
Legend for Figure 1-20
(1) MTC unit
(2) LED panel of the MTC unit
Fig. 2-20 LED indications at the MTC
2.13.2 INFORMATION ABOUT THE ICN-D NODE

Intelligent Can Node - Digital (Dashboard) with max. 64 free programmable in- and outputs.
Fig. 2-21 Details of an ICN-D node
(1) ICN-D node (3) Connectors X0 - X8
(2) DIP switches (4) Status LEDs
For further information also refer to the SERVICE MANUAL, chapter 14.
TS 08199-xD-GB-2 PC4000-6 2 - 23
2.13.2.1 VIEW ONTO AN ICN-D NODE WITHOUT WIRING
Fig. 2-22 View onto an ICN-D node without wiring
(1) ICN-D node
(2) DIP switches
(3) Status LEDs
(4) Allocation of the Status LEDs
(5) Connector X0 (power supply 24V, ground, CAN bus 3x)
(6) Connectors X1 - X8 (in- & outputs)
(7) Ground receptacle
For details about the DIP switches refer to section 2.13.4 on page 2-29 in this manual.
2 - 24 PC4000-6 TS 08199-xD-GB-2
2.13.2.2 VIEW ONTO THE STATUS LEDS AT THE ICN-D NODE
Fig. 2-23 View onto the Status LEDs at the ICN-D node
(1) Allocation of the Status LEDs
(2) ICN-D node unit
(3) Status LED (4x)
2.13.2.3 GENERAL INFORMATION ON THE LED CONTROL

The node status (ICN-D) is indicated by the following 4 LEDs:
– PWR LED (red = RESET, green = normal operation)

– CAN LED (CAN-Run and CAN-Error)
– ERR LED (red and green)
– DIAG LED (red and green)
TS 08199-xD-GB-2 PC4000-6 2 - 25
Overview over all possible LED conditions at the ICN-D node
LED State Meaning
Indication of Logic Power Supply and Operational State
OFF Vcc not ON!

PWR
red System in RESET condition
green System RUNNING
Indication of CAN Communication.
green blinking Pre-operational
green single flash Stopped

CAN
green ON Operational
red OFF No error in the CAN bus
red ON CAN bus OFF
ERR + DIAG OFF No errors or warnings present
ERR green ON Internal warning present
ERR red ON Internal error present

ECU ERR
ECU DIAG ERR red ON + DIAG red ON An internal trouble code is set
ERR green + DIAG red blinking alternately An internal trouble code is set
Internal error or warning present

DIAG green blinking
(depending on the state of the ERR LED)
2 - 26 PC4000-6 TS 08199-xD-GB-2
2.13.3 INFORMATION ABOUT THE ICN-V NODE

Intelligent Can Node - Variable (Valve) with max. 8 variable free programmable in- and outputs.
The ICN-V node box may contain 1 or 2 node units. Each node unit is connected with a 55-pin central connector.
For more details refer to the SERVICE MANUAL, chapter 14.
2.13.3.1 VIEW ONTO AN ICN-V NODE
Fig. 2-24 View onto an ICN-V node
(1) ICN-V node box (dual unit)
(2) V-node connector, 55 pins (LH)
(3) V-node connector, 55 pins (RH)
(4) V-node socket, 55 pins
TS 08199-xD-GB-2 PC4000-6 2 - 27
2.13.3.2 VIEW ONTO AN OPEN ICN-V NODE AND ITS DIP-SWITCHES
Fig. 2-25 View onto an open ICN-V node and its DIP-switches
(1) ICN-V node, taken out of the node box
(2) DIP-switches of an ICN-V node
2 - 28 PC4000-6 TS 08199-xD-GB-2
2.13.4 DIP SWITCHES AT THE ICN-D AND ICN-V NODES
Fig. 2-26 DIP switches at the ICN-D and ICN-V nodes
General information about the DIP switches
– The DIP switches 1 - 7 define the node number (binary), which is node #17 in the above illustration.
– The DIP switches 8 - 10 define the CAN bus transfer speed (kbaud).
– The adjustment principle and function of the DIP switches is the same for the ICN-V and ICN-D nodes.
Adjustment of the DIP switches
– The DIP switches of a new node unit are pre-adjusted ex factory.

– If the DIP adjustment needs to be rechecked e.g. for troubleshooting, refer to he CoDeSys HMI software tool
or to the Wiring Diagram. The individual patterns of the DIP switches are shown there for each node unit.
TS 08199-xD-GB-2 PC4000-6 2 - 29
Basics about "How to crimp" Introduction & General Information for Troubleshooting
2.14 BASICS ABOUT "HOW TO CRIMP"
2.14.1 STRIPPING A WIRE FOR USE WITH THE HDT 48 CRIMP TOOL
Fig. 2-27 Stripping a wire for use with the HDT 48 crimp tool
Step 1 Choose the correct wire cross section [mm2] respectively AWG for the contact being used.
Measure from the end of the wire the recommended strip length according to the contact size.
Step 2 Place the wire into the stripping tool at the recommended strip length.
Strip the wire according to stripping tool instructions.
After stripping, a small piece of the insulation should come off.
Step 3 Check for any broken strands or for a dent in the wire.
If either exist, the wire is damaged and should be cut and stripped again.
Measure the exposed strands to be sure the crimp length is correct.
2.14.2 VIEW ONTO THE DEUTSCH CRIMP TOOL HDT 48
Fig. 2-28 View onto the Deutsch crimp tool HDT 48
2 - 30 PC4000-6 TS 08199-xD-GB-2
Introduction & General Information for Troubleshooting Basics about "How to crimp"
2.14.3 ADJUSTMENT OF THE WIRE SIZE AT THE DEUTSCH CRIMP TOOL

HDT 48
Fig. 2-29 Adjustment of the wire size at the Deutsch crimp tool HDT 48
2.14.3.1 WIRE CROSS SECTION UNITS IN MM2 AND AWG

The below scale of the crimping tool uses the units mm2 and AWG (American Wire Gauge).
Free conversion charts and/or free calculators to convert between mm2 and AWG are open to the public.
Refer to the following sample illustration of an AWG gauge.
Fig. 2-30 View onto an AWG gauge
TS 08199-xD-GB-2 PC4000-6 2 - 31
Basics about "How to crimp" Introduction & General Information for Troubleshooting
2.14.4 CRIMPING INSTRUCTIONS (FOR DEUTSCH CRIMP TOOL HDT 48)
Fig. 2-31 Crimping instructions (for Deutsch crimp tool HDT 48)
Step A 1. Strip the insulation from the wire, refer to section 2.14.1 on page 2-30.
2. Raise the selector knob and rotate it until the arrow is aligned with the wire gauge to be crimped,
refer to illustration Fig. 2-29 on page 2-31.
Step B 3. Loosen the lock nut (1) and turn the adjusting screw (2) in until it stops.
Step C 4. Insert a contact into the insertion point (3), turn the adjusting screw clockwise out until the contact
is flush or a bit above flush with the indentor cover.
5. Tighten the lock nut.
Step D 6. Insert the wire into the contact (4). The contact must be centered between the indicators.
7. Close the handles until the handles stop.
8. Release the handles and remove the crimped contact.
After completion:
The correct assembly can be checked visually. When stripped, the insulation should expose a conductor length
that will pass beyond the inspection hole in the contact. There should be about 0.63 to 2.54 mm of free conductor
between the contact and the insulation on the wire.
After crimping, check for:
1. Damaged wire strands
2. Missing wire strands
3. Wire strands not entering the contact barrel or splayed wires
4. Wire not inserted to the proper depth in the contact, not visible through the inspection hole
If any of the above conditions exists, please discard the contact, re-cut and strip the wire, and start the crimping
process over.
2 - 32 PC4000-6 TS 08199-xD-GB-2
Introduction & General Information for Troubleshooting Cable Shielding
View onto a proper crimp
Fig. 2-32 View onto a proper crimp
Crimp is OK if:
– Conductor strands must be visible through the inspection hole (1).

– Crimp centered (2) between the inspection hole and the crimp barrel end.
– Insulation gap (3) 0.66 to 2.54 mm
For more detailed crimp specifications refer to the instructions which are delivered with the crimp tool.
2.15 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.
TS 08199-xD-GB-2 PC4000-6 2 - 33
Cable Shielding Introduction & General Information for Troubleshooting
2 - 34 PC4000-6 TS 08199-xD-GB-2
Mounting Locations and Connector Types
3 MOUNTING LOCATIONS
AND CONNECTOR TYPES
TS 08199-xD-GB-2 PC4000-6 3 -1
Component location Mounting Locations and Connector Types
3.1 COMPONENT LOCATION
3.1.1 VIEW ONTO THE SUPERSTRUCTURE
Fig. 3-1 View onto the Superstructure
3 -2 PC4000-6 TS 08199-xD-GB-2
Mounting Locations and Connector Types Component location
Legend for Fig. 3-1 - View onto the Superstructure
(1) Hydraulically operated access ladder
(2) Battery main switches (batteries G1-G4)
(2a) Battery main switches (batteries G8-G9)
(3) Lift cylinder for access ladder
(4) Batteries, location below the catwalk (batteries G1-G4)
(5) Control switch for access ladder
(6) Emergency engine shut down switch
(7) Fuel tank
(8) Cab base, contains the electronic components of the VHMS system, the electrical switch boards,
and the batteries G8 & G9
(9) Side window of operator’s cab
(10) Swing circle guard
(11) Emergency escape ladder
(12) Engine air cleaners
(13) Exhaust mufflers
(14) Air duct
(15) Extinguishing agent tank assemblies, only on machines equipped with a fire detection, actuation and
suppression system
(16) Counterweight
(17) Main control valves & remote control valves with high pressure in-line filters
(18) Hydraulic oil reservoir
(19) Return oil filters and leak oil filter
(20) Hydraulic oil cooler
(21) Swing machinery
(22) Distributor manifold
(23) Swing circle pinion Lubrication System (SLS)
(24) Central Lubrication System (CLS)
(25) Node box, location 40
TS 08199-xD-GB-2 PC4000-6 3 -3
3.1.2 LOCATION OF ENGINE ELECTRICAL PARTS (1)
Fig. 3-2 Location of Engine Electrical Parts (1)
3 -4 PC4000-6 TS 08199-xD-GB-2
Legend for Fig. 3-2 - Location of Engine Electrical Parts (1)
52B018-1 Engine air filter clogging sensor
52B064 Engine speed sensor
52B093-1 Prelube pressure switch (opens at 0.17 bar)
52G005-1.D+ Alternator terminal D+
52G045-1 Engine remote oil tank refilling system
52K030-1 Pre-lube switch
52Q002a-1 Starter relay
52Q002b-1 Starter relay
52Q004 Magnetic clutch compressor
52Q502a-1 Engine cold start aid solenoid valve
52Q502b-1 Engine cold start aid solenoid valve
57B049 PTO lube oil temperature sensor
59B015 Hydraulic oil temperature sensor
59B162 Suction tank pressure sensor
60P140 Acoustic signal
63B103-1 Engine remote oil tank level sensor
63B106-1 Engine oil level sensor
TS 08199-xD-GB-2 PC4000-6 3 -5
3.1.3 LOCATION OF ENGINE ELECTRICAL PARTS (2)
Fig. 3-3 Location of Engine Electrical Parts (2)
Legend for Fig. 3-3 - Location of Engine Electrical Parts (2)
51B110 Intake air temperature sensor 52B064 Engine speed sensor
52B018-1 Engine air filter clogging sensor 52G005-1 Alternator
3 -6 PC4000-6 TS 08199-xD-GB-2
3.1.4 LOCATION OF HYDRAULIC COMPONENTS (1)
Fig. 3-4 Location of Hydraulic Components (1)
TS 08199-xD-GB-2 PC4000-6 3 -7
Legend for Fig. 3-4 - Location of Hydraulic Components (1)
Solenoid valves
57K506a-1 Cooler fan RPM control, minimum speed

57K506b-1 Cooler fan RPM control, medium speed
57K517 Qmin control (pump control system)
57K517a ½ Qmax, reduced oil flow at cold oil [below T2]
57K553-1 Reduction pre-load pressure PTO gear lubrication - oil cooler
57K561-1 X1 pressure, pumps 1 – 4
57K620 Hydraulic swing brake, operating pressure
57K626 Flow reduction swing (pump 1)
57K630 Fixed pump 1 (max. flow, X1 = 45 bar)
57K631 Fixed pump 3 (max. flow, X1 = 45 bar)
57K636 Engine radiator fan speed (proportional valve)
57K646 Energy Efficiency (pump 2 & 4)
57K647 Energy Efficiency (pump 3)
57K648 Energy Efficiency (pump 1)
57Q505 Slew parking brake operating pressure
57Q516 Travel parking brake operating pressure
57Q623a Ladder, raise
57Q623b Ladder, lower
57Q624a Refilling arm, raise
57Q624b Refilling arm, lower
57Q624c Refilling arm stop, hold position
57Q625 Ladder, fast movement
57Q627 Proportional swing brake pressure
Filters
33 Pilot pressure
34.1 Hydraulic oil cooler fan drive
34.2 Engine radiator fan drive
36 PTO gear lubrication
Others
(29) Pressure relief valve – PTO gear lubrication

(31.1) Pressure relief valve – hydraulic oil cooler fan drive, with solenoid valve 57K506a/b-1
for fan RPM control
(31.2) Pressure relief valve - engine radiator fan drive, with proportional solenoid valve 57K636-1
for fan RPM control
(47) Pressure reducing valve – track tensioning system (35 bar)
(124) Pressure relief valve medium speed cooler fan
(152) Pressure reducing valve – Energy Efficiency (X3 ~ 18 bar, pre-adjustment)
(252.1) Pressure reducing valve for pilot pressure X2 (45 bar)
(252.2) Pressure relief valve for pump support pressure X4 (60 bar)
(253.1) Change-over valve – electronic pump regulation or hydraulic constant regulation
(253.2) Pressure reducing valve – hydraulic constant regulation
(255.4) Pressure reducing valve – ½ Qmax
(257.1) Pressure relief valve – safety valve for travel brake / track tensioning system (55 bar)
(258.3) Pressure relief valve – safety valve for hydraulic access ladder (70 bar)
3 -8 PC4000-6 TS 08199-xD-GB-2
3.1.5 LOCATION OF HYDRAULIC COMPONENTS (2)
Fig. 3-5 Location of Hydraulic Components (2)
Legend for Fig. 3-5 - Location of Hydraulic Components (2)
40B015 Temperature sensor
57B049-1 Gear oil temperature sensor
59B162 Pressure sensor suction oil tank
TS 08199-xD-GB-2 PC4000-6 3 -9
3.1.6 LOCATION OF THE REMOTE CONTROL VALVES
Fig. 3-6 Location of the Remote Control Valves
3 - 10 PC4000-6 TS 08199-xD-GB-2
Legend for Fig. 3-6 - Location of the Remote Control Valves
Remote control Function

Directional Proportional
unit
solenoid solenoid BHA FSA
schematic code
61K540 Boom raising

61K573
61K541 Boom lowering
61K538 Stick extending Clam closing

61K572
61K539 Stick retracting Clam opening
(15.1)
61K536 Bucket filling Bucket filling
61K571
61K537 Bucket dump Stick extending
61K534 L.H. crawler reverse

61K570
61K535 L.H. crawler forward
61K524 L.H. swing

61K565
61K525 R.H. swing
61K522 Bucket filling (curl)

(14.1) 61K564
61K523 Bucket emptying
61K520 Boom raising

61K563
61K526 R.H. swing

61K566
61K527 L.H. swing
61K532 Boom lowering Bucket filling

(14.2) 61K569
61K533 Boom raising Boom raising
61K530 Stick extending

61K568
61K531 Stick retracting
61K546 Boom raising

61K576
61K544 Bucket filling (curl)

61K575
61K545 Bucket emptying
(15.2)
61K542 Stick extending
61K574
61K543 Stick retracting
61K528 R.H. crawler forward

61K567
61K529 R.H. crawler reverse
TS 08199-xD-GB-2 PC4000-6 3 - 11
3.1.7 LOCATION OF THE HIGH PRESSURE SENSORS
Fig. 3-7 Location of the High Pressure Sensors
Legend for Fig. 3-7 - Location of the High Pressure Sensors
61B087a Pressure sensor – Input pressure control block I
61B087b Pressure sensor – Input pressure control block II
61B087c Pressure sensor – Input pressure control block III
61B087d Pressure sensor – Input pressure control block IV
3 - 12 PC4000-6 TS 08199-xD-GB-2
3.1.8 VIEW ONTO THE SLS AND CLS GREASE BARREL AND
THE LUBRICATION CYCLE COMPONENTS
Fig. 3-8 View onto the SLS and CLS Grease Barrel and the Lubrication Cycle Components
TS 08199-xD-GB-2 PC4000-6 3 - 13
Legend for Fig. 3-8 - View onto the SLS and CLS Grease Barrel and the Lubrication Cycle Components
(1) Lubrication pump drive (hydraulic cylinder)
(2) Flow control valve (16 - 19 double strokes / min)
(3) Pressure relief valve
(4) Main pump control solenoid valve (pump ON / OFF)
(5) Hydraulic oil return line
(6) Hydraulic oil supply line (60 bar, X4 pressure)
(7) Lubricant pressure gauge
(8) Lubricant in-line filter
(9) Lubricant pressure release solenoid valve
(10) Lubricant supply line from pump to injector
(11) Lubricant release line
(12) End-line switch
(13) Lubricant injector
(14) Lubricant feed line to swing ring gear
(15) Lubricant pump
(16) Lubricant points (bearings) CLS only
(17) Lubricant container
(18) Breather filter for lubricant container
(19) Grease level sensor (sonar sensor)
(20) Test port lubricant pump drive pressure
(21) Electrical terminal box
(22) Dummy wheel, SLS only
3 - 14 PC4000-6 TS 08199-xD-GB-2
3.1.9 VIEW ONTO THE ELECTRICAL COMPONENTS IN THE CAB BASE
Fig. 3-9 View onto the Electrical Components in the Cab Base
TS 08199-xD-GB-2 PC4000-6 3 - 15
Legend for Fig. 3-9 - View onto the Electrical Components in the Cab Base
(1) Resistor and diode array (11R005, 11R013, 11R016 and 11R017)
(2) ICN-D node (11K302)
(3) MTC-controller (11K301)
(4) ICN-V node (11K305)
(5) Dual ICN-V node (11K303/11K304)
(6) Controller battery (13G008)
(7) Controller battery (13G009)
(8) VHMS controller (10K300)
(9) Battery main switch (71Q002) for controller batteries
(10) Electronic load limiting control (RC4-4)
3 - 16 PC4000-6 TS 08199-xD-GB-2
3.1.10 HYDRAULIC OIL TANK - LOCATION OF ELECTRICAL

COMPONENTS
Fig. 3-10 Hydraulic Oil Tank - Location of Electrical Components
TS 08199-xD-GB-2 PC4000-6 3 - 17
Legend for Fig. 3-10 - Hydraulic Oil Tank - Location of Electrical Components
40B004 Hydraulic oil level sensor (minimum level indication
40B031 Proximity switch for shut-off gate valve
40B050 Hydraulic oil level sensor (refill level indication)
40B105 Hydraulic oil level - pressure transducer
40B163 Pressure return-oil chamber - pressure transducer
40B164 Pressure leak-oil chamber - pressure transducer
40B165 Pressure oil cooler - pressure transducer
40B166 Pressure pre-load (back pressure) valve - pressure transducer
40B267 Thermostat (TT only, hydraulic oil pre-heating)
40G018 Hydraulic oil transfer pump
59B015 Hydraulic oil level sensor (refill level indication
59B162 Hydraulic oil level - pressure transducer
3 - 18 PC4000-6 TS 08199-xD-GB-2
3.1.11 HYDRAULICALLY OPERATED ACCESS LADDER
Fig. 3-11 Hydraulically Operated Access Ladder
TS 08199-xD-GB-2 PC4000-6 3 - 19
Legend for Fig. 3-11 - Hydraulically Operated Access Ladder
A Access ladder in upper position (working position)
B Access ladder in lowered position
(1) Stop bar
(2) Pull chain for emergency lowering of the access ladder
(3) Hydraulic cylinder
70B091 Monitor and control sensor

This sensor monitors the ladder position and controls the moving speed of the ladder.
In case sensor 70B122 fails to function properly, sensor 70B091 prevents unintended
movement of the ladder.
70B122 Safety sensor, located on ladder pivot bracket

Cut out of the pilot control system and actuation of the hydraulic swing brake
with the ladder in lowered position.
70S084 Ladder control switch for lowering and lifting the ladder
70S084a Safety switch for emergency lowering of the access ladder.

When the chain is pulled down with the engine running, the pilot control system
is made inoperative in order to prevent further movement of the shovel.
3 - 20 PC4000-6 TS 08199-xD-GB-2
Mounting Locations and Connector Types Connector Types Overview
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)
TS 08199-xD-GB-2 PC4000-6 3 - 21
Connector Types Overview Mounting Locations and Connector Types
31-pole connector with aluminium housing 21-pole connector with plastic housing
Grease barrel connector CAN bus connector
CAN feed-through into node box Deutsch connectors HD 34/36-18-8-S…
Picture shows socket rear insert.
3 - 22 PC4000-6 TS 08199-xD-GB-2
Deutsch connectors HD 34/36-18-14-S… Deutsch connectors HD 34/36-24-9-S…
Picture shows socket rear insert. Picture shows socket rear insert.
TS 08199-xD-GB-2 PC4000-6 3 - 23
Phoenix Contact connector for ICN-D nodes (10-pole)
Fig. 3-12 Phoenix Contact connector for ICN-D nodes (10-pole)
Legend for Fig. 3-13
(A) Mounting screw
(1 - 10) Cable port
(B) Cable clamp
3 - 24 PC4000-6 TS 08199-xD-GB-2
Connector for IVN-V nodes (55 pins)
Fig. 3-13 ICN-V connector
(1) Connector housing
(2) Pin allocation (55 pins)
TS 08199-xD-GB-2 PC4000-6 3 - 25
3 - 26 PC4000-6 TS 08199-xD-GB-2
Standard Value Table for Electrical Components
4 STANDARD VALUE TABLE

FOR ELECTRICAL
COMPONENTS
TS 08199-xD-GB-2 PC4000-6 4 -1
Used abbreviations
Eng Engine
N.C. Normally Closed
N.O. Normally Open
20S001 Main key switch 20S001
S/M Service Manual
Deutsch T-box Electrical test box for Deutsch connectors
CAN T-box Electrical test box for the CAN bus
Compo- Inspec-
System
Component Measurement
nent tion Judgement table
name conditions
code method
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

off solenoid 31Q599
connector
valve Between (1) - (2) 8.0 ± 2.0Ω
3) Insert T-box

table below, it is normal. 2) Disconnect
resistance
connector
Measure
Engine speed
52B064-1 3) Insert T-box
sensor
4) Pick up
Between (1) - (2) 850 ± 50Ω adjustment:
refer to S/M
If the condition is within the range shown in the
1) 20S001 OFF
resistance
table below, it is normal.

Measure
Intake air
2) Disconnect
temperature 51B110
Engine related parts
Refer to the PT100 connector

sensor Between (1) - (2)
Centigrade/Ohm chart 3) Insert T-box

resistance
Measure
Pre-lube oil table below, it is normal. 2) Disconnect

52B093-1
pressure switch connector
Between (1) - (2) min. 1MΩ
3) Insert T-box
resistance
Measure
Engine 52Q502a-1 table below, it is normal. 2) Disconnect

cold start aid
52Q502b-1 connector
solenoid valve Between (1) - (2) 38 ± 3Ω
3) Insert T-box
1) 20S001 OFF
2) Disconnect
Measure voltage
connector
Engine air filter
52B018-1 3) Insert T-box
clogging sensor
52B019-1 4) 20S001 ON
[N.O. type] Between (1) - (2) 0V 5) Engine high idle
Between (1) - (2) 22 - 24V 6) Filters: clogged
4 -2 PC4000-6 TS 08199-xD-GB-2
Compo- Inspec-
System
name conditions
code method
Engine remote If the condition is within the range shown in the 1) 20S001 OFF
oil tank level table below, it is normal. 2) Disconnect
sensor connector
3) Insert T-box
Measure voltage
[N.C. type] Between (A) - (C) 22 - 24V
4) 20S001 ON
Between (A) - (B) 22 - 24V
→ with oil 5) Engine OFF
63B103-1
1) 20S001 OFF
2) Disconnect
connector
→ without oil
3) Insert T-box
Between (A) - (C) 22 - 24V
4) 20S001 ON
Between (A) - (B) 0V
5) Engine OFF
Measure voltage
Engine oil level connector

sensor 3) Insert T-box
63B106-1
(pressure 4) 20S001 ON
sensor) 5) Engine OFF
Between A (1) - C (4) 22 - 24V
6) Depending on
Engine related parts
Between B (2) - C (4) 0.5 - 9.5V

the oil level

Measure voltage
Fuel level table below, it is normal. 2) Disconnect

sensor connector
31B063 3) Insert T-box
(pressure 4) 20S001 ON
sensor) Between B (2) - A (1) 22 - 24V
Between A (1) - C (3) 0.5 - 9.5V 5) Depending on
the oil level
Measure voltage
Alternator
→ between When the engine is running (high idle) 1) Start engine

52G005-1 27.5 - 29.5 V
alternator 2) Engine high idle
terminal D+ Info:
and chassis If the battery is cold, or after starting in cold
areas, the voltage may not increase for a time.

resistance
Measure

Shunt resistor 71T003 1) 20S001 OFF
Between (R) - (L) 4.5 ± 0.5Ω 2) Disconnect cables

Measure
voltage
Ambient temp
13B090 connector
sensor Refer to the PT100
Between (B) - (C) 3) Insert T-box
Centigrade/Volt chart
4) 20S001 ON
TS 08199-xD-GB-2 PC4000-6 4 -3
Compo- Inspec-
System
name conditions
code method

Measure voltage
2) Insert T-box
PTO lube oil 3) 20S001 ON
pressure switch Between (1) - (2) 22 - 24V
57B017-1 4) Engine OFF
[N.C. type] 5) Engine high idle
Between (1) - (2) 0V 6) From switch point
0.5bar
Measure
PTO lube oil

voltage
PTO & related parts
temperature 57B049-1 connector

sensor Refer to the PT100 3) Insert T-box
Between (B) - (C)
Centigrade/Volt chart
4) 20S001 ON
resistance
Measure

PTO connector
lube oil filter Between (1) - (2) min. 1MΩ
3) Insert T-box
clogging sensor 57B027-1
4) 20S001 ON
Measure
voltage
[N.O. type] 5) Engine high idle

Between (1) - (2) 22 - 24V 6) From switch point
5bar
resistance
Measure
PTO preload
pressure 57K553-1
connector
solenoid valve Between (1) - (2) 23 ± 1.0Ω
3) Insert T-box
resistance
Measure
Refilling arm
solenoid valve 57Q624a
connector
→ up Between (1) - (2) 20 ± 1.0Ω
3) Insert T-box
resistance
Measure
Refilling arm table below, it is normal. 2) Disconnect

solenoid valve 57Q624b
connector
→ down Between (1) - (2) 20 ± 1.0Ω
3) Insert T-box
Refilling arm

resistance
Measure
Refilling arm table below, it is normal. 2) Disconnect

solenoid valve 57Q624c
connector
→ enable Between (1) - (2) 35 ± 1.0Ω
3) Insert T-box
Refilling arm
limit switch table below, it is normal. 2) Disconnect
Measure voltage
[N.O. type] connector

3) Insert T-box
→ arm in down 55B023 Between (A) - (B) 22 - 24V 4) 20S001 ON
position Between (A) - (C) 0V
5) Engine OFF
→ arm in up
Between (A) - (C) 22 - 24V 6) Engine high idle
position
4 -4 PC4000-6 TS 08199-xD-GB-2
Compo- Inspec-
System
name conditions
code method
Measure voltage
Up: connector
Ladder limit
70B122 3) Insert T-box
switch
Between (A) - (B) 22 - 24V 4) 20S001 ON
Down: Between (A) - (C) 0V
[N.O. type] 70B091 5) Engine OFF
Between (A) - (C) 22 - 24V 6) Engine high idle
resistance If the condition is within the range shown in the 1) 20S001 OFF
Measure
Ladder
Ladder

solenoid valve 57Q623b
connector
→ lower Between (1) - (2) 20 ± 1.0Ω
3) Insert T-box
resistance
Measure
Ladder
solenoid valve 57Q625
connector
→ fast Between (1) - (2) 35 ± 1.0Ω
3) Insert T-box
resistance
Measure
Ladder
connector
→ raise Between (1) - (2) 20 ± 1.0Ω
3) Insert T-box
resistance
Measure
Swing
parking brake 57Q505
connector
3) Insert T-box
resistance
Measure
Oil cooler 57K506a-1 table below, it is normal. 2) Disconnect

fan drive
57K506b-1 connector
3) Insert T-box
Hydraulic system

resistance
Measure
Travel table below, it is normal. 2) Disconnect

parking brake 57Q516
connector
3) Insert T-box
resistance
Measure
Qmin table below, it is normal. 2) Disconnect

57K517
solenoid valve connector
Between (1) - (2) 35 ± 1.0Ω
3) Insert T-box
resistance
Measure
Qmax ½ table below, it is normal. 2) Disconnect

57K517a
Between (1) - (2) 35 ± 1.0Ω
3) Insert T-box
TS 08199-xD-GB-2 PC4000-6 4 -5
Compo- Inspec-
System
name conditions
code method
1) 20S001 OFF
2) Disconnect
Measure
voltage
connector
Between (1) - (2) 22 - 24V
3) Insert T-box
4) 20S001 ON
Electronic
pump control 57K561-1 If the condition is within the range shown in the 1) 20S001 OFF
current/resistance
solenoid valve table below, it is normal. 2) Disconnect
connector
Measure
Between (1) - (2)

20 ± 1.0Ω 3) Insert T-box
at the solenoid
4) 20S001 ON
Between (1) - (2) 670 ± 10mA 5) Engine high idle
or at the X2 board 11X_56 pin 17 → no load
Oil cooler If the condition is within the range shown in the 1) 20S001 OFF
resistance
Measure
preload table below, it is normal. 2) Disconnect

40K601
pressure connector
3) Insert T-box
resistance
Measure
Hydraulic table below, it is normal. 2) Disconnect

57K620
slew brake connector
Between (1) - (2) 20 ± 1.0Ω
3) Insert T-box
resistance
Measure
Slew flow
reduction 57K626
connector
Hydraulic system
3) Insert T-box
resistance
Measure

connector
Between (1) - (2) 35 ± 1.0Ω
3) Insert T-box
Slew brake If the condition is within the range shown in the 1) 20S001 OFF
proportional 57Q627 table below, it is normal. 2) Disconnect
Measure
current
3) Insert T-box
4) 20S001 ON
Between (1) - (2) Output 11T016 - R2
11X_56 pin 18 350 - 370mA 5) Engine high idle
6) Press pedal
Fixed pump If the condition is within the range shown in the 1) 20S001 OFF
resistance
Measure
flow solenoid table below, it is normal. 2) Disconnect

57K630
valve connector
Between (1) - (2) 35 ± 1.0Ω
(Pump 1) 3) Insert T-box
Fixed pump If the condition is within the range shown in the 1) 20S001 OFF
resistance
Measure
flow solenoid table below, it is normal. 2) Disconnect

57K631
valve connector
(Pump 3) Between (1) - (2) 35 ± 1.0Ω
3) Insert T-box
resistance
Measure
Coolant fan table below, it is normal. 2) Disconnect

57K636-1
Between (1) - (2) 10 ± 1.0Ω
3) Insert T-box
Energy If the condition is within the range shown in the 1) 20S001 OFF
resistance
Measure
efficiency table below, it is normal. 2) Disconnect

57K646
(Pump 2 & 4) Between (1) - (2) 20 ± 1.0Ω
3) Insert T-box
4 -6 PC4000-6 TS 08199-xD-GB-2
Compo- Inspec-
System
name conditions
code method
resistance
Measure
57K647
(Pump 3) Between (1) - (2) 20 ± 1.0Ω
3) Insert T-box
resistance
Measure
57K648
(Pump 1) Between (1) - (2) 20 ± 1.0Ω
3) Insert T-box
61K563
61K564 If the condition is within the range shown in the 1) 20S001 OFF
Remote
resistance
Measure
61K565 table below, it is normal.

control 2) Disconnect
61K566
proportional connector
61K567
solenoid valve Between (1) - (2) 24 ± 1.0Ω 3) Insert T-box
61K568
61K569
61K570
Remote
resistance
Measure
61K572 table below, it is normal.

control 2) Disconnect
61K573
proportional connector
61K574 Between (1) - (2) 24 ± 1.0Ω
solenoid valve 3) Insert T-box
61K575
61K576
Hydraulic system
61K520
resistance
Measure
Remote 61K522 table below, it is normal.

2) Disconnect
control 61K523
connector
solenoid valve 61K524
Between (1) - (2) 20 ± 1.0Ω 3) Insert T-box
61K525
61K526
61K527
resistance
Measure
Remote 61K529 table below, it is normal. 2) Disconnect

control 61K530
connector
solenoid valve 61K531 Between (1) - (2) 20 ± 1.0Ω
61K532 3) Insert T-box
61K533
61K534
resistance
Measure
Remote 61K536 table below, it is normal.

2) Disconnect
control 61K537
connector
solenoid valve 61K538
Between (1) - (2) 20 ± 1.0Ω 3) Insert T-box
61K539
61K540
61K541
resistance
Measure
Remote 61K543 table below, it is normal. 2) Disconnect

control 61K544
connector
solenoid valve 61K545 Between (1) - (2) 20 ± 1.0Ω
61K546 3) Insert T-box
61K547
TS 08199-xD-GB-2 PC4000-6 4 -7
Compo- Inspec-
System
name conditions
code method
Hydraulic oil table below, it is normal. 2) Disconnect
level sensor connector
Measure voltage
Between (A) - (C) 22 - 24V 3) Insert T-box
→ with oil Between (A) - (B) 22 - 24V
4) 20S001 ON
40B004
1) 20S001 OFF
2) Disconnect
→ without oil connector
(Shutdown) Between (A) - (C) 22 - 24V
3) Insert T-box
4) 20S001 ON
Hydraulic oil table below, it is normal. 2) Disconnect
level sensor connector
Measure voltage
Between (A) - (C) 22 - 24V

→ with oil 3) Insert T-box
Between (A) - (B) 22 - 24V
4) 20S001 ON
40B050
→ without oil connector
(Refill mess.) Between (A) - (C) 22 - 24V 3) Insert T-box
4) 20S001 ON
Measure voltage
2) Disconnect
Hydraulic system
Hydraulic oil connector

level sensor 3) Insert T-box
40B105 Between (A) - (B) 22 - 24V
(pressure
4) 20S001 ON
transducer)
5) Depending on the
Between (C) - (A) 0.5 - 9.5V
hydraulic oil level
Hydraulic oil 1) 20S001 OFF
Measure
voltage
temperature 2) Disconnect
59B015
sensor Refer to the PT100 connector
Between (B) - (C)
(PT100 type) Centigrade/Volt chart 3) Insert T-box

Measure voltage
Hydr. oil tank connector

shut off gate 3) Insert T-box
valve 40B031 Between (A) - (B) 22 - 24V 4) 20S001 ON
(proximity Between (A) - (C) 0V
switch) 5) Main gate closed
Between (A) - (C) 22 - 24V 6) Main gate open

connector
Measure voltage
Floating switch Boom:

at 20X810a 20S095 3) Insert T-box
Between (B) - (L/K) 22 - 24V 4) 20S001 ON
Between (B) - (L/K) 22 - 24V
Floating switch Stick: 5) Press switch
at 20X910a 20S098
Between (B) - (L/K) 0V 7) Switch in neutral
Between (B) - (L/K) 0V position
4 -8 PC4000-6 TS 08199-xD-GB-2
Compo- Inspec-
System
name conditions
code method

Measure voltage
61B087-a connector
High pressure
switch 61B087-b 3) Insert T-box
Between (A) - (C) 22 - 24V
61B087-c 4) 20S001 ON
(analog) 61B087-d
5) Engine high idle
Between (B) - (C) 0.5 - 9.5V 6) Depending on
pressure
Measure voltage
X1 pressure connector
57B085-1 Between (A) - (C) 22 - 24V
4) 20S001 ON
(analog)
5) Engine high idle
Between (B) - (C) 0.5 - 9.5V
6) max. 60bar
Measure voltage
2) Disconnect
X2 pressure connector
57B086 Between (A) - (C) 22 - 24V
4) 20S001 ON
(analog)
Hydraulic system
5) Engine high idle

Between (B) - (C) 0.5 - 9.5V
6) max. 60bar
Measure voltage
Preload valve connector

pressure 3) Insert T-box
sensor 40B166 Between (A) - (C) 22 - 24V
4) 20S001 ON
(analog) 5) Depending on the
Between (B) - (C) 0.5 - 9.5V pressure
6) max. 60bar
Measure voltage
Leak oil
connector
chamber
40B164 Between (A) - (C) 22 - 24V
sensor 4) 20S001 ON
5) Depending on the
(analog)
6) max. 6bar
Measure voltage
Return oil
connector
chamber
40B163 Between (A) - (C) 22 - 24V
sensor 4) 20S001 ON
5) Depending on the
(analog)
6) max. 6bar
TS 08199-xD-GB-2 PC4000-6 4 -9
Compo- Inspec-
System
name conditions
code method
Measure voltage
Suction tank
connector
pressure
sensor 59B162 3) Insert T-box
Between (A) - (C) 22 - 24V
4) 20S001 ON
(analog)
5) Engine high idle
Between (B) - (C) 0.5 - 9.5V
Hydraulic system
6) Range: -1 ~ +1bar

connector
Measure voltage
3) Insert T-box
Oil cooler 4) 20S001 ON
pressure 40B165
Between (A) - (C) 22 - 24V 5) Open terminals
sensor
1, 2 & 3 at T-box
6) Depending on the
7) max. 60bar

connector
Measure voltage
3) Insert T-cable
End line switch Between (A) - (B) 22 - 24V
80B043 4) 20S001 ON
grease
62B046 5) Engine high idle
pressure
6) Grease pump
running
Between (A) - (B) 0V 7) Grease pressure
180bar present
If the condition is within the range shown in the 1) Engine high idle
resistance
Grease system
Measure
table below, it is normal. 2) Grease pump

Grease pump 62Q507
running
solenoid valve 62Q509
3) Grease pressure
Between (D) - (F/H) 22 ± 1.0Ω
below 180bar
If the condition is within the range shown in the 1) Engine high idle
Grease line
resistance

Measure
2) Grease pump
running
62Q509a
(Vent valve) 3) Grease pressure
Between (D) - (F/H) 22 ± 1.0Ω
below 180bar
Measure current

connection
Grease barrel 62B108
3) Insert T-cable
level sensor 62B109
4) 20S001 ON
Between (B) - (B) 4 - 20mA 5) Depending on
the grease level
4 - 10 PC4000-6 TS 08199-xD-GB-2
Compo- Inspec-
System
name conditions
code method
Measure voltage
Magnetic clutch connection
52Q004
compressor 3) Insert T-cable
4) 20S001 ON
Air conditioning
Between (1) - (gnd) 22 - 24V

5) Switch ON A/C

Measure voltage connector
Heater mixing 3) Insert T-box
20Q097
valve 4) 20S001 ON
5) Open terminals
1 & 2 at T-box
Between (1) - (2) 22 - 24V
6) Switch ON heater

connection
Measure voltage
3) Insert T-cable
Actuator pedal 4) 20S001 ON
20S021a
→ left crawler
5) Move pedal
Between 11X_20 - 87 0 up to +10V
→ forward
6) Move pedal
Between 11X_20 - 87 0 up to -10V
→ backward

connection
Measure voltage
3) Insert T-cable
Actuator pedal 4) 20S001 ON
20S021b
Electronic control levers
→ right crawler
5) Depress pedal
→ forward
6) Depress pedal
→ backward
Measure voltage

Actuator pedal connection
20S022
→ slew brake 3) Insert T-cable
4) 20S001 ON
5) Depress pedal
table below, it is normal. 1) 20S001 OFF
Betw. 11X_00 - 7 L 0 up to -10V 2) Disconnect
Measure voltage
connection
Control lever 3) Insert T-cable
→ left hand Betw. 11X_00 - 7 R 0 up to +10V
20S020 4) 20S001 ON
X & Y axis 5) Move lever to left
Betw. 11X_00 - 12 F 0 up to +10V & right side
6) Move lever to front
& backward
Betw. 11X_00- 12 B 0 up to -10V
TS 08199-xD-GB-2 PC4000-6 4 - 11
Compo- Inspec-
System
name conditions
code method
table below, it is normal. 1) 20S001 OFF
Between 11X_00-9 L 0 up to -10V 2) Disconnect
Measure voltage
connection
Control lever 3) Insert T-cable
→ right hand Between 11X_00-9 R 0 up to +10V
20S019 4) 20S001 ON
X & Y axis 5) Move lever to left
Between 11X_00-14 F 0 up to +10V & right side
Electronic control levers
6) Move lever to front

Between 11X_00-14 B 0 up to -10V & backward

Measure voltage

20S024
→ clam open 3) Insert T-cable
4) 20S001 ON
5) Depress pedal

Measure voltage

20S023
→ clam close 3) Insert T-cable
4) 20S001 ON
5) Depress pedal
10R100 If the condition is within the range shown in the
resistance
1) 20S001 OFF
Measure
CAN bus 10R101 table below, it is normal.

CAN
2) Disconnect
resistor 20R101
Between (A) - (B) 120Ω CAN connector
40R101
4 - 12 PC4000-6 TS 08199-xD-GB-2
References for Troubleshooting (CAN Bus & Node Outputs)
5 REFERENCES FOR
TROUBLESHOOTING
(CAN BUS & NODE
OUTPUTS)
TS 08199-xD-GB-2 PC4000-6 5 -1
CAN-Bus trouble or Node Output Trouble References for Troubleshooting (CAN Bus & Node Outputs)
5.1 CAN-BUS TROUBLE OR NODE OUTPUT TROUBLE

Overview
If the CAN bus or any node output is disturbed, the following REAL TIME MONITOR screen provides detailed
information on the trouble.
Fig. 5-1 Sub-screen 3/3 (Electr Equipment Diagnosis)
The screen includes two partitions as follows.
REMARKS: The upper screen partition (1) has first priority, and the lower screen partition (2) has lower priority.
(1) Upper partition of the REAL TIME MONITOR - CAN bus
This partition of the screen (with higher priority) gives information on the CAN bus condition. If any CAN bus
trouble is displayed here, trouble message G00308 is set as well.
(2) Lower partition of the REAL TIME MONITOR - Node outputs
This partition of the screen (with lower priority) gives information on node outputs. This partition is only active
if no trouble for the CAN bus is reported. If any node output trouble is displayed here, trouble message
G00043 is set as well.
5 -2 PC4000-6 TS 08199-xD-GB-2
References for Troubleshooting (CAN Bus & Node Outputs) CAN-Bus trouble or Node Output Trouble
5.1.1 TROUBLE CAN-BUS OR CAN-HARDWARE (G00308)

In case a CAN bus trouble occurs, the following information can be displayed in the upper partition (1) of the
REAL TIME MONITOR.
CAN-NODE ERROR TYPE 0 All CAN nodes OK. No problem detected in the CAN bus.
1 Connection to the concerned CAN bus interrupted.

e.g. - Broken wire in the main line or in a branch line.
2 The concerned CAN bus is not active.

e.g. - CAN bus defective
- CAN bus not present
- Wrong adjustment of DIP switch(es)
CAN NODE NUMBER Number of that node in the CAN bus, where the trouble is detected.
If CAN-NODE ERROR TYPE is indicated as trouble kind "1" or "2":
– Trouble code G00308 is also set.

– The MTC blinks out a binary code plus an add-on binary code.
– The concerned CAN nodes are indicated in the CoDeSys HMI visualization (CAN bus overview).
For further information on "How to identify the trouble" and "Which method is used for troubleshooting" refer to the
troubleshooting procedure of G00308 on page 7-209.
TS 08199-xD-GB-2 PC4000-6 5 -3
CAN-Bus trouble or Node Output Trouble References for Troubleshooting (CAN Bus & Node Outputs)
5.1.2 TROUBLE OUTPUT SHORT-CIRCUIT (G00043)

In case a node output trouble occurs, the following information can be displayed in the lower partition (2) of the
REAL TIME MONITOR.
Precondition: - No CAN bus trouble is displayed in the upper partition of the below REAL TIME MONITOR.
- Otherwise the CAN bus trouble needs repair at first.
- In this case refer to section 5.1.1 on page 5-3 (Trouble CAN-BUS or CAN-Hardware (G00308).
The 4 entries in the lower partition (2) of the above REAL TIME MONITOR indicate the status information for
trouble code G00043 (Trouble Output Short-circuit) as follows:
Displayed Information Output Error Type Remark
0 = All outputs OK Standard condition, all outputs error-free
1 = No power supply Node output power supply faulty
OUTPUT ERROR TYPE Node output section is switched OFF & external
2 = External power feed-in
voltage (+24V) is fed-in, short circuit to 24V
Short circuit in the ground cable of the node

3 = Short circuit or cable break
output section.
CAN-NODE NUMBER Number of the affected node
CONNECTOR NUMBER Number of the affected node connector
PIN-NUMBER Number of the affected pin at the node connector
5 -4 PC4000-6 TS 08199-xD-GB-2
References for Troubleshooting (CAN Bus & Node Outputs) CAN-Bus trouble or Node Output Trouble
Troubleshooting Procedures for G00043
Output
Error Output Condition Procedure
Type
G00043 is not displayed

- Standard condition.
0 All outputs OK - All outputs error-free.
- No troubleshooting for the node outputs necessary.
G00043 is displayed
- Node output power supply faulty.
- The node output doesn’t receive power supply (24V) from the upstream
circuit breaker.
1 No power supply - Refer to the Wiring Diagram.
- Find the displayed node and its affected connector/pin.
- Check the power supply of the affected node output section.
- Locate the problem and repair as necessary.
- Recheck the system for proper function.
G00043 is displayed
- Node output section is switched OFF, nevertheless external voltage
(24V) is fed-in.
- Short circuit to power (+24V) occurred.
External power
2 - Refer to the Wiring Diagram.
feed-in
- Find the displayed node output section and its affected connector/pin.
- Check the wiring and locate the short circuit to +24V.
- Repair as necessary.
G00043 is displayed
- Short circuit in the ground cable of the output section.
Short circuit or - Refer to the Wiring Diagram.

3 - Find the displayed node and its affected connector/pin.
cable break
- Locate the short circuit to ground or the wiring interruption.
- Repair as necessary.
TS 08199-xD-GB-2 PC4000-6 5 -5
Sequence of the CAN nodes at the CAN bus References for Troubleshooting (CAN Bus & Node Outputs)
5.2 SEQUENCE OF THE CAN NODES AT THE CAN BUS

In case of a multiple trouble, the VHMS monitor displays only one faulty node.
The faulty node which is closest to the MTC is displayed first.
1 The nodes in the direction MTC Hydraulic tank are displayed first.
2 The nodes in the direction MTC operator‘s cab are displayed thereafter.
Refer to the following chart, which lists the nodes in their sequence at the CAN bus.
Component code Component type Location
20K309 ICN-D Operator‘s cab 2
20K310 ICN-V Operator‘s cab
11K301 MTC Cab base
11K302 ICN-D Cab base
11K303 ICN-V Cab base
51K317 ICN-D Machinery house - engine room
51K318 ICN-V Machinery house - engine room
51K319 ICN-V Machinery house - engine room
56K314 ICN-D Machinery house - pump area
56K315 ICN-V Machinery house - pump area
56K316 ICN-V Machinery house - pump area
40K311 ICN-D Hydraulic tank
40K312 ICN-D Hydraulic tank
40K313 ICN-V Hydraulic tank 1
5 -6 PC4000-6 TS 08199-xD-GB-2
References for Troubleshooting (CAN Bus & Node Outputs) Troubleshooting for Relay Monitored Node Outputs
5.3 TROUBLESHOOTING FOR RELAY MONITORED

NODE OUTPUTS
General
The following procedures describe troubleshooting procedures for trouble messages, which indicate problems with
the monitoring of Node Output Signals via a primary and a redundant electronic relay.
Trouble monitoring covers 2 different trouble conditions:
1) Relay Check The system monitors if both relays (a & b) including wiring are good or faulty.
2) Output Signal Check The system monitors if the circuit between node output and relay is good or faulty.
5.3.1 RELAY CHECK
Exemplary troubleshooting chart for a Relay Check
The exemplary troubleshooting chart refers to the Relay Check for the primary relay 56K250a and its
redundant relay 56K250b.
G00107 Trouble slew parking brake control 56K250a

G00109 Trouble slew parking brake control 56K250b (redundant)
Individual troubleshooting for a Relay Check
If any trouble message for a comparable monitoring circuit is displayed:
Use the following troubleshooting chart as a pattern.
Apply the respective Component Codes which are involved in the comparable trouble message.
Apply the specifications of the respective Equipment and Wiring Diagram

(node no., connector no., pin no., etc).
Comparable trouble codes for Relay Check
Comparable trouble codes for Relay Check concerning "Monitoring via primary and redundant electronic
relay" are as follows. If one of these trouble codes would be displayed, use the following troubleshooting
chart (G00107/G00109 on page 5-8) as a guideline for troubleshooting.
G00111 G00113 G00115 G00117 G00223 G00225 G00234 G00236
G00309 G00311 G00313 G00315 G00317 G00319 G00321 G00323
TS 08199-xD-GB-2 PC4000-6 5 -7
Troubleshooting for Relay Monitored Node Outputs References for Troubleshooting (CAN Bus & Node Outputs)
G00107 - Trouble slew parking brake control 56K250a

G00109 - Trouble slew parking brake control 56K250b
[1/4]
Trouble code G00107 - Trouble slew parking brake control 56K250a
Trouble
G00107 & G00109 G00109 - Trouble slew parking brake control 56K250b
- This message is displayed if the electronic relay 56K250a or its wiring is defective (relay check).
Contents of trouble
- The troubleshooting procedure for the redundant relay 56K250b is analogously.
If relay 56K250a or 56K250b or its wiring is defective, the electric circuit is interrupted and the
Related information function (slew parking brake) is no longer available.
REMARKS: G00107/G00109 is only displayed once during one "Key switch ON" period.
- Background colour of the trouble code information: yellow
Action of controller
- Acoustic signal (20P022) in the cab ON.
Problem that appears
The function (slew parking brake) is not available.
on the machine
Instruction message 2 Inform service.
Nominal
Possible cause Step Test condition & Inspection Procedure
value
Main key switch 20S001 ON
Visually check the LEDs at 56K250a or 56K250b.
(1) LED yellow
(2) LED red
(3) A2 = GND
(4) A1 = 24V
(5) Switch contacts (13/14)

- No power supply (A1)
- No ground (A2)
- Relay inoperative
- Relay output wiring 1
(13/14) defective Specifications of the slew parking brake switch 20S029
G00107 56K250a 20S029 in position 1 brake applied

G00109 56K250b
0V at relay 56K250a/b
0V at solenoid 57Q505
Both relay LEDs (yellow & red) OFF
20S029 in position 0 brake released

Both relay LEDs (yellow & red) ON
Toggle switch 20S029 and check the power supply at the relay
(G00107 56K250a / G00109 56K250b).
According to the trouble message the relay reaction is not as specified.

- Refer to the Wiring Diagram and check the relay and its wiring.
5 -8 PC4000-6 TS 08199-xD-GB-2

[2/4]
Nominal
value
REAL TIME MONITOR - Relay Check
1. 20S001 ON
2. Engine OFF
3. REAL TIME MONITOR

14 Other items
Screen 2/5
4. Toggle 20S029 from switch position 0 to switch position 1.
5. The REAL TIME MONITOR shows "0" only, it doesn’t change from "0" to "1"
(confirmation of trouble).
Indication
Voltage Brake
REAL TIME MONITOR
1 24 V Released
0 0V Applied
Continue trouble-
shooting of step 1 1
(cross check)
Bring the machine back into the original condition.

Final check 2
Start the machine and verify that the trouble code does not arise again.
TS 08199-xD-GB-2 PC4000-6 5 -9
View onto the CoDeSys HMI Visualization screen for trouble code G00107
[3/4]
Fig. 5-2 View onto the CoDeSys HMI Visualization screen for trouble code G00107
5 - 10 PC4000-6 TS 08199-xD-GB-2
Wiring Diagram (56K250a & 56K250b) for trouble code G00107

(Wiring Diagram for G00109 is analogously)
[4/4]
Fig. 5-3 Wiring Diagram (56K250a & 56K250b) for trouble code G00107
TS 08199-xD-GB-2 PC4000-6 5 - 11
5.3.2 OUTPUT CHECK
Exemplary troubleshooting chart for an Output Check
The exemplary troubleshooting chart refers to the Output Check for the primary relay 56K250a and its
redundant relay 56K250b.
G00108 Trouble slew parking brake control Output to 56K250a

G00110 Trouble slew parking brake control Output to 56K250b
Individual troubleshooting for an Output Check
If any trouble message for a comparable monitoring circuit is displayed:
Use the following troubleshooting chart as a pattern
Apply the respective Component Codes which are involved in the comparable trouble message
Apply the specifications of the respective Equipment and Wiring Diagram

(node no., connector no., pin no., etc)
Comparable trouble codes for Output Check
Comparable trouble codes for Output Check concerning "Monitoring via primary and redundant electronic
relay" are as follows. If one of these trouble codes would be displayed, use the following troubleshooting
chart (G00108/G00110 on page 5-13) as a guideline for troubleshooting.
G00112 G00114 G00116 G00118 G00224 G00226 G00235 G00237
G00310 G00312 G00314 G00316 G00318 G00320 G00322 G00324
5 - 12 PC4000-6 TS 08199-xD-GB-2
G00108 - Trouble slew parking brake control Output to 56K250a

G00110 - Trouble slew parking brake control Output to 56K250b
[1/4]
Trouble code G00108 - Trouble slew parking brake control Output to 56K250a
Trouble
G00108 & G00110 G00110 - Trouble slew parking brake control Output to 56K250b
- This message is displayed if the wiring between node output and solenoid (via relay 56K250a)
Contents of trouble is interrupted (output check).
- This is a control function for the connection between node output and solenoid.
- Also check for G00043. If trouble message G00043 is displayed (short circuit at the node output)
Related information follow the troubleshooting procedure for G00043 first.
- If the connection between node output and solenoid is faulty, the function (slew parking brake)
is no longer available.
Action of controller - Acoustic signal (20P022) in the cab ON.
on the machine
Nominal
value
The node output signal Main key switch 20S001 ON & 20S029 in position 0
via relay to the Refer to the Wiring Diagram and check the wiring between node output and
solenoid is disturbed 1 solenoid.
G00108 56K250a
G00110 56K250b Repair the wiring between node output and solenoid (via relay) as necessary.
REAL TIME MONITOR - Output check
1. Main key switch 20S001 ON.
2. Engine OFF.

14 Other items
Screen 2/5
4. Switch 20S029 in position 0.
5. Verify the Output Check on the REAL TIME MONITOR.
Continue trouble-
(cross check)
Digit "0" in line OUTPUT CHECK for 56K250a confirms the trouble message.
TS 08199-xD-GB-2 PC4000-6 5 - 13

[2/4]
Nominal
value
REAL TIME MONITOR - Output Signal check
Confirm the output signal from switch 20S029 over the MTC and CAN bus to
node 14 (connector 3, pin 2).
1. 20S001 ON.
2. Engine OFF.
15 Output Signals
Screen 12/24
5. Verify the Output Signals on the REAL TIME MONITOR.
20S029 in position 0 Output Signal = 1
If the REAL TIME MONITOR indication doesn’t change from "0" to "1"
check node 14.
Continue trouble-
(cross check)
Applied logic for 56K250a and 56K250b:
If slew parking brake switch 20S029 is in position 0

24V at the output
REAL TIME MONITOR displays 1
– Output Signal = 1 for 56K250a indicates that the signal is transferred via
MTC to the node output.
– The fault is located in the wiring between node output and solenoid.
Verify if other relevant trouble codes are set in this situation
e.g. G00043 (Trouble output short-circuit).
Locate the problem and repair as necessary.

Final check 2
5 - 14 PC4000-6 TS 08199-xD-GB-2
[3/4]
TS 08199-xD-GB-2 PC4000-6 5 - 15

[4/4]
5 - 16 PC4000-6 TS 08199-xD-GB-2
TS 08199-xD-GB-2 PC4000-6 5 - 17
5 - 18 PC4000-6 TS 08199-xD-GB-2
Tables for Testing and Troubleshooting
6 TABLES FOR TESTING

AND TROUBLESHOOTING
TS 08199-xD-GB-2 PC4000-6 6 -1
Index of Tables in this section Tables for Testing and Troubleshooting
6.1 INDEX OF TABLES IN THIS SECTION

Test Value Table for Temperature Sensors (PT100) Centigrade - Volt, on page 6-3
Test Value Table for Temperature Sensors (PT100) Centigrade - Ohm, on page 6-4
Table of Trouble Codes (G-Codes), on page 6-5
Table of Instruction Messages, on page 6-11
Table of Binary Codes, on page 6-14
Table of Add-On Binary Codes for G00308, on page 6-16
Binary Output Signals on the VHMS Monitor, on page 6-17
Power Supply, on page 6-19
Cable Colour Identification, on page 6-20
6 -2 PC4000-6 TS 08199-xD-GB-2
Tables for Testing and Troubleshooting Test Value Table for Temperature Sensors (PT100) Centigrade - Volt
6.2 TEST VALUE TABLE FOR TEMPERATURE SENSORS

(PT100) CENTIGRADE - VOLT
Temperature and voltage values for testing the signal voltage of PT100 temperature sensors
which are equipped with a transducer unit.
°C 0 -1 -2 -3 -4 -5 -6 -7 -8 -9
-50 0.50 - - - - - - - - -
-40 0,95 0.905 0.86 0.815 0.77 0.725 0.68 0.635 0.59 0.545
-30 1.40 1.355 1.31 1.265 1.22 1.175 1.13 1.085 1.04 0.995
-20 1.85 1.805 1.76 1.715 1.67 1.625 1.58 1.535 1.49 1.445
-10 2.30 2.255 2.21 2.165 2.12 2.075 2.03 1.985 1.94 1.895
0 2.75 2.705 2.66 2.615 2.57 2.525 2.48 2.435 239 2.345
°C 0 -1 -2 -3 -4 -5 -6 -7 -8 -9
0 2.75 2.795 2.84 2.885 2.93 2.975 3.02 3.065 3.11 3.155
10 3.20 3.245 3.29 3.335 3.38 3.452 3.47 3.515 3.56 3.605
20 3.65 3.695 3.74 3785 3.83 3.875 3.92 3.965 4.01 4.055
30 4.10 4.145 4.19 4.235 4.28 4.325 4.37 4.415 4.46 4.505
40 4.55 4.595 4.64 4.685 4.73 4.775 4.82 4.865 4.91 4.955
50 5.00 5.045 5.09 5.135 5.18 5.225 5.27 5.315 5.36 5.405
60 5.45 5.495 5.54 5.585 5.63 5.675 5.72 5.765 5.81 5.855
70 5.90 5.945 5.99 6.035 6.08 6.125 6.17 6.215 6.26 6.305
80 6.35 6.395 6.44 6.485 6.53 6.575 6.62 6.665 6.71 6.755
90 6.8 6.845 6.89 6.935 6.98 7.025 7.07 7.115 7.16 7.205
100 7.25 7.295 7.34 7.385 7.43 7.475 7.52 7.565 7.61 7.655
110 7.70 7.745 7.79 7.835 7.88 7.925 7.97 8.015 8.06 8.105
120 8.15 8.195 8.24 8.85 8.33 8.375 8.42 8.465 8.51 8.555
130 8.60 8.645 8.69 8.735 8.78 8.825 8.87 8.915 8.96 9.005
140 9.05 9.095 9.14 9.185 9.23 9.275 9.32 9.365 9.41 9.455
150 9.50 - - - - - - - - -
(1) Transducer
Fig. 6-1 Temperature Sensor PT100
TS 08199-xD-GB-2 PC4000-6 6 -3
Test Value Table for Temperature Sensors (PT100) Centigrade - Ohm Tables for Testing and Troubleshooting
6.3 TEST VALUE TABLE FOR TEMPERATURE SENSORS

(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. 6-2 PT100 Temperature Charts (degree centigrade - resistance)
6 -4 PC4000-6 TS 08199-xD-GB-2
Tables for Testing and Troubleshooting Table of Trouble Codes (G-Codes)
6.4 TABLE OF TROUBLE CODES (G-CODES)
Explanation of the columns in the following Trouble Code chart
Column 1 G-Code G-Code number
Colour Code of
Column 2 0 = Red, 1 = Yellow, 2 = Green
Top Message
Instruction Number of the Instruction Message, which is displayed together with

Column 3
Message No. the Trouble Code (numbers 1 - 58)
1 = displayed once
Column 4 Display 2 = displayed at each occurrence
N = NOT displayed
Column 5 Acoustic Signal Y = an acoustic signal sounds if the relating trouble occurs
The error/message is saved in a History Memory:

1 = Service & Operator History
Column 6 Memory 2 = Service History
3 = Operator History
5 = VHMS History
Column 7 G-Code Message Displayed text of the Trouble Code
NOTE! For the table of C-Codes (engine Trouble Codes) refer to the SERVICE MANUAL, chapter 14.
Table of G-Codes
Acoustic Signal
Message No.
Instruction
Colour
G-Code G-Code Message
Memory
Code
Display
G00001 0 1 2 1 Trouble Shut-Off (gate) valve
G00002 2 37 2 3 Test speed 1800 1/min engine 1
G00003 1 38 1 1 Trouble pump controller
G00005 1 39 1 3 Low hydraulic oil level
G00007 0 2 2 1 Trouble hydraulic oil level
G00012 1 17 1 3 Central lubrication system grease level too low
G00013 1 17 1 3 Slew ring gear lubr. system grease level too low
G00020 0 4 2 1 Trouble Shut-Off (gate) valve (Start blocked)
G00031 2 - 2 Y 3 Set engine to low idle
G00032 1 2 1 1 Trouble starter
G00033 1 2 1 1 Trouble VHMS-Controller
G00034 1 2 1 1 Trouble VHMS-Display
G00035 0 34 2 1 Trouble totally loss gear oil (PTO 1)
TS 08199-xD-GB-2 PC4000-6 6 -5
Table of Trouble Codes (G-Codes) Tables for Testing and Troubleshooting
Acoustic Signal
Message No.
Instruction
Colour
Memory
Code
Display
G00039 2 - 2 Y 3 Actuate engine speed selector switch
G00043 1 2 2 Y 1 Trouble output short-circuit
G00048 0 2 2 Y 1 Trouble emergency safety circuit
G00053 1 56 2 Y 1 Reset emergency safety circuit
G00054 1 2 1 Y 1 Monitoring idle position cut off
G00060 0 6 2 1 Fire in the power house
G00061 0 2 2 1 Trouble monitoring, engine 1 speed too low
G00062 0 2 2 1 Trouble monitoring, engine 1 speed too high
G00063 0 2 1 1 Trouble monitoring hydraulic oil temp
G00064 0 2 1 1 Trouble monitoring hydraulic oil level
G00065 1 2 1 1 Very low hydraulic oil level
G00066 0 2 2 1 Trouble hydraulic oil temperature
G00067 1 2 1 1 Trouble battery voltage too high
G00069 1 2 1 1 Trouble monitoring oil temperature gear (PTO 1)
G00070 1 2 2 Y 1 Trouble oil temperature gear (PTO 1)
G00071 1 2 2 Y 1 Trouble gear lubrication (PTO 1)
G00081 0 2 2 1 Trouble lubrication system
G00086 2 12 2 Y 3 SHUTDOWN
G00087 2 2 Y 3 Stop all movements for low idle
G00090 0 8 2 Y 1 Trouble power supply
G00091 0 9 2 3 Pilot control cut out
G00092 0 10 2 3 Emergency shut-down at access ladder
G00093 0 10 2 3 Emergency shut-down at valve block
G00094 0 10 2 3 Emergency shut-down at hydraulic control panel
G00095 0 10 2 3 Emergency shut-down in cabin
G00096 0 14 2 3 Pilot control cut out
G00099 0 48 2 Y 1 Trouble power supply
G00100 0 11 2 3 Maintenance safety switch
G00102 1 2 2 Y 3 Switch off wiper [S/N 08199 only]
G00103 1 47 2 Y 1 Faulty switch 20M004 [S/N 08199 only]
G00104 1 15 2 Y 1 Trouble battery current
6 -6 PC4000-6 TS 08199-xD-GB-2
Acoustic Signal
Message No.
Instruction
Colour
Memory
Code
Display
G00105 1 16 2 Y 1 Trouble battery charging current too low
G00107 1 2 1 Y 1 Trouble slew parking brake control 56K250a
G00108 1 2 1 Y 1 Trouble slew parking brake control Output to 56K250a
G00109 1 2 1 Y 1 Trouble slew parking brake control 56K250b
G00110 1 2 1 Y 1 Trouble slew parking brake control Output to 56K250b
G00111 1 2 1 Y 1 Trouble travel parking brake control 56K251a
G00112 1 2 1 Y 1 Trouble travel parking brake control Output to 56K251a
G00113 1 2 1 Y 1 Trouble travel parking brake control 56K251b
G00114 1 2 1 Y 1 Trouble travel parking brake control Output to 56K251b
G00115 1 2 1 Y 1 Trouble slew hydraulic brake control 56K252a
G00116 1 2 1 Y 1 Trouble slew hydraulic brake control Output to 56K252a
G00117 1 2 1 Y 1 Trouble slew hydraulic brake control 56K252b
G00118 1 2 1 Y 1 Trouble slew hydraulic brake control Output to 56K252b
G00140 1 17 1 1 Trouble monitoring X1-1 Pressure
G00141 1 17 1 1 Trouble monitoring X2-Pressure
G00147 1 17 1 1 Trouble monitoring gear lubrication (PTO 1)
G00148 1 17 1 1 Trouble monitoring fuel level
G00151 1 17 1 1 Trouble monitoring gear (PTO) oil filter 1
G00154 1 17 1 1 Trouble monitoring return oil filter
G00155 1 17 1 1 Trouble monitoring leak oil filter
G00159 1 17 1 1 Trouble monitoring breather filter
G00160 1 17 1 1 Trouble monitoring engine air cleaner 1
G00161 1 17 1 1 Trouble monitoring battery voltage
G00162 1 17 1 1 Trouble monitoring charging-/discharging current
G00164 1 17 1 1 Trouble air cleaner 1
G00165 1 17 1 1 Trouble breather filter hydraulic oil tank
G00166 1 17 1 1 Trouble oil filter gear (PTO 1)
G00169 1 17 1 1 Trouble return oil filter hydraulic oil tank
G00170 1 17 1 1 Trouble leak oil filter hydraulic oil tank
G00176 1 17 1 1 Trouble battery voltage too low
G00177 1 17 1 1 Trouble battery charging circuit
TS 08199-xD-GB-2 PC4000-6 6 -7
Acoustic Signal
Message No.
Instruction
Colour
Memory
Code
Display
G00178 1 17 1 1 Trouble battery charging current too high
G00179 1 17 1 1 Trouble control pressure X1-1
G00180 1 17 1 1 Trouble pilot pressure X2 too low
G00181 1 17 1 1 Trouble pilot pressure X2 too high
G00184 1 20 1 Y 1 Central lubrication system empty
G00185 1 20 1 Y 1 Trouble central lubrication system
G00186 1 20 1 Y 1 Trouble central lubrication system
G00187 1 20 1 Y 1 Slew ring gear lubrication system empty
G00188 1 20 1 Y 1 Trouble slew ring gear lubrication system
G00189 1 20 1 Y 1 Trouble slew ring gear lubrication system
G00207 1 2 1 Y 1 Engine remote oil tank 1 empty
G00216 1 2 2 Y 1 Trouble software not compatible
G00218 2 0 2 Y - Switch off all motors for running transfer pump
G00220 1 2 2 Y 1 Trouble transfer pump motor overheated
G00223 1 2 2 Y 1 Trouble starter control 51K001a-1
G00224 1 2 2 Y 1 Trouble starter control Output to 51K001a-1
G00225 1 2 2 Y 1 Trouble starter control 51K001b-1
G00226 1 2 2 Y 1 Trouble starter control Output to 51K001b-1
G00231 1 2 2 Y 1 Trouble pilot control lever 20S019
G00232 1 2 2 Y 1 Trouble pilot control lever 20S020
G00233 1 2 2 Y 1 Trouble pilot control 11Q045
G00234 1 2 2 Y 1 Trouble pilot control 11K111a
G00235 1 2 2 Y 1 Trouble pilot control Output to 11K111a
G00236 1 2 2 Y 1 Trouble pilot control 11K111b
G00237 1 2 2 Y 1 Trouble pilot control Output to 11K111b
G00238 1 2 2 Y 1 Trouble supply by key switch 11Q044
G00240 2 21 1 1 Trouble hydraulic oil temperature
G00242 2 22 2 3 Engine 1 already running
G00243 2 23 1 Y 3 Fill up fuel tank
G00245 0 24 2 1 Engine shutdown from ground
G00246 2 25 2 3 Hydraulic oil temperature
6 -8 PC4000-6 TS 08199-xD-GB-2
Acoustic Signal
Message No.
Instruction
Colour
Memory
Code
Display
G00252 0 10 2 1 Emergency shut-down at access ladder
G00253 0 10 2 1 Emergency shut-down at valve block
G00254 0 10 2 1 Emergency shut-down at hydraulic control panel
G00255 0 10 2 1 Emergency shut-down in cabin
G00257 2 30 2 3 Hydraulic oil temperature
G00261 1 11 2 1 Maintenance Safety Switch
G00262 1 20 1 Y 1 Trouble screen at hydr. cooler entry clogged
G00308 0 3 2 Y 1 Trouble CAN-Bus or CAN-Hardware
G00309 1 2 1 Y 1 Trouble ladder up 56K253a
G00310 1 2 1 Y 1 Trouble ladder up Output to 56K253a
G00311 1 2 1 Y 1 Trouble ladder up redundant 56K253b
G00312 1 2 1 Y 1 Trouble ladder up redundant Output to 56K253b
G00313 1 2 1 Y 1 Trouble ladder down 56K254a
G00314 1 2 1 Y 1 Trouble ladder down Output to 56K254a
G00315 1 2 1 Y 1 Trouble ladder down redundant 56K254b
G00316 1 2 1 Y 1 Trouble ladder down redundant Output to 56K254b
G00317 1 2 1 Y 1 Trouble service arm up 56K255a
G00318 1 2 1 Y 1 Trouble service arm up Output to 56K255a
G00319 1 2 1 Y 1 Trouble service arm up redundant 56K255b
G00320 1 2 1 Y 1 Trouble service arm up redundant Output to 56K255b
G00321 1 2 1 Y 1 Trouble service arm down 56K256a
G00322 1 2 1 Y 1 Trouble service arm down Output to 56K256a
G00323 1 2 1 Y 1 Trouble service arm down redundant 56K256b
G00324 1 2 1 Y 1 Trouble service arm down redundant Output to 56K256b
G00325 1 2 1 Y 1 Trouble service arm input
G00326 1 2 1 Y 1 Trouble ladder input
G00327 1 2 1 Y 1 Trouble parking brake input
G00328 1 2 1 Y 1 Trouble start input
G00330 1 2 2 Y 1 Trouble pilot control 11Q111
G00331 2 57 2 3 Automatic after_running engine 1
G00333 1 2 2 Y 1 Trouble battery charger relay
TS 08199-xD-GB-2 PC4000-6 6 -9
Acoustic Signal
Message No.
Instruction
Colour
Memory
Code
Display
G00417 1 2 2 Y 1 Communication failure PLC <==> VHMS-Controller
G00420 1 2 2 Y 1 Connector sel error
G00421 1 2 2 Y Farm sys error
G00422 1 2 2 Y 1 Can-net sys (J1939)
G00423 1 2 2 Y 1 Application sys error
G00425 1 2 2 1 Settings impossible to take over into the PLC
G00491 1 2 2 Y 1 Communication failure MH800 <==> VHMS-Controller
6 - 10 PC4000-6 TS 08199-xD-GB-2
Tables for Testing and Troubleshooting Table of Instruction Messages
6.5 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.
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
Ladder end switch or lock lever contact open

9 or service arm down or unlock.
Emergency shut-down switch was

actuated.
10
- Unlock before restarting.
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
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.
TS 08199-xD-GB-2 PC4000-6 6 - 11
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 - 12 PC4000-6 TS 08199-xD-GB-2
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
Switch off and restart motor

44 (It may be necessary to wait for cool down)
Switch off windscreen wiper

46
and call service.
Only upper windscreen wiper!

47
Inform service.
No 24V at circuit breaker 11F013a

48
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
TS 08199-xD-GB-2 PC4000-6 6 - 13
Table of Binary Codes Tables for Testing and Troubleshooting
6.6 TABLE OF BINARY CODES

The following table shows the general Binary Codes which can be flashed out at the MTC (LED 1 & LED 2),
while the main key switch is ON.
For details of the Binary Codes and their indication at the MTC refer to the OPERATION & MAINTENANCE
MANUAL, chapter 3.8 Electrical Equipment in Cab Base.
Indication of the Binary Digits 0 & 1
Binary digit LED 1 LED 2
0 OFF ON
1 ON ON
If a Binary Code or several Binary Codes are set, the MTC continues to flash out these codes during the current
runtime of the MTC.
To delete Binary Codes: Main key switch OFF + wait until the MTC is totally shut down (all LEDs OFF).
Input Digits of
Binary Code G-Code Message
No. G-Code
01 000001 001 Trouble Shut-Off (gate) valve
02 000010 007 Trouble hydraulic oil level
03 000011 020 Trouble Shut-Off (gate) valve (Start blocked)
04 000100 033 Trouble VHMS-Controller
05 000101 034 Trouble VHMS-Display
06 000110 035 Trouble totally loss gear oil (PTO 1)
08 001000 061 Trouble monitoring, engine 1 speed too low
09 001001 062 Trouble monitoring, engine 1 speed too high
10 001010 063 Trouble monitoring hydraulic oil temperature
13 001101 070 Trouble oil temperature gear (PTO 1)
14 001110 071 Trouble gear lubrication (PTO 1)
16 010000 092 Emergency shut-down at access ladder
17 010001 093 Emergency shut-down at valve block
18 010010 094 Emergency shut-down at hydraulic control panel
19 010011 095 Emergency shut-down in cabin
22 010110 100 Maintenance Safety Switch
23 010111 147 Trouble monitoring gear lubrication (PTO 1)
25 011001 238 Trouble supply by key switch 11Q044
27 011011 245 Engine shutdown from ground
28 011100 252 Emergency shut-down at access ladder
6 - 14 PC4000-6 TS 08199-xD-GB-2
Tables for Testing and Troubleshooting Table of Binary Codes
Input Digits of
Binary Code G-Code Message
No. G-Code
29 011101 253 Emergency shut-down at valve block
30 011110 254 Emergency shut-down at hydraulic control panel
31 011111 255 Emergency shut-down in cab
34 100010 261 Maintenance Safety Switch
40 101000 060 Fire in the power house
50 110010 090 Trouble power supply
51 110011 0998 Trouble power supply
63 111111 308 Trouble CAN-Bus or CAN-Hardware
TS 08199-xD-GB-2 PC4000-6 6 - 15
Table of Binary Codes Tables for Testing and Troubleshooting
6.6.1 TABLE OF ADD-ON BINARY CODES FOR G00308

If Trouble Code G00308 Trouble CAN-Bus or CAN-Hardware is set, the MTC flashes out an additional Binary
Code which indicates the number of the node unit that fell out of the CAN bus system.
The MTC flashes out the Binary Codes in the following sequence:
Sequence Binary Code Meaning Remark
1 111111 G00308 Trouble CAN-Bus or CAN-Hardware Standard Code
2 001010 (sample) CAN-Node 10 no longer connected to Bus: ICNV-05 location 20 Add-On Code
The following table shows the additional Binary Codes which are flashed out at the MTC (LED 1 and LED 2) in
combination with trouble code G00308 (111111).
Input
Binary Code ( 111111+ ) Trouble CAN Node Connection
No.
02 000010 CAN-Node 02 no longer connected to Bus: ICND-01 location 11
03 000011 CAN-Node 03 no longer connected to Bus: ICNV-01 location 11
6 - 16 PC4000-6 TS 08199-xD-GB-2
Tables for Testing and Troubleshooting Binary Output Signals on the VHMS Monitor
6.7 BINARY OUTPUT SIGNALS ON THE VHMS MONITOR

The following table shows the Binary Output Signals which are displayed via VHMS.
These Output Signals can be used for testing and troubleshooting.
For more details of VHMS refer to the SERVICE MANUAL and to the OPERATION & MAINTENANCE MANUAL.
Brief Instruction for Switching the Output Signals ON/OFF
Step No. Procedure
1 Enter the VHMS Service Level
2 Select option "08 Setting" on the SERVICE MENU SELECT screen
3 Open sub-screen 5/8, OTHER SETTINGS 2/2
4 Select option "PLC-evaluation ON/OFF"
5 Switch the PLC-evaluation OFF
6 Enter the REAL TIME MONITOR
7 Select option 15 Output signals
8 Select the required Output and switch it ON or OFF for testing
9 After testing is finished switch the PLC-evaluation ON again
Condi-
Location
Component tion at Screen

Node VHMS Display Text REAL TIME MONITOR
Code Activa- No.
tion
11K050 24V 11K304 Bucket cut-off Output signals Ext. low volt. 6/24
Engine enable
11K064-1 24V 11K304 Output signals Ext. low volt. 8/24
[engine controller and fuel valve]
11K080 24V 11K305 Use control block 1 Output signals Ext. low volt. 5/24
11K111a 24V 11K303 Pilot control supply Output signals Ext. low volt. 7/24
11K111b 24V 11K303 Pilot control supply redundant Output signals Ext. low volt. 7/24
11P029 24V 11K305 Crawler operating hour meter Output signals Ext. low volt. 8/24
11 11Q020 24V 11K304 Horn ON Output signals Ext. low volt. 6/24
11Q023 24V 11K304 Superstructure lighting Output signals Ext. low volt. 9/24
11Q023a 24V 11K304 Superstructure lighting Output signals Ext. low volt. 9/24
11Q044 24V 11K304 Power via key switch Output signals Ext. low volt. 6/24
11Q045 24V 11K304 Main supply pilot control Output signals Ext. low volt. 7/24
11Q090 24V 11K304 Emergency lighting ladder Output signals Ext. low volt. 9/24
11Q100 24V 11K303 Self holding Output signals Ext. low volt. 6/24
11Q122 0V 11K305 Stabilized current supply Output signals Ext. low volt. 7/24
TS 08199-xD-GB-2 PC4000-6 6 - 17
Binary Output Signals on the VHMS Monitor Tables for Testing and Troubleshooting
Condi-
Location

Code Activa- No.
tion
20P022 24V 20K310 Acoustic signal Output signals cab 3/24
20P056 24V 20K310 Shutdown prewarning Output signals cab 3/24
20P145-1 24V 20K310 VHMS lamp red 1 Output signals cab 4/24
20P146-1 24V 20K310 VHMS lamp yellow 1 Output signals cab 4/24
20
20Q067 24V 20K310 Cab blower Output signals cab 3/24
20Q194 24V 20K309 Upper wiper stop Output signals cab 2/24
20Q197 24V 20K309 Upper wiper slow Output signals cab 1/24
20Q198 24V 20K309 Upper wiper fast Output signals cab 1/24
40K601 24V 40K313 Oil cooler back-pressure Output signals Hydraulic tank 17/24
40
40Q062 24V 40K313 Transfer pump Output signals Hydraulic tank 17/24
51K001a-1 24V 51K318 Starter relay 1 Output signals Engine room 11/24
51K001b-1 24V 51K319 Starter relay 1 redundant Output signals Engine room 11/24
51
51K045-1 24V 51K317 Relay RPM shifting 1 Output signals Engine room 11/24
51K164-1 24V 51K317 Oil tank 1 empty Output signals Engine room 11/24
52Q502a-1 24V 51K318 Cold start 1 Output signals Engine 10/24

52
52Q502b-1 24V 51K318 Cold start 1 Output signals Engine 10/24
55P052 24V 51K319 Hydraulic oil tank full Output signals Service arm 18/24
55P076 24V 51K319 CLS 1 Grease barrel full Output signals Service arm 18/24
55 55P078 24V 51K319 SLS Grease barrel full Output signals Service arm 18/24
55P139 24V 51K318 Fuel level tank full Output signals Service arm 18/24
55P142-1 24V 51K318 Engine oil tank full Output signals Service arm 19/24
56K250a 24V 56K315 Parking brake Output signals Pump room 12/24
56K250b 24V 56K316 Parking brake redundant Output signals Pump room 12/24
56K251a 24V 56K315 Travel brake Output signals Pump room 12/24
56K251b 24V 56K316 Travel brake redundant Output signals Pump room 12/24
56K252a 24V 56K315 Hydraulic slew brake Output signals Pump room 13/24
56K252b 24V 56K316 Hydraulic slew brake red Output signals Pump room 13/24
56K253a 24V 56K314 Ladder up Output signals Ladder 21/24

56
56K253b 24V 56K314 Ladder up redundant Output signals Ladder 21/24
56K254a 24V 56K314 Ladder down Output signals Ladder 21/24
56K254b 24V 56K314 Ladder down redundant Output signals Ladder 21/24
56K255a 24V 56K314 Service arm up Output signals Service arm 20/24
56K255b 24V 56K314 Service arm up redundant Output signals Service arm 20/24
56K256a 24V 56K314 Service arm down Output signals Service arm 20/24
56K256b 24V 56K314 Service arm down redundant Output signals Service arm 20/24
6 - 18 PC4000-6 TS 08199-xD-GB-2
Tables for Testing and Troubleshooting Power Supply
Condi-
Location

Code Activa- No.
tion
57K553-1 24V 56K316 Gear oil cooler back-pressure Output signals Control panel 16/24
57K506a-1 24V 56K316 Valve fan drive 1 min. Output signals Control panel 16/24
57K506b-1 24V 56K316 Valve fan drive 1 med. Output signals Control panel 16/24
57K646 24V 56K315 Pump control Output signals Control panel 15/24
57 57K626 24V 56K315 Pump control Output signals Control panel 14/24
57K517a 24V 56K316 Pump control Output signals Control panel 14/24
57Q624c 24V 56K315 Service arm enable Output signals Service arm 19/24
57Q625 24V 56K315 Ladder movement fast Output signals Ladder 21/24
60 60P140 24V 51K318 Travel motion horn Output signals Superstructure 24/24
61Q632a 24V 40K313 Auto float stick Output signals Ext. low volt. 5/24
61 61Q633a 24V 40K313 Auto float stick Output signals Ext. low volt. 5/24
61Q635a 24V 40K313 Auto float boom Output signals Ext. low volt. 5/24
62Q507 24V 40K313 CLS 1 Lubrication pump Output signals Lubric. Syst. 23/24
62Q507a 24V 40K313 CLS 1 Release lubrication line Output signals Lubric. Syst. 23/24
62
62Q509 24V 11K303 SLS Lubrication pump Output signals Lubric. Syst. 23/24
62Q509a 24V 11K303 SLS Release lubrication line Output signals Lubric. Syst. 23/24
test_leve Test power supply for lever Output signals Ext. low volt. 8/24
6.8 POWER SUPPLY
Circuit Electric Appliance
11F013 Binary sensors
11F013a Analog sensors
TS 08199-xD-GB-2 PC4000-6 6 - 19
Cable colour identification Tables for Testing and Troubleshooting
6.9 CABLE COLOUR IDENTIFICATION
Short Marks
Colour Colour
(English) (German) Standard IEC German German
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 PC4000-6 TS 08199-xD-GB-2
Troubleshooting by Trouble Code
7 TROUBLESHOOTING BY
TROUBLE CODE
TS 08199-xD-GB-2 PC4000-6 7 -1
G00001 - Trouble Shut-Off (gate) valve

[1/5]
Trouble code
Trouble 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.
- If the SHUTDOWN BYPASS setting for the option "Shut-Off (gate) valve" is set to OFF on the
VHMS monitor, the engine is shut down if the main gate valve is not completely open.
Related information Refer to Fig. 7-3 on page 7-5.
REMARKS: For detailed information on the VHMS settings refer to the SERVICE MANUAL,
chapter 14, section SHUTDOWN BYPASS ON/OFF.
- Background colour of the trouble code information: red
- The MTC blinks out the binary code 000001
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.
Nominal
value
Main key switch 20S001 ON.
Yes Go to next step.
Open the main gate

The engine is stopped, valve completely and
because the main gate verify that trouble code
1 Verify if the main gate valve is fully open or not.
valve at the hydraulic G00001 (or G00020)
oil tank is not fully open Is the main gate valve fully open? No is not set again.
If trouble code G00020
is set, refer to the trou-
bleshooting chart of
G00020.
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.
7 -2 PC4000-6 TS 08199-xD-GB-2

[2/5]
Nominal
value
Prepare with main key switch 20S001 OFF.
Then carry out troubleshooting with main key switch ON.
Disconnect the cable connector from the Vmin 22V

3
proximity switch and measure the supply Yes Go to step 6.
voltage at the connector terminal A. Vmax 24V
Is supply voltage present? No Go to next step.
Incorrect or no
supply voltage at
Vmin 22V
the proximity switch
40B031 Yes Go to next step.
Vmax 24V
Check if supply voltage is present at the power
4 supply line 11F013. Follow the trouble-
Is supply voltage present? shooting chart for
No trouble code G00090
"Trouble power
supply".
Main key switch 20S001 OFF.
Yes Go to next step. Rmax 1Ω
Malfunction in the
power supply wiring Refer to the Wiring Diagram. Disconnection or short
between proximity 1. Disconnect the connector from the circuit in any wire
switch 40B031 and proximity switch. segment (including
circuit breaker 11F013 5 connectors) between
2. Check the wire segments between the proximity switch and
(disconnection or No
proximity switch and the power supply line circuit breaker.
defective contact in for continuity.
any connector) Locate the problem
Is continuity present? and repair as
necessary.
VHMS Service Menu ON - Input check at node 11
1. Engine OFF Input
Yes Go to step 8.
2. 20S001 ON signal = 1
(refer to Fig. 7-2 on page 7-5)
03 Hydraulic
6
Screen 4/4
Malfunction in the 4. Check the input signal of 40B031 No Go to next step.

signal wiring between on the VHMS monitor.
proximity switch 1 = ON input
40B031 and node 11 0 = OFF no input
(40K311) Is the input displayed?
(disconnection or Main key switch 20S001 OFF.
defective contact in
any connector) Refer to the Wiring Diagram. R40R008
1. Check resistor 40R008: 820Ω
Yes Got to next step.
Disconnect the wires from 40R008 Rwire
and measure its resistance. max 1Ω
7
2. Check the signal wiring:
Check the signal wire segments Locate the problem
for continuity. No and repair as
Do all measurement readings meet the necessary.
specifications?
TS 08199-xD-GB-2 PC4000-6 7 -3

[3/5]
Nominal
value
Defective ground
connection at the Malfunction in any wire
proximity switch Disconnect the cable connector from the segment (including
40B031 8 proximity switch and check for proper connectors) between
ground connection at connector terminal B. proximity switch and
(disconnection or No ground line (GND).
defective contact in Is the ground connection ok?
and repair as
necessary.
Then carry out troubleshooting the main key switch ON.
If the switch function is Switch
not as specified closed:
Defective proximity
9 replace the proximity Rmax 1Ω
switch 40B031 Using the Deutsch T-box, check the proximity switch switch and verify that
for continuity in both switch positions. the repair was Switch
successful. open:
R∞Ω
Got to final step 10.
- Bring the machine back into the original condition.
- Move the main key switch in OFF position until the MTC is totally shut down,
Final check 10
in order to reset the binary code 000001
- Start the machine and verify that the trouble code 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
7 -4 PC4000-6 TS 08199-xD-GB-2
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR
[4/5]
Fig. 7-2 Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR
In the REAL TIME MENU select item 03 Hydraulic Then select screen 4/4 of the REAL TIME MONITOR
View onto the setting for SHUTDOWN BYPASS on the VHMS monitor
Setting 1: SHUTDOWN BYPASS OFF
Standard setting for operation

Bypass OFF = Shutdown function ON
Setting 2: SHUTDOWN BYPASS ON
Exceptional setting for testing and troubleshooting only

Bypass ON = Shutdown function OFF
NOTE! If the SHUTDOWN function is bypassed (setting 2),

engine operation is possible even the main gate
valve is closed! Fig. 7-3 Setting for SHUTDOWN BYPASS
TS 08199-xD-GB-2 PC4000-6 7 -5
Wiring Diagram (40B031) for trouble code G00001 (Main gate valve open)
[5/5]
Fig. 7-4 Wiring Diagram (40B031) for trouble code G00001 (Main gate valve open)
7 -6 PC4000-6 TS 08199-xD-GB-2
G00002 - Test speed 1800 1/min engine 1

[1/2]
Trouble code
Trouble Test speed 1800 1/min engine 1
G00002
Contents of trouble Test speed 1800 rpm is activated by switch 11S041-1 [NO] in the cab base.
Related information If the Quantum engine control module is switched to ground, the engine speed is fixed at 1800 rpm.
Action of controller Background colour of the trouble code information: green

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
value
The function "test Main key switch 20S001 ON.

speed 1800 rpm" If it is necessary, toggle the switch in order to No further trouble-
1 Yes
is activated (switch disable the test speed function. shooting necessary.
11S041-1 is closed) Is the test speed function disabled? No Go to next step.
Check the switch for continuity between the Switch
terminals 1 and 1a. closed:
- Toggle the switch and check for continuity Rmax 1Ω
Defective switch again. Switch
11S041-1 (switch 2 - Turn the main key switch in ON position. open:
does not open) Toggle switch 11S041-1 and check if the R ∞Ω
message on the display disappears. Replace switch
Do the measurements correspond to the 11S041-1 and verify
No
specification and does the trouble message that the repair was
disappear? successful.
Vmin 22V
3 Check if supply voltage is present at the switch Yes Go to step 6.
terminal 1a. Vmax 24V
Incorrect or no supply Is supply voltage present?
voltage in the electrical No Go to next step.
circuit of switch
11S041-1 No power in the supply
line of 11F013.
Check if trouble code G00090 "Trouble power
Yes Follow the trouble-
4 supply" is set.
shooting chart for
Is trouble code G00090 displayed? trouble code G00090.
No Go to next step.
Final check 5
TS 08199-xD-GB-2 PC4000-6 7 -7
Wiring Diagram (11S041-1) for trouble code G00002

[2/2]
Fig. 7-5 Wiring Diagram (11S041-1) for trouble code G00002
7 -8 PC4000-6 TS 08199-xD-GB-2
G00003 - Trouble pump controller

[1/4]
Trouble code
Trouble Trouble pump controller
G00003
Contents of trouble The microcontroller RC4-4 (10K032) of the Electronic Load Limiting Control signals a problem.
Related information If trouble code G00003 is displayed, the electronic pump regulation system is inoperative.
Action of controller Background colour of the trouble code information: yellow
- The electronic pump control circuit is disturbed.

- The hydraulic performance is too slow (or bad).
Problem that appears REMARKS: If you need to keep the shovel busy and if it is not possible to perform the repair in
on the machine an appropriate space of time, the pump regulation may be switched into the
hydraulic mode temporarily.
For more information refer to step 4 in the following troubleshooting chart.
Instruction message 38 If failure exists further, inform service.
Nominal
value
Engine running at high idle.
Keep the control levers in neutral position.
On normal regulation condition the green LED The power supply for Vmin 22V
11P063 at the X2 board is permanently the pump controller
Vmax 24V
switched ON (24V). RC4-4 and the
Yes electrical circuit
inside the controller
is faultless.
Go to next step.
The pump controller The system assumes

RC4-4 (10K032) 1 that the power input to
may be defective the pump controller at
connector 11X_10,
pins 33, 34, 35 is OK.
The electrical circuit
No
inside the pump
controller is defective.
Replace the pump
controller and check
the system for proper
function.
Check if the green LED 11P063 at the X2

board is permanently switched ON.
Is the green LED switched ON (24V)?
TS 08199-xD-GB-2 PC4000-6 7 -9

[2/4]
Nominal
value
The pump controller Engine running at high idle.
RC4-4 (10K032) for Keep the control levers in neutral position.
electronic pump REMARKS: If any trouble is detected in the pump regulation system the red
regulation signals 2 LED 11P138 at the X2 board is flashing blink codes.
any malfunction in
For the meaning of the blink codes refer to the following chart:
the pump regulation
system
Blink Refer to Error Output

Possible cause Effect Procedure
code Fig. no. message stored
Main pumps
57K561-1, pro-
Electric circuit of 57K561-1 running with Check solenoid valve
1 1 portional sole- Yes
open or short to ground max. power or the electric circuit.
noid valve (1)
(Qmax)
Engine is not running or
engine rpm too low.
Check signal and
Reduced
2 2 Low speed (1) No connection to 52B064-1,
No signal from engine hydraulic power
speed sensor 52B064-1 or or trouble code G00061.
circuit short or interrupted
Malfunction of Check high idle limitation
Engine defective or
3 2 High speed (1) Yes the load limiting (Cummins Service) or
engine rpm too high.
control trouble code G00062.
Check alternator
Engine charg-
Low battery Battery voltage below or trouble codes:
4 - Yes ing voltage too
voltage approx. 17 V G00104, G00105
low
G00176, G00177
57K561-2, pro-
5 - portional sole- Yes
noid valve (2)
For engine 2 (PC5500 & PC8000) only.
6 - Low speed (2) No
7 - High speed (2) Yes
Engine running at high idle without hydraulic load.

Checking the output signals of the pump controller
Open terminal 11X_56-17.
Install a multi-tester at the terminals of 11X_56-17.

Step 2
continued Measure the current [mA].
Standard: 670 ± 10 mA
Close the terminal of 11X_56-17 again.

Otherwise check 57K561-1 and the wiring.
Blink code 1 Check the resistance of 57K561-1 between pin 1 & 2.

Standard: 20 ± 1Ω
Fig. no. 1
7 - 10 PC4000-6 TS 08199-xD-GB-2

[3/4]
Nominal
value
Step 2
continued
Blink code 2 & 3
Fig. no. 2
Checking the resistance of the rpm sensor 52B064-1

Engine OFF - Main key switch 20S001 OFF.
1. Disconnect the connector of the engine speed sensor 52B064-1
2. Check the resistance between pin 1 & 2 Standard: 850 ± 50Ω
3. Otherwise replace the sensor 52B064-1 and adjust as described above.
Checking the rpm sensor 52B064-1
Engine OFF - Main key switch 20S001 OFF - Lock out switch 50S058 locked.
1. Disconnect the engine speed sensor 52B064-1 and visually check for damage.
2. Mount 52B064-1 and adjust the gap as follows:
Turn the sensor in clockwise until it touches the flywheel, then unscrew the sensor ¾ turns,
and fasten the locknut securely.
Checking the input signal to the pump controller
Step 2 Engine running at high idle.

continued 1. Check the voltage at 11X_51.38 to ground Standard: approx. 2.5V
2. Otherwise check the wiring to the rpm sensor 52B064-1
TS 08199-xD-GB-2 PC4000-6 7 - 11

[4/4]
Nominal
value
If LED 11P138 (red) is flashing any blink code, Yes Go to final step 5.
follow the according procedure in the above
Continued 2 chart.
No Go to next step.
Could you locate and repair the problem?
Refer to the SERVICE MANUAL section ELECTRONIC
The proportional valve PUMP REGULATION SYSTEM subsection CHECKS
57K561-1 has been 3 AND ADJUSTMENT. Go to final step 5.
replaced Check and adjust the system as described in this
section.
If you need to keep the shovel busy and if it is not possible to perform the repair
in an appropriate space of time, the pump regulation may be switched into the
hydraulic mode temporarily.
Turn the lever (253.1) at the valve cartridge block (1) into the horizontal position
(H) in order to work in the hydraulic mode only, and put the machine back into
operation.
(1) Valve cartridge block

REMARKS:
In case the electronic
pump regulation is 4
inoperative follow the
procedure beside.
(253.1) Emergency lever

for pump control
(electronic and hydraulic mode)
REMARKS: In the hydraulic mode (H) the rated output power is reduced to
approx. 75%. Therefore it is necessary to perform the repair as
soon as possible.

Final check 5
7 - 12 PC4000-6 TS 08199-xD-GB-2
G00005 - Low hydraulic oil level

[1/3]
Trouble code
Trouble Low hydraulic oil level
G00005
Pressure transducer 40B105 detected that the hydraulic oil level is low
(below the temperature- dependent amount)
Conditions for the generation of trouble code G00005:
Contents of trouble - The main key switch 20S001 is in ON position for more than 10 seconds.
- The engine is shut off for more than 15 seconds and the attachment is in its defined position
(refer to Fig. 7-6 on page 7-15 of this troubleshooting chart, showing the hydraulic oil tank label
incl. the defined positions at the bottom)
Related information Pressure sensor 40B105 transmits a pre-warning message for the hydraulic oil level.

Risk, to run out of hydraulic oil.
on the machine
Instruction message 39 Inform service if attachment in defined position.
Nominal
value
Check with stopped engine and the attachment in its defined position.
In consideration of the kind of attachment Refill specified
(BHA or FSA) and the hydraulic oil tempera- hydraulic oil and
ture, check the hydraulic oil level sight gauge, Yes verify that trouble
and verify if the hydraulic oil level corresponds code G00005 is
Hydraulic oil level low 1 to the displayed trouble message. not displayed again.
Refer to illustration Fig. 7-6 on page 7-15,
which shows the hydraulic oil tank label with
the relevant oil levels on the left and right side No Go to next step.
of the label.
Is the oil level too low?
Then carry out troubleshooting with main key switch OFF.
Vmin 22V
Disconnect the cable connector from the
2 Yes Go to step 5.
Incorrect or no supply pressure transducer and measure the
supply voltage at connector terminal B. Vmax 24V
voltage in the circuit of
pressure transducer Is supply voltage present? No Go to next step.
40B105
Follow the trouble-
Check if trouble code G00099
Yes shooting chart for
3 "Trouble power supply" is set.
trouble code G00099.
Is trouble code G00099 displayed?
No Go to next step.
TS 08199-xD-GB-2 PC4000-6 7 - 13
G00005 - Low hydraulic oil level

[2/3]
Nominal
value
Disconnection in the Disconnection or short
wiring between circuit in any wire
pressure transducer segment (including
Refer to the Wiring Diagram and check the
40B105 and the power connectors) between
wire segments between pressure transducer
supply line of circuit 4 pressure transducer
and the power supply line 11F013a for
breaker 11F013a and the line of the
continuity. No
(disconnection or circuit breaker
defective contact in Is continuity present? 11F013a.
and repair as
necessary.
Disconnection or short
Disconnection in the circuit in any wire
Disconnect connector 2 from node 11 and
signal wiring between segment (including
measure at the terminal of 40X340-3.
pressure transducer connectors) between
40B105 terminal C Refer to the Wiring Diagram and check the
5 pressure transducer
and node 11 signal wiring segments between the pressure
and cable connector
transducer, terminal C, and the cable No
(disconnection or 40X340, terminal 3,
connector 40X340, pin 3, and node 11
defective contact and node 11
(connector 2, pin 3) for continuity.
in any connector) (connector 2, pin 3).
Is continuity present?
Locate the problem
and repair as
necessary.
Defective shield wiring* Disconnection or short
at the pressure trans- Disconnect the cable connector from the circuit in any wiring
ducer 40B105 pressure transducer. segment (including
(disconnection or Refer to the Wiring Diagram and check the connectors) between
defective contact 6
shield wiring segments for proper ground cable connector
in any connector) connection and continuity between connector No terminal A and the
*Refer to section 2.15 terminal A and shield line 40X340-1. shield line 40X340-1.
CABLE SHIELDING Are ground connection and continuity ok? Locate the problem
and repair as
necessary.
Defective pressure Vmin 0.5V
Using the Deutsch T-box measure the signal Yes Go to next step.
transducer 40B105 Vmax 9.5V
7 voltage at connector terminal C of the pressure
(missing or poor transducer. Replace the pressure
signal current)
Does the measurement meet the transducer and verify
No
specification? that the repair was
successful.
Final check 8
7 - 14 PC4000-6 TS 08199-xD-GB-2
Wiring Diagram, oil level label, and defined position of the attachment (G00005)
[3/3]
Fig. 7-6 Wiring Diagram, oil level label, and defined position of the attachment (G00005)
TS 08199-xD-GB-2 PC4000-6 7 - 15
G00007 - Trouble hydraulic oil level

[1/2]
Trouble code
Trouble Trouble hydraulic oil level
G00007
Contents of trouble Sensor 40B004 [NO] indicates that the hydraulic oil level is below the minimum refill level.
- If the sensor 40B004 does not sense oil, its signal voltage turns to 0V.
- If the sensor signal voltage continues to be 0V for 10 seconds, trouble code G00007 is set.
Setting options on the VHMS Service Level for too low hydraulic oil level:
A) If the Shutdown Bypass setting for the hydraulic oil level is set to OFF, the engine is stopped.
Related information B) If the Shutdown Bypass setting for the hydraulic oil level is set to ON, the engine is not stopped.
REMARKS: The MTC compares the signals of 40B004 and 40B105 for consistency.
- If the signals are consistent trouble code G00007 is set.
- If the signals are inconsistent trouble code G00064 is set.

Action of controller - Engine shutdown (option)
Problem that appears - Risk, to run out of hydraulic oil.
on the machine - Engine shutdown is possible, if the Shutdown Bypass for the hydraulic oil level is set to OFF.
Nominal
value
Check the hydraulic oil level at the sight glass and fill up hydraulic oil.
Hydraulic oil needs
1 Observe the hydraulic oil temperature and refill oil up to the appropriate level.
refilling Sight glass
Verify if other trouble messages concerning the hydraulic oil are displayed.
If other messages are displayed follow their instructions as necessary.
- Move the main key switch in OFF position until the MTC is totally shut down, in
Final check 2
order to reset the binary code 000010
7 - 16 PC4000-6 TS 08199-xD-GB-2
Wiring Diagram (40B004) and the defined position of the attachment (G00007)
[2/2]
Fig. 7-7 Wiring Diagram (40B004) and the defined position of the attachment (G00007)
TS 08199-xD-GB-2 PC4000-6 7 - 17
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
Trouble
G00012 & G00013 G00013 - Slew ring gear lubr. system grease level too low
- Monitoring of CLS (Central Lubrication System) grease level - 62B108.
Contents of trouble - Monitoring of SLS (Slew ring gear Lubrication System) grease level - 62B109.
- The reserve level in the CLS grease barrel respectively in the SLS grease barrel is reached.
- The sensing range of the grease level sensors is programmed ex factory.
Further adjustment is not possible.
- The grease level sensors do not trigger the bucket cut-off function.
LED functions
(A) Green Power supply (24V) is present

(B) Orange Same function as (C)
(C) Orange Object detected (normal operational condition)
(C) Red Error condition
Related information - Grease may be too close to the ultrasonic sensor
- Sensor may be contaminated with grease
- Sensor may be defective
Overview
Lube Syst. Sensor Node

CLS 62B108 12
SLS 62B109 3

Risk, to run out of grease.
on the machine
Instruction message 17 Inform service till end of shift and then press cancel button.
Nominal
value
Press the cancel
button and refill the
Using the dipstick, verify if the grease level specified grease.
The concerned grease in the concerned barrel corresponds Yes
barrel (CLS or SLS) 1 to the displayed message. Verify that trouble code
needs refilling G00012 or G00013 is
Is the grease level too low? not displayed again.
No Go to next step.
7 - 18 PC4000-6 TS 08199-xD-GB-2

[2/6]
Nominal
value
The ultrasonic sensor may be covered with (a) Clean the lower
grease or the concerned grease barrel may be sensor surface
overfilled. and/or
(a) Is the lower surface of the ultrasonic sensor (b) Reduce the grease
covered with grease? level in the barrel.
and/or Yes
Then verify if the
(b) Is the grease barrel overfilled? problem is solved.
[LEDs (B) & (C) = ON
(orange) and G00012/
Definition of the grease levels
G00013 no longer
displayed].
LEDs (B) & (C) of the
concerned grease level
2
sensor (62B108 or
62B109) light up red
If LED (A) lights green

under these trouble
No conditions, the sensor
may be disturbed.
Go to step 8.

Remove the cover of the junction box on top Vmin 22V
3 of the concerned grease barrel. Measure the Yes Go to step 6.
Vmax 24V
Incorrect or no supply supply voltage at terminal 1 of the terminal
voltage in the circuit of block inside the junction box.
the concerning grease No Go to next step.
Is supply voltage present?
level sensor (62B108
or 62B109) Vmin 22V
Yes Go to step 6.
[Green sensor LED (A) Vmax 24V
Check if supply voltage is present at the
does not light up] Follow the trouble-
4 power supply line 11F013a.
shooting chart for
Is supply voltage present? No trouble code G00099
"Trouble power
supply".
TS 08199-xD-GB-2 PC4000-6 7 - 19

[3/6]
Nominal
value
Disconnection in the Main key switch 20S001 OFF.
wiring between the Yes Go to next step. Rmax 1Ω
concerned grease
level sensor (62B108 Disconnection or short
or 62B109) and the circuit in any wiring
power supply line of Refer to the Wiring Diagram and check the segment (including
circuit breaker wiring segments between the concerned connectors) between
11F013a 5 the concerned grease
grease level sensor and the power supply line
for continuity. No level sensor and the
(disconnection or
line of the circuit
defective contact in Is continuity present? breaker 11F013a.
any connector or in the
junction box on top of Locate the problem
the concerned grease and repair as
barrel) necessary.
Disconnection in the
signal wiring between Disconnection or short
the concerned grease Disconnect the signal line of the concerned circuit in any wiring
level sensor (62B108 grease level and the respective node. segment of the signal
or 62B109) and node 62B108: Node 12, connector 2, terminal 3 line (including connec-
12 or 3 62B109: Node 3, connector 1, terminal 7 tors and junction box)
6 between the con-
(disconnection or Refer to the Wiring Diagram and check the
No cerned grease level
defective contact in signal wiring segments between the sensor and the relating
any connector or in the concerned grease level sensor and the node/connector/termi-
junction box on top of relating node connector/terminal for continuity. nal.
the concerned grease
Is continuity present? Locate the problem
barrel)
and repair as
necessary.
Defective shield wiring*
at the cables of the
concerned grease level Disconnection or short
sensor (62B108 or circuit in any wiring
62B109) Refer to the Wiring Diagram and check the segment (including
7 shield wiring segments for continuity and connectors) between
(disconnection or
proper ground connection to the shield line. No the cable shield and
defective contact
in any connector) Are continuity and ground connection ok? the ground line.
*Refer to section 2.15 Locate the problem
CABLE SHIELDING and repair as
necessary.
7 - 20 PC4000-6 TS 08199-xD-GB-2

[4/6]
Nominal
value
Upper
sensing
Move any plate closer than 7 cm towards the range limit:
8
Wrong sensor reaction lower sensor surface. LEDs (B) and (C) should <7cm
or turn from orange (OK) to red (ERROR). Replace the concerned
defective grease level Do the LEDs turn from orange to red? grease level sensor
sensor (62B108 or No
and verify that the
62B109) repair was successful.
(missing or poor signal Prepare with main key switch 20S001 OFF.
current) Then carry out troubleshooting with main key switch ON.
Measure the signal current of the concerned
9 If the signal current is wrong,
grease level sensor at the relating terminal in
replace the concerned grease ISignal
the junction box.
level sensor and verify that 4-20mA
Refer to the latest version of:
the repair was successful.
PARTS & SERVICE NEWS AH10510.
Final check 10
TS 08199-xD-GB-2 PC4000-6 7 - 21
Wiring Diagram (62B108 & 62B109) for trouble codes G00012 & G00013
[5/6]
Fig. 7-8 Wiring Diagram (62B108 & 62B109) for trouble codes G00012 & G00013
7 - 22 PC4000-6 TS 08199-xD-GB-2
Wiring Diagram (junction box) for trouble codes G00012 & G00013
[6/6]
Fig. 7-9 Wiring Diagram (junction box) for trouble codes G00012 & G00013
TS 08199-xD-GB-2 PC4000-6 7 - 23
G00020 - Trouble Shut-Off (gate) valve (Start blocked)

[1/5]
Trouble code
Trouble Trouble Shut-Off (gate) valve (Start blocked)
G00020
- After main key switch 20S001 is switched ON (engine still OFF), the proximity switch 40B031
Contents of trouble monitors the gate valve between hydraulic tank and suction tank.
- Engine start is disabled if the valve is not completely open.
Related information If the voltage at the proximity switch 40B031 is 0 V, the main gate valve should be closed.

If the SHUTDOWN BYPASS setting for the option "Shut-Off (gate) valve (Start bl.)" is set to OFF
Action of controller on the VHMS monitor, the engine start is blocked if the main gate valve is not completely open.
Refer to illustration Fig. 7-13 on page 7-28.
For detailed information on the VHMS settings refer to the SERVICE MANUAL, chapter 14,
section SHUTDOWN BYPASS ON/OFF.
The engine start is blocked.
on the machine
Start blocked because of main Shut-Off (gate) valve.
Instruction message 4 - Open the Shut-Off (gate) valve.
Nominal
value
Open the gate valve
completely and verify
Engine start is impossi- that trouble code
ble, because the gate Verify if the gate valve is fully open or not. G00020 is no longer
1
valve at the hydraulic Is the gate valve fully open? No set.
oil tank is not fully open If trouble code G00001
is set, refer to trouble-
shooting chart
G00001.
Gap:
Yes Go to next step. approx.
3-5mm
The gap between the
Check for the proper gap between the Adjust the gap.
proximity switch
40B031 and the 2 proximity switch and the open main gate valve. Verify that the
open main gate valve Does the gap correspond to the specification? proximity switch does
is too large No not touch the gate
valve when the gate
valve is completely
open.
7 - 24 PC4000-6 TS 08199-xD-GB-2

[2/5]
Nominal
value
3 proximity switch and insert the Deutsch T-box. Yes Go to step 6.
Vmax 24V
Measure the supply voltage at the connector
terminal A.
Incorrect or no supply No Go to next step.
voltage at the Is supply voltage present?
proximity switch Vmin 22V
40B031 Yes Go to next step.
Vmax 24V
power supply line 11F013. Follow the trouble-
4
shooting chart for
"Trouble power
supply".
Malfunction in the
power supply wiring Refer to the Wiring Diagram. Disconnection or short
between proximity 1. Disconnect the connector from the circuit in any wire
switch 40B031 and proximity switch. segment (including
circuit breaker 11F013 5 connectors) between
2. Check the wire segments between proximity switch and
proximity switch and power supply line circuit breaker 11F013.
defective contact in 11F013 for continuity.
necessary.
1. Engine OFF Input
Yes Go to step 8.
2. 20S001 ON signal = 1
03 Hydraulic
6
Screen 4/4
Malfunction in the 4. Check the input signal of 40B031 No Go to next step.

signal wiring between on the VHMS monitor.
proximity switch 1 = ON input
40B031 and node 11 0 = OFF no input
(40K311) Is the input displayed?
(disconnection or Main key switch 20S001 OFF.
any connector) Refer to the Wiring Diagram. R40R008
1. Check resistor 40R008: 820Ω
Yes Got to next step.
Disconnect the wires from 40R008 Rwire
and measure its resistance. max 1Ω
7
2. Check the signal wiring:
Check the signal wire segments Locate the problem
for continuity. No and repair as
Do all measurement readings meet the necessary.
specifications?
TS 08199-xD-GB-2 PC4000-6 7 - 25

[3/5]
Nominal
value
Defective ground circuit in any wiring
Disconnect the cable connector from the segment (including
connection at the
8 proximity switch and check for proper ground connectors) between
proximity switch
connection at the connector terminal B. No proximity switch and
40B031
Is the ground connection ok? the ground line (GND).
Locate the problem
and repair as
necessary.
If the switch function VSignal
is not as specified closed:
Defective proximity Disconnect the sensor connector and insert the
9 replace the proximity 0V
switch 40B031 Deutsch T-box.
switch and verify that
Measure the signal voltage at terminal C with the repair was VSignal
closed and open gate valve. successful. open:
Go to final step 10. 22-24V

- Move the main key switch in OFF position until the MTC is totally shut down, in
Final check 10
order to reset the binary code 000011
View onto the gap of proximity switch 40B031 (G00020)
(1) Proximity switch (40B031)
(A) Gap 3 - 5 mm
Fig. 7-10 Gap at the proximity switch 40B031
7 - 26 PC4000-6 TS 08199-xD-GB-2
Wiring Diagram (40B031) for trouble code G00020 (Main gate valve closed)
[4/5]
Fig. 7-11 Wiring Diagram (40B031) for trouble code G00020 (Main gate valve closed)
TS 08199-xD-GB-2 PC4000-6 7 - 27
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR
[5/5]
Fig. 7-12 Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR
In the REAL TIME MENU select item 03 Hydraulic Then select screen 4/4 on the REAL TIME MONITOR


NOTE! If the SHUTDOWN function is bypassed (setting 2),

engine start is possible even the main gate valve
is closed! Fig. 7-13 Setting for SHUTDOWN BYPASS
7 - 28 PC4000-6 TS 08199-xD-GB-2
G00031 - Set engine to low idle

[1/3]
Trouble code
Trouble Set engine to low idle
G00031
Contents of trouble Engine speed switch (20S030) is set to High Idle. Switch location: RH hand lever 20S019.
During the engine start sequence this switch prevents the engine to run directly at high idle
Related information
after engine startup.
- Background colour of the trouble code information: green
- The VHMS buzzer (20P022) is beeping, when the engine start switch is turned to ON.
Engine start is blocked.
on the machine
Instruction message 0 ---
Nominal
value
Toggle the switch
Switch 20S030 Check the switch setting. Yes
1 to Low Idle.
is set to High Idle Is the switch set to High Idle?
No Go to next step.
1. Engine OFF
2. 20S001 ON
3. REAL TIME MONITOR – In case of malfunction refer
(refer to Fig. 7-12 on page 7-28) to the Wiring Diagram.
07 Manual Switch – Check the condition of the
Switch 20S030 or its
2 Screen 2/4 monitoring loop at node 2,
wiring is defective
4. Check the input signal of 20S030 connector 7, pin 4.
on the VHMS monitor. – If a sporadic interruption
1 = ON input High Idle exists, further inspection
0 = OFF no input Low Idle of the circuit is required.
The displayed input must change over (0 1)
when you toggle the switch.
Final check 3
TS 08199-xD-GB-2 PC4000-6 7 - 29
Wiring Diagram (20S030) for trouble code G00031

[2/3]
Fig. 7-14 Wiring Diagram (20S030) for trouble code G00031
Input signal of the engine speed switch 20S030 on the REAL TIME MONITOR
[3/3]
Fig. 7-15 Input signal of the engine speed switch 20S030 on the REAL TIME MONITOR
In the REAL TIME MENU select item 07 Manual Switch Then select screen 2/4 on the REAL TIME MONITOR
7 - 30 PC4000-6 TS 08199-xD-GB-2
G00032 - Trouble starter

[1/3]
Trouble code
Trouble Trouble starter
G00032
- Monitoring of the start sequence after successful pre-lube (not direct starter monitoring)
Contents of trouble
- Protection of starter motors - a too long cranking time is to be prevented.
- The monitoring time for the cranking phase within the start sequence is 20 seconds.
- If during the cranking phase no engine speed higher than 300 RPM is detected within the limit
Related information of 20 s, message G00032 is displayed.
- If relay 51K003c/d does not close, the system recognizes that the engine is not running.
- If G00032 is displayed, the start sequence is not automatically stopped.
- During one "Main key switch ON" cycle, the message is displayed once.
The engine does not start within the specified time limit.
on the machine
Nominal
value
The engine does not Main key switch 20S001 ON.

start during the Verify if any engine trouble code (C-code) Contact the Cummins tcranking
1 Yes
specified cranking is displayed, which inhibits engine start. Service. max. 20s
time (20 s) Is a corresponding C-code displayed? No Go to next step.
The ambient tempera- Start the engine using the Cold Start Aid Yes Go to final step.
ture requires operation equipment. For operation instruction refer to
2
of the Cold Start Aid the OPERATION & MAINTENANCE MANUAL.
equipment No Go to next step.
Does the engine start within the specified
cranking time (20 s)?
Refer to the Cummins Troubleshooting & Yes Go to next step.
Repair Manual for QSK60 engine, to the
The Cold Start Aid OPERATION & MAINTENANCE MANUAL,
equipment does not 3 and to the Wiring Diagram.
work properly Repair as necessary
Check the Cold Start Aid system for proper No
and restart the engine.
function.
Is the Cold Start Aid function OK?
Starter pinion and/or Engine standing still.
flywheel gear teeth Maintenance safety switch 50S058 OFF & locked.
are worn. 4 Inspect starter pinion and flywheel gear teeth Replace worn parts as
Abnormal noise during Yes
for wear. necessary.
cranking possible.
Is abnormal wear detectable? No Go to next step.
Actuate the engine start sequence.
Starting voltage too low Check the battery voltage during cranking Yes Go to next step.
or on the REAL TIME MONITOR. The voltage
5 Replace the starter
starter motor(s) should not drop below 18V.
defective No batteries
Is the battery voltage during cranking higher
(71G001~71G004)
than 18V?
TS 08199-xD-GB-2 PC4000-6 7 - 31
G00032 - Trouble starter

[2/3]
Nominal
value
Main key switch 20S001 OFF during repair.
After repair 20S001 ON and restart engine.
Defective starter(s) 6
Replace both starters and check for proper
Go to final step.
cable connections.
Final check 7
Wiring Diagram (Cold Start Signal) for trouble code G00032
Fig. 7-16 Wiring Diagram (Cold Start Signal) for trouble code G00032
7 - 32 PC4000-6 TS 08199-xD-GB-2
Wiring Diagram ("Engine running" signal) for trouble code G00032

[3/3]
Fig. 7-17 Wiring Diagram ("Engine running" signal) for trouble code G00032
TS 08199-xD-GB-2 PC4000-6 7 - 33
G00033 - Trouble VHMS-Controller

[1/1]
Trouble code
Trouble Trouble VHMS-Controller
G00033
Contents of trouble VHMS controller (hardware) defective due to internal malfunction.
Related information Verify this trouble message with CoDeSys Visualization software tool.
- The VHMS system is frozen and the VHMS monitor is frozen.

Action of controller - Operation of key pads and F-keys not possible.
- The MTC blinks out the binary code 000100.
As the VHMS controller is defective, the complete monitoring system is out of operation.
on the machine
Nominal
value
VHMS controller - Please contact KMG or your dealer for further action.
inoperative due to an 1 A specified controller unit is needed.
internal malfunction - Replace the VHMS controller and check the system for proper function
Final check 2
in order to reset the binary code 000100.
7 - 34 PC4000-6 TS 08199-xD-GB-2
G00034 - Trouble VHMS-Display

[1/1]
Trouble code
Trouble Trouble VHMS-Display
G00034
Contents of trouble VHMS display (20P047) inoperative due to internal malfunction (hardware).
Related information Verify this trouble message with CoDeSys Visualization software tool.
- The VHMS display is out of operation.

As the VHMS display is defective, the complete monitoring system is out of operation.
on the machine
Nominal
value
VHMS display - Please contact KMG or your dealer for further action.
inoperative due to an 1 A specified display unit is needed.
internal malfunction - Replace the VHMS display and check the system for proper function
Final check 2
TS 08199-xD-GB-2 PC4000-6 7 - 35
G00035 - Trouble totally loss gear oil (PTO 1)

[1/5]
Trouble code
Trouble Trouble totally loss gear oil (PTO 1)
G00035
(a) Engine standing still - Engine start is blocked if sensor 57B175-1 doesn’t sense oil.
Contents of trouble
(b) Engine running - Direct engine shutdown if sensor 57B175-1 doesn’t sense oil.
Sensor open signal voltage = 0 V no oil
Related information
Sensor closed signal voltage = 24 V oil present
If the SHUTDOWN BYPASS setting for the option "Trouble totally loss gear oil (PTO 1)" is set to
Action of controller OFF at the VHMS monitor, Engine start blocked and Engine shutdown will occur if PTO 1 gear oil
level is below sensor 57B175-1. Refer to illustration Fig. 7-20 on page 7-39.
For detailed information on the VHMS settings refer to the SERVICE MANUAL, chapter 14,
section SHUTDOWN BYPASS ON/OFF.
Engine start is blocked and running engine is shutdown.
on the machine
Instruction message 34 Call service because of shutdown.
Nominal
value
Check for leaks and
refill specified gear oil.
PTO 1 gear oil level Verify if PTO 1 gear oil level is below sensor
Yes Verify that trouble code
is below sensor 1 57B175-1.
G00035 is not
57B175-1 Is the gear oil level too low? displayed again.
No Go to next step.
Disconnect the cable connector from the gear Vmin 22V
2 oil level sensor, insert the Deutsch T-box, and Yes Go to step 4.
Vmax 24V
measure the supply voltage at the cable
connector, terminal A.
Incorrect or no supply No Go to next step.
voltage in the circuit Is supply voltage present?
of gear oil level sensor Vmin 22V
57B175-1 Yes Go to next step.
Vmax 24V
3
shooting chart for
"Trouble power
supply".
Defective ground circuit in any wiring
connection at the
4 gear oil level sensor and check for proper connectors) between
gear oil level sensor
ground connection at the connector terminal C. No gear oil level sensor
57B175-1
Is the ground connection ok? and ground line.
Locate the problem
and repair as
necessary.
7 - 36 PC4000-6 TS 08199-xD-GB-2
G00035 - Trouble totally loss gear oil (PTO 1)

[2/5]
Nominal
value
51R008max
820Ω
Disconnection in the Disconnection or
signal wiring between Disconnect the signal line connector 1, short circuit in any
gear oil level sensor terminal 2, from node 17 (51K317). wiring segment
57B175-1, terminal B, Refer to the Wiring Diagram and check the (including connectors)
and node 17 5
signal wiring segments between the oil level between gear oil
(disconnection or sensor, terminal B, and the node connector 1, No level sensor and node
defective contact terminal 2, for continuity. cable connector 1,
in any connector) Is continuity present? terminal 2.
Locate the problem
and repair as
necessary.
Open the REAL TIME MONITOR and check Replace the gear oil VSignal
Defective gear oil level the sensor signal. level sensor and verify open: 0V
6
sensor 57B175-1 Refer to illustration Fig. 7-19 on page 7-39. Yes that the repair was VSignal
Is the sensor signal = 0 (no oil) even there is successful.
closed:
enough gear oil in the PTO 1? Go to final step. 22-24V
Final check 7
TS 08199-xD-GB-2 PC4000-6 7 - 37
View onto the location of sensor 57B175-1 at the PTO (G00035)

[3/5]
Fig. 7-18 G00035 - View onto the location of sensor 57B175-1 at the PTO
(1) PTO drive flange Engine side
57B175-1 Location of the PTO 1 gear oil level sensor Power take-off side
57B049-1 Location of the PTO 1 gear oil temperature sensor Power take-off side
7 - 38 PC4000-6 TS 08199-xD-GB-2
Input signal (analog) of the PTO 1 gear oil sensor 57B175-1 on the REAL TIME MONITOR
[4/5]
Fig. 7-19 Input signal (analog) of the gear oil level sensor 57B175-1 on the REAL TIME MONITOR
In the REAL TIME MENU select item 02 PTO 1 Then select the REAL TIME MONITOR screen 1/1
Fig. 7-20 View onto the setting for SHUTDOWN BYPASS on the VHMS monitor


REMARKS: If the SHUTDOWN function is bypassed (setting 2), engine operation is possible even PTO 1 gear oil
may be missing!
TS 08199-xD-GB-2 PC4000-6 7 - 39
Wiring Diagram (57B175-1) for trouble code G00035

[5/5]
Fig. 7-21 Wiring Diagram (57B175-1) for trouble code G00035
7 - 40 PC4000-6 TS 08199-xD-GB-2
G00039 - Actuate engine speed selector switch

[1/1]
Trouble code
Trouble Actuate engine speed selector switch
G00039
This message only appears if the option Engine after-run (5 minutes) is activated for the machine.
Applied logic:
1) Engine running at Low Idle
Contents of trouble 2) The system initiates an engine after-run (cooling-down phase)
3) The operator switches 20S030 to High Idle
4) Message G00039 is displayed
5) High Idle is not activated
Related information In the background a delayed Engine after-run is proceeded.

- During the Engine after-run the system prevents switching to High Idle.
Engine after-run for 5 minutes.
on the machine
TS 08199-xD-GB-2 PC4000-6 7 - 41
G00043 - Trouble output short-circuit

[1/1]
Trouble code
Trouble Trouble output short-circuit
G00043
Contents of trouble This trouble message is generated if a problem at any node output occurs.
- In order to identify the affected node number and to receive more information on the kind of
trouble, open:
REAL TIME MONITOR
05 Electrical Equipm
Related information 3/3 Electr Equipment Diagnosis
- For further information on node output errors also refer to section 5.1.2 on page 5-4
(TROUBLE OUTPUT SHORT-CIRCUIT).
- If trouble message G00308 is also displayed, follow the troubleshooting procedure of G00308 at
first. G00308 has higher priority.
Action of controller - If any monitored function is affected by this output trouble, an output check message over the
electronic relays (e.g. control output 56K250a/b) is displayed.
The affected function(s) is inoperative.
on the machine
Nominal
value
Open the REAL TIME MONITOR
05 Electrical Equipm.
Screen 3/3 (Electr Equipment Diagnosis) Troubleshooting procedure
Sample display (according to the displayed sample)
OUTPUT ERROR TYPE =2
CAN-NODE NUMBER =9
CONNECTOR NUMBER =6
PIN-NUMBER =2
– Use the Wiring Diagram.

– Find node no. 9.
1 – Locate connector 6, pin 2.
– Check the node wiring
according to the displayed
OUTPUT ERROR TYPE 2.
The node output section is
Check the entry in line OUTPUT ERROR TYPE: switched OFF, nevertheless
external voltage (24V) is fed-in.
0 = All outputs OK
Short circuit to power (+24V)
1 = No power supply
occurred.
2 = External power feed-in (short ckt to 24V)
3 = Short circuit or cable break (short ckt to ground) – Locate the short circuit.
For further information on node output errors – Repair as necessary.
also refer to section 5.1.2 on page 5-4
(TROUBLE OUTPUT SHORT-CIRCUIT).
Final check 2
7 - 42 PC4000-6 TS 08199-xD-GB-2
G00048 - Trouble emergency safety circuit

[1/1]
Trouble code
Trouble Trouble emergency safety circuit
G00048
Contents of trouble The monitoring loop of the emergency stop circuit is inoperative.
Related information The function of the emergency stop circuit is still guaranteed.

- Engine shut down.
- Engine start blocked.
Running engine is shutdown and engine start is blocked.
on the machine
Nominal
value
The monitoring loop of
the emergency stop
circuit is inoperative, - Check the relay and its wiring and locate the trouble. Verify that the repair was
1
because relay - Repair as necessary. successful.
11K044a or its
wiring is defective.
Final check 2
Wiring Diagram (11K044a) for trouble code G00048
Fig. 7-22 Wiring Diagram (11K044a) for trouble code G00048
TS 08199-xD-GB-2 PC4000-6 7 - 43
G00053 - Reset emergency safety circuit

[1/1]
Trouble code
Trouble Reset emergency safety circuit
G00053
- This message is displayed after an emergency stop.
Contents of trouble
- It is a request to reset the emergency safety circuit (20S001 OFF ON).
To do:
Related information For a complete reset it is necessary to keep 20S001 in OFF position until all LEDs at the MTC are
switched OFF. After that switch 20S001 ON again.
- The MTC blinks out the binary code 110001, plus the binary code of the respective shut down.
Engine start is blocked, even if the respective emergency button was unlocked.
on the machine
Instruction message 56 Key switch off and back on !
7 - 44 PC4000-6 TS 08199-xD-GB-2
G00054 - Monitoring idle position cut off

[1/3]
Trouble code
Trouble Monitoring idle position cut off
G00054
- Relay 11K032 monitors the zero position of the control elements (joystick/pedal)
Contents of trouble
- 11K032 is a redundant relay which also monitors itself.
If one of the two 11K032 monitoring circuits -primary or redundant circuit- is out of order,
Related information
message G00054 is displayed.

One circuit of the redundant monitoring system at 11K032 is out of order.
on the machine
Nominal
value
1. Engine OFF
2. 20S001 ON Fault
3. REAL TIME MONITOR - Check relay 11K032
(refer to Fig. 7-24 on page 7-47) 0
and/or its wiring.
Relay 11K032 or its 13 Pilot control VHMS,
1 - Repair as necessary. REAL
wiring is defective Screen 6/6
TIME
4. Check the input signal of 11K032
MONITOR
on the VHMS monitor.
0 = OFF Fault OK
1 = ON OK 1
Go to next step.
Which state is displayed, 0 or 1?
VHMS Service Menu ON - Check Failure History
1. Engine OFF
Refer to the Wiring
2. 20S001 ON
Diagram and check:
Sporadic malfunction 3. SERVICE MENU SELECT VHMS,
2 - Wiring
of relay 11K032 (refer to Fig. 7-25 on page 7-47) Wiring
- Relay 11K032
05 Failure History Diagram
Repair or replace as
4. Check the occurrence of G00054 in the necessary
Failure History chart.
Final check 3
TS 08199-xD-GB-2 PC4000-6 7 - 45
Wiring Diagram (11K032) for trouble code G00054

[2/3]
Fig. 7-23 Wiring Diagram (11K032) for trouble code G00054
7 - 46 PC4000-6 TS 08199-xD-GB-2
Input signal (analog) of relay 11K032 on the REAL TIME MONITOR (G00054)
[3/3]
Fig. 7-24 G00054 - Input signal (analog) of relay 11K032 on the REAL TIME MONITOR
Exemplary view onto the VHMS Failure History (G00054)
Fig. 7-25 G00054 - Exemplary view onto the VHMS Failure History
TS 08199-xD-GB-2 PC4000-6 7 - 47
G00060 - Fire in the power house

[1/4]
Trouble code
Trouble Fire in the power house
G00060
- Monitoring of the emergency shut-off and fire suppression system (optional equipment).
Contents of trouble
- If fire alarm is initiated the engine is shutdown.
All relevant information about the CHECKFIRE SC-N 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.
Case A - Fire activated the fire suppression system.
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
value
Remove the residues
of the extinguishing
agent and clean the
power house as
Make sure that no danger or risk of injury exists necessary.
Fire alarm was before entering the power house. The detection and
initiated and the fire Identify the cause of the fire in the power house. actuation system and
suppression system the fire suppression
A
was activated in order systems must be
to extinguish a fire in REMARKS: Also refer to the troubleshooting checked, recharged,
the power house procedures which are described in the and approved by
manual of the system manufacturer. authorized service
personnel immediately
after operation.
Rectify the cause for
the fire.
Remove the residues
of the extinguishing
agent and clean the
power house as
Make sure that no danger or risk of injury exists before necessary.
entering the power house. The detection and
Fire alarm was
Identify the cause of the fire in the power house. actuation system and
initiated due to a
the fire suppression
false alarm and the B
systems must be
fire suppression
REMARKS: Also refer to the troubleshooting checked, recharged,
system was activated
procedures which are described in the and approved by
manual of the system manufacturer. authorized service
personnel immediately
after operation.
the false fire alarm.
7 - 48 PC4000-6 TS 08199-xD-GB-2
G00060 - Fire in the power house

[2/4]
Nominal
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.
system was not
the false fire alarm.
activated.
Final check
TS 08199-xD-GB-2 PC4000-6 7 - 49
Wiring Diagram (fire alarm) for trouble code G00060

[3/4]
Fig. 7-26 Wiring Diagram (fire alarm) for trouble code G00060
7 - 50 PC4000-6 TS 08199-xD-GB-2
Wiring Diagram (10B351 in the safety circuit) for G00060

[4/4]
Fig. 7-27 Wiring Diagram (10B351 in the safety circuit) for G00060
TS 08199-xD-GB-2 PC4000-6 7 - 51
G00061 - Trouble monitoring, engine 1 speed too low

[1/3]
Trouble code
Trouble Trouble monitoring, engine 1 speed too low
G00061
- A malfunction in the monitoring loop for too low engine speed is detected.
Contents of trouble - The RPM-module 51T018-1 sends an RPM-signal below 160 RPM while 51K003b-1 signals
an engine speed higher than 300 RPM.
- This message could be displayed during an engine start sequence which is not successful.
Related information - Also a problem with the engine speed converter (51T018-1) or its wiring causes this
trouble message.
Engine start is impossible.
on the machine
Nominal
value
REAL TIME MONITOR - 51K003b-1 input check
1. 20S001 ON
2. Engine OFF
3. REAL TIME MONITOR OK
(refer to Fig. 7-28 on page 7-53) 0 Signal = 0V
01 Engine 1
Go to next step.
Screen 5/6
The Cummins ECM
4. Check the input signal of 51K003b-1 VHMS,
transmits a wrong
1 on the REAL TIME MONITOR. REAL
engine speed signal
at pin C 0 OK (signal indicates engine OFF) TIME
No RPM-signal (<300 1/min) from MONITOR
engine ECM. Signal = 0V Fault
1 Fault (signal indicates running eng.) Signal = 24V

1 Check the Quantum
RPM-signal (>300 RPM) from engine
ECM is present. Signal = 24V module with Cummins
service.
Which signal state is displayed, 0 or 1?

Engine at low idle (850±50 RPM).
At this stage the RPM signal of converter 51T018-1 is
The engine speed below 160 RPM, even the engine is running at low idle
converter 51T018-1 (inconsistent signal).
transmits a wrong 2 VHMS,
signal. REAL
(refer to Fig. 7-29 on page 7-54) Go to next step.
TIME
51T018-1 or its wiring 01 Engine 1
MONITOR
defective. Screen 1/6
2. Check the input signal of 51T018-1
on the REAL TIME MONITOR.
7 - 52 PC4000-6 TS 08199-xD-GB-2
G00061 - Trouble monitoring, engine 1 speed too low

[2/3]
Nominal
value
20S001 OFF - Engine OFF - 50S058 locked.
Refer to the SERVICE MANUAL, section
MAIN HYDRAULIC PUMPS AND PUMP
REGULATION SYSTEM, and find the
adjustment procedure for the engine speed
sensor (pick up). approx.
Engine speed sensor Yes Go to final step.
In the first step remove the engine speed 10VAC
(pick up) 52B064-1,
sensor and clean the sensor tip from magnetic
possible problems:
3 chips and dirt as described. Then follow the
- Wrong adjustment adjustment procedure and perform the final
- Contamination check.
- Sensor defective
If necessary replace the pick up (52B064-1).
The terminal numbers of your shovel may
differ from the terminal numbers mentioned in
the Service Manual. Refer to the Wiring No Go to next step.
Diagram for the individual terminal numbers.
Could you rectify the problem?
Defective RPM-module Imin 0mA
51T018-1 Yes Go to next step.
4 Measure the signal current at terminals Imax 20mA
(missing or poor signal
current) or wrong set- 1+ and 1- of the RPM-module. Replace the RPM-
ting Do the measurements meet the specification? module if necessary
No
and verify that the
repair was successful.
Final check 5
Input signal (analog) of 51K003b-1 on the REAL TIME MONITOR (G00061)
Fig. 7-28 G00061 - Input signal (analog) of 51K003b-1 on the REAL TIME MONITOR
TS 08199-xD-GB-2 PC4000-6 7 - 53
Wrong signal of the engine speed converter on the REAL TIME MONITOR (G00061)
[3/3]
Fig. 7-29 G00061 - Wrong signal of the engine speed converter on the REAL TIME MONITOR
Wiring Diagram (engine speed) for trouble code G00061
Fig. 7-30 Wiring Diagram (engine speed) for trouble code G00061
7 - 54 PC4000-6 TS 08199-xD-GB-2
G00062 - Trouble monitoring, engine 1 speed too high

[1/2]
Trouble code
Trouble Trouble monitoring, engine speed too high
G00062
Contents of trouble A malfunction in the monitoring loop for too high engine speed is detected (2000 RPM and higher)
Possible causes for this trouble message are:

- RPM-module 51T018-1 or its wiring defective
Related information
- Engine speed sensor 52B064-1 or its wiring defective
- Wrong adjustment of 52B064-1
Action of controller - The MTC blinks out the binary code 001000
- Engine shutdown
- Engine re-start is blocked (for engine re-start reset the MTC 20S001 OFF and ON).
on the machine
Nominal
value
20S001 OFF - Engine OFF - 50S058 locked
Refer to the SERVICE MANUAL, section
MAIN HYDRAULIC PUMPS AND PUMP
REGULATION SYSTEM, and find the
adjustment procedure for the engine speed
sensor (pick up). approx.
Engine speed sensor Yes Go to final step.
In the first step remove the engine speed 10VAC
(pick up) 52B064-1,
sensor and clean the sensor tip from magnetic
possible problems:
1 chips and dirt as described. Then follow the
- Wrong adjustment adjustment procedure and perform the final
- Contamination check.
- Sensor defective
If necessary replace the pick up (52B064-1).
The terminal numbers of your shovel may
differ from the terminal numbers mentioned in
the Service Manual. Refer to the Wiring No Go to next step.
Diagram for the individual terminal numbers.
Defective RPM-module Imin 4mA
51T018-1 Yes Go to next step.
2 Measure the signal current at terminals Imax 20mA
(missing or poor signal
current) or wrong set- 1+ and 1- of the RPM-module. Replace the RPM-
ting Do the measurements meet the specification? module if necessary
No
and verify that the
Final check 3
TS 08199-xD-GB-2 PC4000-6 7 - 55
Wiring Diagram (engine speed) for trouble code G00062

[2/2]
Fig. 7-31 Wiring Diagram (engine speed) for trouble code G00062
7 - 56 PC4000-6 TS 08199-xD-GB-2
G00063 - Trouble monitoring hydraulic oil temp

[1/2]
Trouble code
Trouble Trouble monitoring hydraulic oil temp
G00063
- A malfunction in the monitoring loop for the hydraulic oil temperature is detected.
Contents of trouble - The system assumes that the hydraulic oil temperature sensor 59B015 (PT100 type) or the
wiring circuit of the monitoring system is defective.
- Within the temperature range of -32°C up to +132°C the sensor 59B015 generates
a voltage signal in the range of 0.5 - 9.5V.
Related information
- For quick troubleshooting action open the REAL TIME MONITOR 03 Hydraulic, screen 4/4,
and check the displayed hydraulic oil temperature.
- If trouble code G00063 is set, G00240 (Trouble hydraulic oil temperature) is also set
automatically.
Problem that appears - Monitoring of the hydraulic oil temperature sensor is disabled.
on the machine - Due to G00240 pump regulation is set to Qmax 1/2.
Nominal
value
Check the wiring between sensor and Yes Go to next step. Rmax 1Ω
connector 51X152:
pin 23 to shield
Wiring or connector Repair or replace
1 pin 24 to A
problem No according to the actual
pin 25 to C
pin 26 to B Wiring Diagram.
– Check the input signal at node 17
(51K317). Measure the input signal VSignal
Yes Go to final step.
of 59B015 at connector 2, pin 6. 0.5-9.5V
No input signal – Measure the signal voltage and
2
at node 17 compare the voltage to your Real-Time
temperature.
No Go to next step.
Does the signal correspond to the Real-Time
temperature?
Check the signal voltage of temperature A sporadic malfunction
sensor 59B015 and compare to the PT100 Yes may exist. Further
voltage chart. inspection is required. Refer to
Insert the T-box at the sensor connector the PT100
Sensor defective 3
and measure the signal voltage between voltage
pin B and C. Replace the PT100 chart
No
sensor.
Does the signal voltage correspond to the
PT100 voltage chart?
Final check 4
TS 08199-xD-GB-2 PC4000-6 7 - 57
Wiring Diagram (59B015) for trouble code G00063

[2/2]
Fig. 7-32 Wiring Diagram (59B015) for trouble code G00063
7 - 58 PC4000-6 TS 08199-xD-GB-2
G00064 - Trouble monitoring hydraulic oil level

[1/3]
Trouble code
Trouble Trouble monitoring hydraulic oil level
G00064
The signals of the hydraulic oil level sensors 40B105 (refilling level indication) and
Contents of trouble
40B004 (minimum level indication) are inconsistent.
If trouble code G00064 is displayed, the hydraulic oil level sensor 40B004 has a malfunction.
Related information
REMARKS: If sensor 40B004 does not sense oil, its signal voltage turns to 0V.
Action of controller Background colour of the trouble code information: red

on the machine
Nominal
value
The signal of the Check with stopped engine and the attachment in its defined position.
hydraulic oil level
sensor 40B004 If the actual hydraulic oil level in the main hydraulic oil
1 reservoir is higher than the level of sensor 40B004,
(minimum level Go to next step.
then sensor 40B004 or its wiring can be assumed to be
indication)
defective.
is disturbed
Then carry out troubleshooting with main key switch 20S001 ON.
Disconnect the cable connector from the oil Vmin 22V
level sensor 40B004. Yes Go to step 5.
2 Vmax 24V
Insert the Deutsch T-box, and measure the
supply voltage at the cable connector
Incorrect or no supply terminal A. No Go to next step.
voltage in the circuit of Is supply voltage present?
the oil level sensor
Vmin 22V
40B004 Yes Go to step 5.
Vmax 24V
3
shooting chart for
"Trouble power
supply".
wiring between the oil Disconnection or short
level sensor 40B004 circuit in any wiring
Refer to the Wiring Diagram and check the segment (including
and the power supply
wiring segments between oil level sensor connectors) between
line of circuit breaker 4
40B004 and the power supply line for oil level sensor 40B004
11F013
continuity. No and the line of the
(disconnection or
Is continuity present? circuit breaker.
and repair as
necessary.
TS 08199-xD-GB-2 PC4000-6 7 - 59
G00064 - Trouble monitoring hydraulic oil level

[2/3]
Nominal
value
circuit in any wiring
Defective ground
oil level sensor 40B004 and check for connectors) between
connection at the oil 5
proper ground connection at oil level sensor 40B004
level sensor 40B004 No
connector terminal C. and the ground
Is the ground connection ok? line (C).
Locate the problem
and repair as
necessary.
Disconnection in the Refer to the relating Wiring Diagram and check Disconnection or short
signal wiring between the input signal at node 11 (40K311). circuit in any wiring
the oil level sensor Disconnect the signal line connector 3, segment (including
40B004 terminal B terminal 8 from node 11. connectors) between
and node 11 6 oil level sensor 40B004
Refer to the Wiring Diagram and check the and node 11,
signal wiring segments between the oil level cable connector 3,
defective contact in sensor 40B004, terminal B, and node 11 terminal 8.
any connector) cable connector 3, terminal 8 for continuity.
Locate the problem
necessary.
Then carry out troubleshooting with main key switch 20S001 ON.
Using the Deutsch T-box, measure the signal VSignal
voltage at connector terminal B of the oil level open: 0V
sensor 40B004: A sporadic malfunction
Yes may exist. Further VSignal
Defective oil level (1) When the sensor is dipped into oil
7 inspection is required. closed:
sensor 40B004 (sensor closed) approx.
(2) When it is not touching oil 24V
(sensor open). Replace the oil level
Do the measurements meet the sensor 40B004 and
No
specifications? verify that the repair
was successful.
Final check 8
7 - 60 PC4000-6 TS 08199-xD-GB-2

[3/3]
TS 08199-xD-GB-2 PC4000-6 7 - 61
G00065 - Very low hydraulic oil level

[1/1]
Trouble code
Trouble Very low hydraulic oil level
G00065
Contents of trouble Message: Refill hydraulic oil!
- 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 40B105 generates the message.

on the machine
Nominal
value
-Check the hydraulic oil level at the sight glass and fill up hydraulic oil.
Hydraulic oil needs
1 Observe the hydraulic oil temperature and refill oil up to the appropriate level.
refilling Sight glass
- Verify if other trouble messages concerning the hydraulic oil are displayed.
If other messages are displayed follow their instructions as necessary.
Final check 2
View onto the hydraulic oil level label
Fig. 7-34 View onto the hydraulic oil level label
7 - 62 PC4000-6 TS 08199-xD-GB-2
G00066 - Trouble hydraulic oil temperature

[1/3]
Trouble code
Trouble Trouble hydraulic oil temperature
G00066
Overheated hydraulic oil is detected.
Contents of trouble Machine configuration for option Bucket Shut-off at too high hydraulic oil temperature
Case A) Option = ON
Case B) Option = OFF
- The hydraulic oil temperature sensor 59B015 detects an oil temperature >T4.
Related information - For the definition of the hydraulic oil temperatures T1, T2, T3, T4 refer to the oil temperature table
on page 7-65 of this troubleshooting chart.
- On condition that the engine is running: the fan speed is set to max. speed.
The hydraulic oil is overheated.
Case A) Option = ON Bucket is shut-off
on the machine
Case B) Option = OFF Bucket NOT shut-off Continuous buzzer sound (20P022) in the cab
Nominal
value
Engine running at high idle, with max. fan speed.
Using a laser temperature meter check the
hydraulic oil temperature at the temperature Yes Go to next step.
The hydraulic oil sensor 59B015.
1 Check for other
is overheated For the defined hydraulic oil temperatures refer relating trouble codes
to the oil temperature table on page 7-65. No and follow the relating
Does the measured hydraulic oil temperature troubleshooting chart
indicate overheating as well? as necessary.
Wrong hydraulic oil Check the hydraulic oil settings (oil type, Adjust the hydraulic oil
settings may cause 2 viscosity) in the service mode of the VHMS settings in the service
the problem system. No mode of the VHMS
Are the oil settings correct? system and recheck for
normal range.
Yes Go to next step. RPMmax
Maximum fan speed is achieved if no voltage Refer to the SERVICE 1250±50
(0V) is applied at both solenoid valves MANUAL, section RPMmed
57K506a-1 and 57K506b-1. Therefore Hydraulic Oil Cooling, 1000±50
disconnect the cable connectors from both and perform the setting
The fan is not driven solenoid valves 57K506a-1 & 57K506b-1. of the max. fan speed.
3
at max. speed If the fan speed does not increase, check the
No If the setting is not as
hydraulic settings for the fan speed (refer to specified follow the
the Service Manual). Connect both cable adjustment and/or
connectors to the solenoid valves 57K506a-1 inspection procedures
and 57K506b-1 again. in the SERVICE
Is the setting for max. fan speed correct? MANUAL
as necessary.
TS 08199-xD-GB-2 PC4000-6 7 - 63

[2/3]
Nominal
value
Shut the engine OFF.
REMARKS: This test step must only be - Clean the hydraulic
performed if the engine oil cooler with a water
Any clogged hydraulic is standing still. pressure cleaner as
oil cooler caused the Perform a visual inspection of the hydraulic oil necessary.
4 Yes
overheating of the cooler. Also open the swing out doors of the - Continue to work and
hydraulic oil cooler frame and check for deposits between monitor the hydraulic
these door wings. oil temperature on
Is intense pollution present? the VHMS display.
No Go to next step.
Overheating due to any Continue to work and
malfunction in the 5 Check the hydraulic system by performing the monitor the hydraulic PM-
hydraulic system PM-Clinic. oil temperature on the CLINIC
VHMS display.
Final check 6
7 - 64 PC4000-6 TS 08199-xD-GB-2
Wiring Diagram (57K506a-1 / 57K506b-1) and location for G00066

[3/3]
Fig. 7-35 Wiring Diagram (57K506a-1 / 57K506b-1) and location for G00066
Hydraulic oil temperature table
Fig. 7-36 Hydraulic oil temperature table
TS 08199-xD-GB-2 PC4000-6 7 - 65
G00067 - Trouble battery voltage too high

[1/2]
Trouble code
Trouble 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, otherwise trouble code
G00161 should be displayed.

-
on the machine
Nominal
value
REAL TIME MONITOR - 11T080 input check
A) Measure the charging voltage between Vcharge
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
(VHMS).
The voltage regulator
in the alternator may 1. 20S001 ON
be defective and 1 2. Engine running at high idle
causes the battery
over voltage No Replace the alternator.
Screen 1/3
4. Check the input signal of 11T080 on the
REAL TIME MONITOR.
Does the charging voltage meet the
specification?
Resistor 11T080 or If trouble code G00161 Trouble monitoring Yes Go to final step.
its wiring may be the battery voltage is displayed at the same time,
2 follow the belonging procedures.
cause for the battery A sporadic malfunction
over voltage Could you rectify the problem? No may exist. Further
inspection is required.
Final check 3
7 - 66 PC4000-6 TS 08199-xD-GB-2
Wiring Diagram (11T080) and component location for G00067

[2/2]
Fig. 7-37 Wiring Diagram (11T080) and component location for G00067
G00067 - Input signal of 11T080 on the REAL TIME MONITOR
Fig. 7-38 G00067 - Input signal of 11T080 on the REAL TIME MONITOR
TS 08199-xD-GB-2 PC4000-6 7 - 67
G00069 - Trouble monitoring oil temperature gear (PTO 1)

[1/3]
Trouble code
Trouble Trouble monitoring oil temperature gear (PTO 1)
G00069
- A malfunction in the monitoring loop for the gear oil temperature (PTO-1) is detected.
Contents of trouble - The system assumes that the gear oil temperature sensor 57B049-1 (PT100 type)
or the wiring circuit of the monitoring system is defective.
Within the temperature range of -32°C up to +132°C sensor 57B049-1 generates a voltage signal of
Related information
0.5 - 9.5 V.

Monitoring of the gear oil temperature (PTO 1) is disabled.
on the machine
Nominal
value
Check the wiring between sensor 57B049-1

and connector 51X252 for continuity: Yes Go to next step. Rmax 1Ω
Wiring or connector pin 26 to shield
1
problem pin 27 to A
28 to C
Repair or replace the
29 to B
No wiring according to the
Is continuity present? Wiring Diagram.

– Check the input signal of 57B049-1 at
node 18 (51K318). Measure the input VSignal
signal of 57B049 at connector 0, pin 4. Yes Go to final step.
0.5-9.5V
No input signal at – Measure the signal voltage and compare
2
node 18 the voltage to your Real-Time tempera-
ture.
Does the voltage signal correspond to the No Go to next step
Real-Time temperature?

Check the signal voltage of temperature Refer to
A sporadic malfunction
sensor 57B049-1 and compare to the PT100 the PT100
Yes may exist. Further
voltage chart. voltage
inspection is required.
Sensor defective 3 Insert the T-box at the sensor connector and chart
measure the signal voltage between pin B and
C. Replace the PT100
No
Does the signal voltage correspond to the sensor.
PT100 voltage chart?
Final check 4
7 - 68 PC4000-6 TS 08199-xD-GB-2
Input of 57B049-1 on the REAL TIME MONITOR (G00069)

[2/3]
Fig. 7-39 G00069 - Input of 57B049-1 on the REAL TIME MONITOR
Gear oil temperature (PTO 1) on the Main Gauge Screen (G00069)
Fig. 7-40 G00069 - Gear oil temperature (PTO 1) on the Main Gauge Screen
TS 08199-xD-GB-2 PC4000-6 7 - 69
Wiring Diagram (57B049-1) and component location for G00069

[3/3]
Fig. 7-41 Wiring Diagram (57B049-1) and component location for G00069
7 - 70 PC4000-6 TS 08199-xD-GB-2
G00070 - Trouble oil temperature gear (PTO 1)

[1/3]
Trouble code
Trouble Trouble oil temperature gear (PTO 1)
G00070
- The PTO gear oil temperature sensor 57B049-1 (PT100 type) signals overheating.
Contents of trouble - The system assumes that the gear oil temperature sensor 57B049-1 or the wiring circuit of the
monitoring system is not defective.
PTO gear oil temperature for 5 seconds > TG2
For the definition of the PTO gear oil temperatures refer to the following table:
Related information

The PTO gear oil is overheated.
on the machine
Nominal
value
Using a laser temperature meter, verify if the PTO gear
oil temperature at the temperature sensor 57B049-1 is
PTO gear oil too high.
1
overheated For the location of 57B049-1 refer to Go to next step.
Fig. 7-42 on page 7-73.
For the definition of the PTO gear oil temperatures refer
to the above table (Z 26718).
Check the PTO gear oil level with the dipstick
as described in the OPERATION & Refill or drain PTO
PTO gear oil level gear oil until the target
2 MAINTENANCE MANUAL, section
too low level is reached. OM/M
Every 50 Operating Hours or Weekly. No
Is the PTO gear oil level within the specified Then monitor the PTO
range? gear oil temperature
again.
Adjust the PTO gear oil
Wrong PTO gear oil Check the PTO gear oil settings (oil type and settings on the service
settings may cause 3 viscosity) on the service level of the VHMS level of the VHMS
the problem system. No system.
Are the oil settings correct? Then verify that the
gear oil temperature
is in normal range.
TS 08199-xD-GB-2 PC4000-6 7 - 71
G00070 - Trouble oil temperature gear (PTO 1)

[2/3]
Nominal
value
- Maximum fan speed is achieved if no voltage Yes Go to next step. RPMmax.
(0V) is applied at both solenoid valves 1250±50
57K506a-1 and 57K506b-1. Refer to the SERVICE
MANUAL, section RPMmed.
- Therefore disconnect the cable connectors Hydraulic Oil Cooling, 1000±50
from both solenoid valves 57K506a-1 & and perform the setting
The fan is not driven 57K506b-1. of the max. fan speed.
4
at max. speed - If the fan speed does not increase, check the
No If the setting is not as
hydraulic settings for the fan speed (refer to specified follow the
the SERVICE MANUAL). adjustment and/or
- Connect both cable connectors to the inspection procedures
solenoid valves 57K506a-1 and 57K506b-1 in the SERVICE
again. MANUAL as
necessary.
Is the setting for max. fan speed correct?
Engine OFF & maintenance safety switch 50S058 OFF + locked
REMARKS: This test step must only be - Clean the gear oil/
performed if the engine is hydraulic oil cooler
Any clogged gear oil standing still. with a pressure
cooler segment in the cleaner as
hydraulic oil cooler - Perform a visual inspection of the gear oil
5 cooler segments. Yes necessary.
frame caused the
overheating of the - Also open the swing out doors of the cooler - Continue to work and
PTO gear oil frame and check for deposits between these verify that the PTO
door wings. gear oil temperature
is in normal range.
Is intense pollution present?
No Go to next step.
- Carry out adjust-
ments as necessary.
- After that verify that
the PTO gear oil
Overheating due to Refer to the SERVICE MANUAL, chapter 2, temperature is in
any malfunction in the 6 section PTO Lubrication and Cooling and normal range.
PTO lubrication system follow the given adjustment procedures. No - If any other relating
Are the adjustments as specified? trouble code is
present, follow the
troubleshooting
procedures of the
corresponding
troubleshooting
chart.
Final check 7
7 - 72 PC4000-6 TS 08199-xD-GB-2
Location of the PTO 1 gear oil level dipstick and temperature sensor 57B049-1
[3/3]
Fig. 7-42 Location of the PTO 1 gear oil level dipstick and temperature sensor 57B049-1
(1) PTO drive flange Engine side
(2) Dipstick for PTO 1 gear oil level Engine side
57B175-1 Location of the PTO 1 gear oil level sensor Power take-off side
57B049-1 Location of the PTO 1 gear oil temperature sensor Power take-off side
TS 08199-xD-GB-2 PC4000-6 7 - 73
G00071 - Trouble gear lubrication (PTO 1)

[1/2]
Trouble code
Trouble Trouble gear lubrication (PTO 1)
G00071
Pressure sensor 57B017-1 (NC*) signals, that there is no pressure in the PTO gear lubrication
Contents of trouble system, even the engine is running.
*NC = Normally Closed
Basic sensor data (57B017-1)

REAL TIME MONITOR
Condition Value State
Signal
Related information
No pressure 0V Switch closed 0
Pressure present 24 V Switch open 1
Switch point 0.5 bar

Risk, to operate the machine without PTO gear lubrication (PTO overheating).
on the machine
Nominal
value
Refer to the SERVICE MANUAL, chapter 2, Carry out adjustments
section PTO Lubrication and Cooling and as necessary.
1 follow the given adjustment procedures. After that recheck if the
No
Are the pressure adjustments as specified? PTO gear lubrication
No PTO gear lubrica-
pressure is in normal
tion pressure present
range.
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.
Final check 3
7 - 74 PC4000-6 TS 08199-xD-GB-2

[2/2]
TS 08199-xD-GB-2 PC4000-6 7 - 75
G00081 - Trouble lubrication system

[1/5]
Trouble code
Trouble Trouble lubrication system
G00081
The movement of the bucket will be disabled, if there was no successful lubrication cycle during the
Contents of trouble
last approx. 4 working hours (option).
The function Bucket Cut-Off is an option.
Related information
Via the CoDeSys Visualization software this option can be activated or deactivated.
If the optional function Bucket Cut-Off is activated:

- In case of trouble, bucket movement is disabled (lubrication cycle not complete) and message
G00081 is displayed.
If this option is deactivated:
on the machine
- In case of trouble, message G00081 is displayed and continuous buzzer sound (20P022)
is generated in the cab.
- Bucket movement is not cut-off.
Nominal
value
Engine running at high idle & ladder up & safety lever down
- Follow the trouble-
Check if any trouble code(s) concerning the shooting chart of the
lubrication systems is present. displayed trouble
code(s) and rectify
Problem in the Is any trouble code for the lubrication systems the lubrication
lubrication system(s). present? problem.
A problem with the - After the repair manu-
lubrication cycles 1 INFO Yes ally activate the lubri-
causes bucket cut-off Remember the PauseTime setting is reduced cation system and
(option) or continuous to 30 s under the following conditions: recheck for proper
buzzer sound (20P022) - If you entered the VHMS Service Level or function.
in the cab - Also verify that the
- After the first manual lubrication cycle was
started. bucket motion is no
longer restricted
If you leave the Service Level again, the pre- (option).
adjusted Pause Time is resumed.
No Go to next step.

Check the function of relay 11K050 in the X2
switch board. Yes Go to next step.
A malfunction of relay 11K050 active (24 V): Replace the relay and
11K050 causes the 2 - Bucket movement enabled check for proper
bucket cut-off 11K050 inactive (0 V): system function.
- Bucket movement disabled No
If the problem is not
Does the function of relay 11K050 meet the yet rectified go to next
above specification? step.
7 - 76 PC4000-6 TS 08199-xD-GB-2
G00081 - Trouble lubrication system

[2/5]
Nominal
value
Repair the wiring or
replace any defective
Yes
electrical component
Refer to the Wiring Diagram: as necessary.
Check if any other
- Check if B+ voltage is present
trouble code is set
Malfunction or damage - Check for proper ground connection
which may be in cross-
in the wiring circuit of 3 - Check the wiring for continuity correlation with the
relay 11K050 - Check the diode for proper condition existing problem.
No
Is any problem diagnosable in the wiring circuit If so, follow the
of relay 11K050? according trouble-
shooting chart and
after that recheck for
proper system function.
Final check 4
TS 08199-xD-GB-2 PC4000-6 7 - 77
Operation cycles of the lubrication systems

[3/5]
Fig. 7-44 Operation cycles of the lubrication systems
7 - 78 PC4000-6 TS 08199-xD-GB-2
Wiring Diagram (11K050) for trouble code G00081

[4/5]
Fig. 7-45 Wiring Diagram (11K050) for trouble code G00081
TS 08199-xD-GB-2 PC4000-6 7 - 79
Wiring Diagram (pilot control slew & stick) for trouble code G00081
[5/5]
Fig. 7-46 Wiring Diagram (pilot control slew & stick) for trouble code G00081
7 - 80 PC4000-6 TS 08199-xD-GB-2
G00086 - SHUTDOWN
[1/1]
Trouble code
Trouble SHUTDOWN
G00086
If a trouble is detected (on machine or engine side) which causes a delayed (10 s)
engine shutdown:
Contents of trouble - Message G00086 is displayed
- Buzzer sound (20P056) in the cab continuously ON
- Delayed engine shutdown (if the engine is running)
- The time delay of 10 seconds gives the operator the chance to bring the attachment in its defined
Related information parking position, before the engine is shutdown.
- The message is displayed one-time before shutdown.
Action of controller - 20P056 in the cab ON
- Engine restart impossible
Machine down due to any serious trouble.
on the machine
Instruction message 12 Operate the machine into the parking position.
Nominal
value
The serious trouble which caused the engine shutdown will be displayed on the
VHMS monitor and/or a binary code is blinked out at the MTC:
Any serious trouble G-code machine trouble
caused a delayed 1 or
engine shutdown C-code engine trouble
Follow the troubleshooting procedure of the displayed trouble code and rectify
the problem.
TS 08199-xD-GB-2 PC4000-6 7 - 81
G00087 - Stop all movements for low idle

[1/1]
Trouble code
Trouble Stop all movements for low idle
G00087
REMARKS: Operation of a hydraulic machine is only allowed at high idle.
Contents of trouble If the engine is switched from high idle to low idle during machine operation, message G00087 will
be displayed, in order to avoid serious trouble.
Examples
a) Switching from high idle to low idle during swing movement:
Related information Collision with the dump truck is possible.
b) Switching from high idle to low idle during downhill traveling:
Travel speed will increase and cavitation at the travel motors is possible.
Faulty operation:
- Stop all movements
on the machine
- Switch high idle ON and continue to work.
Instruction message --- ---
7 - 82 PC4000-6 TS 08199-xD-GB-2
G00090 - Trouble power supply

G00099 - Trouble power supply
[1/2]
Trouble code
G00090 Trouble Trouble power supply
G00099
Contents of trouble The power supply circuit (stabilized B+) for sensors and switches is interrupted.
- The stabilized supply power is provided by the batteries 13G008 and 13G009 (located in the cab
base).
Related information
REMARKS: If the supply voltage (B+) drops below 17V, the monitoring function is shut down
(supply voltage below the self holding voltage).
Background colour of the trouble code information: red
Action of controller G00090 The MTC blinks out the binary code 110010
G00099 The MTC blinks out the binary code 110011
Problem that appears - Engine start is impossible.
on the machine - The monitoring function is inoperative.
8 G00090 No 24V at circuit breaker 11F013 - If failure exist further, inform service.
Instruction message
48 G00099 No 24V at circuit breaker 11F013a - If failure exist further, inform service.
Nominal
value
The batteries 13G008 V min 17V
& 13G009 in the cab 1 Check the batteries. Yes Go to next step.
support are defective V max 24V
Are the batteries OK?
No Replace the batteries.
The circuit between Repair or replace
the batteries 13G008 components as
Refer to the Wiring Diagram. necessary and verify
& 13G009 and the
Check the circuit (wires and electrical components) that the repair was
circuit breaker 2
between the batteries in the cab support and the successful.
11F013 (G00090) or
circuit breaker in the X2 switchboard.
11F013a (G00099) After that go to
is disturbed final step 3.
Final check 3
in order to reset the binary code 110010 (G00090) or 110011 (G00099).
TS 08199-xD-GB-2 PC4000-6 7 - 83
Wiring Diagram (stabilized power supply) for G00090 & G00099

[2/2]
Fig. 7-47 Wiring Diagram (stabilized power supply) for G00090 & G00099
7 - 84 PC4000-6 TS 08199-xD-GB-2
G00091 - Pilot control cut out

[1/2]
Trouble code
Trouble 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.

Hydraulic operation is not possible.
on the machine
Ladder end switch or lock lever contact open or service arm down or unlocked.
Nominal
value
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.
Replace the switch if
it is defective.
Lock lever switch Refer to the Wiring Diagram and check the If the wiring has a
20S105 or its wiring 2 switch function and the belonging wiring. problem, locate the
is defective No problem and repair
Are the switch and its wiring ok?
as necessary.
After repair recheck
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
and follow the instruc-
tions.
TS 08199-xD-GB-2 PC4000-6 7 - 85

[2/2]
Nominal
value
Move the access ladder up.
After that verify the following:
(a) The trouble message is no
Yes longer displayed.
The access ladder Check if the access ladder is down. (b) The excavator can be operated
4
is down Is the access ladder down? normally (hydraulic operation is
no longer blocked).
For detailed information concerning
the access ladder function refer to
No
your SERVICE MANUAL, section
ACCESS LADDER.
Final check 5
View onto the lock lever and the cover of 20S105 (G00091)
(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. 7-48 Lock lever and cover of 20S105
7 - 86 PC4000-6 TS 08199-xD-GB-2
G00092 - Emergency shut-down at access ladder

G00093 - Emergency shut-down at valve block
G00094 - Emergency shut-down at hydraulic control panel
G00095 - Emergency shut-down in cabin
[1/2]
Trouble code G00092 - Emergency shut-down at access ladder
Trouble
G00092 ~ G00095 G00094 - Emergency shut-down at hydraulic control panel
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
57S033c Hydraulic control panel G00094
20S036 Operator´s cab G00095
- Engine start is blocked.

Related information - Trouble code G00053 (Reset emergency safety circuit) is also displayed.
Follow the instructions of G00053.
- Engine start is blocked.
- The MTC blinks out the binary code: 010000 - G00092
010001 - G00093
010010 - G00094
010011 - G00095
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
value
Rectify the cause or
problem.
After that, release the
Any emergency Check the cause for the emergency activation. Yes concerned emergency
shut-off button 1
Is any cause present? shut-down switch(es)
was activated
and reset the safety
circuit.
No Go to next step.
Refer to the Wiring
Diagram. Repair or
The concerned replace the concerned
emergency shut-off Visually inspect the concerned switch, the switch switch or its wiring as
2
button or its wiring contacts, and the respective wiring. necessary.
may be defective
After repair go to
final step 3.
Final check 3
in order to reset the present binary code(s).
TS 08199-xD-GB-2 PC4000-6 7 - 87
Wiring Diagram (emergency switches) for G00092~G00095

[2/2]
Fig. 7-49 Wiring Diagram (emergency switches) for G00092~G00095
7 - 88 PC4000-6 TS 08199-xD-GB-2

[1/2]
Trouble code
Trouble Pilot control cut out
G00096
Contents of trouble Pilot control is locked.
- Pilot control is also locked if the refilling arm is down or if the lock lever is pulled up.
Related information
- Verify the switch setting of the refilling arm enable switch 20S094.

Hydraulic operation is not possible.
on the machine
Enable switch for refilling arm active.
Nominal
value
Toggle the enable
Yes switch to OFF position
[0].
The enable switch For detailed informa-
(20S094 - at the tion on the adjustment
Check the switch position of the refilling arm of the proximity switch
dashboard) for the 1
enable switch. 55B023 at the refilling
refilling arm is in
ON position [1] Is the enable switch in ON position [1]? arm (end position),
No
refer to the latest
version of PARTS &
SERVICE NEWS
AH05539 and follow
the instructions.
(a) Pre-check: Yes Go to final step 3.
Check the supply voltage at terminal A.
The enable switch If supply voltage is not present, locate the Check the electric
(20S094 - at the problem and repair as necessary. circuit below 20X_20
dashboard) for the (terminal 30 at the
In switch position ON [1] there is
refilling arm or its 2 X2 board).
continuity between A → C.
wiring (safety Locate the problem
monitoring of pilot (b) Verification: No
and repair as
control) is defective If the enable switch is in ON position [1]
necessary.
(switch closed), the message should be
displayed on the VHMS monitor. After that verify that
the pilot control is
Is the message displayed when the enable
no longer cut out.
switch is switched to ON position?
Final check 3
TS 08199-xD-GB-2 PC4000-6 7 - 89

[2/2]
7 - 90 PC4000-6 TS 08199-xD-GB-2
G00100 - Maintenance Safety Switch

[1/2]
Trouble code
Trouble 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.
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
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
necessary.
Yes Wiring of 50S058

Refer to the Wiring
Diagram. Locate the
Malfunction of the problem and repair as
maintenance safety Check the function of the maintenance safety necessary.
2
switch 50S058 or switch and its wiring. Verify if other trouble
its wiring Could you identify any trouble? codes are displayed,
which may cause the
problem.
No If any suspicious
trouble message
is displayed, follow
the relating trouble-
shooting procedures.
Final check 3
TS 08199-xD-GB-2 PC4000-6 7 - 91

[2/2]
7 - 92 PC4000-6 TS 08199-xD-GB-2
G00102 - Switch off wiper [S/N 08199 only]

[1/1]
Trouble code
Trouble Switch off wiper
G00102
Contents of trouble A malfunction in the wiper system is detected.
The monitoring system detected any problem with the mechanics or with the logical control of the
Related information
wiper system.

The wiper system is inoperative.
on the machine
Instruction message 2 Inform Service.
Nominal
value
a) Switch OFF the wiper switch (20S011) Repair or replace the
(switch position "0"). defective wiper parts
Malfunction in the b) Pull off the wiper arms from the as necessary (wiper
1
wiper system windscreen. arms and/or wiper
No blade).
Is the wiper system switched OFF and
could you pull off the wiper arms from Recheck the wiper
the windscreen? system for proper
function.
Wiper switched OFF (20S011 in position "0")
a) Press the QUIT button (11S145) at the Yes Go to step 4.
X2 board in the cab base in order to reset
the wiper system.
The logical wiper
control sequence 2 b) After that, the wiper arms should move into
is disturbed their end position.
No Go to next step.
c) Switch ON the wiper.
If the reset was successful, the wiper
function should be proper now.
Does the wiper operate without any problem?
Refer to the latest version of PARTS & Yes Go to step 4.
The basic mechanical SERVICE NEWS AH06533 and follow
adjustment of the wiper 3 the given adjustment instructions. If trouble code G00103
linkage is wrong After that, recheck the wiper system for proper is present, follow the
No
function. relating troubleshoot-
ing procedures.
Does the wiper operate without any problem?
Final check 4
TS 08199-xD-GB-2 PC4000-6 7 - 93
G00103 - Faulty switch 20M004 [S/N 08199 only]

[1/4]
Trouble code
Trouble Faulty switch 20M004
G00103
Contents of trouble The monitoring system detected any problem with the limit switch in the wiper motor (20M004).
The limit switch in the wiper motor (20M004) may have an electrical problem.
Related information
REMARKS: If trouble code G00102 is present, first follow the relating troubleshooting chart.
- The wiper doesn't move in its initial position (end position).

Problem that appears Therefore the logical control sequence may be disturbed and the wiper system is inoperative.
on the machine
- The wiper motor (20M004) or its limit switch may be burnt.
Instruction message 47 Only upper windscreen wiper! - Inform service.
Nominal
value
a) Press the QUIT button (11S145) at the Yes Go to step 6.
X2 board in the cab base in order to reset
the wiper system.
The logical wiper
control sequence 1 b) After that, both wiper arms should move
is disturbed into their end position.
No Go to next step.
c) Switch ON the wipers.
If the reset was successful, the wiper
function should be proper now.
Do the wipers operate without any problem?
Wiper switch 20S011 switched ON.
Check the conditions via VHMS The system assumes
- REAL TIME MONITOR that the upper wiper
- 10 Windscreen Wiper reached its end
position, but the wiper
Conditions: arms don't move.
The upper wiper motor Upper wiper arm
(20M004), the limit When the VHMS
2 in end position VHMS display = 1 Yes
switch, or its wiring shows "1", the wiring
Upper wiper arm between wiper motor
is defective
not in end position VHMS display = 0 20M004, pin 2 and
node 9, connector 3,
For wiper start, the wiper arm has to be in end pin 2 is ok.
position.
Go to step 4.
Do the indications on the REAL TIME
MONITOR correspond to the upper wiper No Go to next step.
arm position?
7 - 94 PC4000-6 TS 08199-xD-GB-2
G00103 - Faulty switch 20M004 [S/N 08199 only]

[2/4]
Nominal
value
Locate the problem and
repair as necessary.
Refer to the Wiring Diagram. If any problem was
The limit switch system Check the wiring between the wiper motor, found and repaired,
3 pin 2, and node 9, connector 3, pin 2 for
is disturbed recheck the wiper
continuity. No
system for proper
Is continuity present? function.
If OK, go to step 6.
If no problem was
found, go to next step.
Replace the wiper motor 20M004. Yes Go to step 6.
During the installation of the wiper motor follow Refer to the Wiring
the adjustment procedures in the PARTS & Diagram.
The wiper motor SERVICE NEWS AH06533 (latest version) Check the relating
4
20M004 is defective and and make sure, that the basic adjustment circuits and the electri-
of the wiper linkage is made properly. No cal components.
After that, recheck the wiper system for After that, verify that
proper function. the wiper function is
Do the wipers operate without any problem? free of problems.
Refer to the Wiring Diagram.
Malfunction in the Check the relating circuits and the electrical
wiring circuit of the 5 components, locate the problem, and repair Go to next step.
wiper system or replace defective components as necessary.
After that, verify that the wipers are working properly.
Final check 6
TS 08199-xD-GB-2 PC4000-6 7 - 95
Wiring Diagram 1 (wiper) for trouble code G00103 [S/N 08199 only]
[3/4]
Fig. 7-52 Wiring Diagram 1 (wiper) for trouble code G00103 [S/N 08199 only]
7 - 96 PC4000-6 TS 08199-xD-GB-2
Wiring Diagram 2 (wiper) for trouble code G00103 [S/N 08199 only]
[4/4]
Fig. 7-53 Wiring Diagram 2 (wiper) for trouble code G00103 [S/N 08199 only]
TS 08199-xD-GB-2 PC4000-6 7 - 97
G00104 - Trouble battery current

[1/3]
Trouble code
Trouble Trouble battery current
G00104
- The discharging current at converter 51T017 is too high.
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.

Risk to discharge batteries completely.
on the machine
Instruction message 15 Load of the batteries too high. - Inform service.
Nominal
value
Main key switch 20S001 ON - Engine OFF.
REMARKS: Replace the alternator.
Before taking the following measurements Yes After repair recheck
check for the correct order of the cable the system for proper
connections at 71T003 "B" and 71T003 "L". function.
In case the cable connections are mixed up,
connect them in the correct order.
B = battery side L = alternator side
Using a clamp-on ammeter measure the

current in front of and behind the shunt
The alternator resistor 71T003.
(52G005-1) is defective 1
(short circuit to ground)
No Go to next step.
Do you measure a negative current flow

< -200A between 71T003 & 52G005-1
and between 71T003 & the batteries?
7 - 98 PC4000-6 TS 08199-xD-GB-2
G00104 - Trouble battery current

[2/3]
Nominal
value
Main key switch 20S001 ON - Engine OFF
(a) If the current flow at one of both
starter motors is too high, both
Refer to the Wiring Diagram. starter motors have to be
Using a clamp-on ammeter: replaced.
- Measure the current between terminal block 71X_71-4 After repair recheck the system
The starter motors for proper function.
and starter motor 52M001-1.
52M001-1 & 52M002-1 2
are defective (b) If no problem could be found,
- Measure the current between terminal block 71X_71-5
check if other trouble codes
and starter motor 52M002-1.
relating to the charging system
- Measure the current between the starter motors are pending.
and ground. If so, follow the relevant
troubleshooting procedures.
Finally go to step 3.
Final check 3
TS 08199-xD-GB-2 PC4000-6 7 - 99
Wiring Diagram (battery current) for trouble code G00104

[3/3]
Fig. 7-54 Wiring Diagram (battery current) for trouble code G00104
7 - 100 PC4000-6 TS 08199-xD-GB-2

G00105 - Trouble battery charging current too low

[1/2]
Trouble code
Trouble Trouble battery charging current too low
G00105
- The charging current from the alternator (52G005-1) is too low.
Contents of trouble
- The monitoring system detected at module 11T080 that the battery voltage dropped below 23V.
Related information - Also see the charging current on the REAL TIME MONITOR (05 Electrical Equipm.)
on the service level of the VHMS system (for further information refer to the SERVICE MANUAL,
section VEHICLE HEALTH MONITORING SYSTEM & MTC CONTROL SYSTEM).

Further engine starts may be impossible due to discharged batteries.
on the machine
Instruction message 16 Batteries are not being charged. - Inform service.
Nominal
value
REMARKS: Vmin
Before taking the following measurements 27.5V
check for the correct order of the cable Vmax
connections at 71T003 "B" and 71T003 "L". 29.5V
In case the cable connections are mixed up,
1 connect them in the correct order.
Replace the alternator
B = battery side L = alternator side and check its wiring.
Measure the charging voltage between No After repair recheck
alternator, terminal B+, and ground. the system for proper
function.
Does the measurement reading meet the
specification?
The alternator Engine running at high idle.
(52G005-1) or its Using a clamp-on ammeter measure the Icharge
wiring is defective Yes Go to final step 4.
charging current in front of and behind the 25-35A
shunt resistor 71T003.
No Go to next step.
If the charging current is too low, replace the

alternator.
TS 08199-xD-GB-2 PC4000-6 7 - 101

G00105 - Trouble battery charging current too low

[2/2]
Nominal
value
(a) Measure both resistors inside the module.
(a) If a resistor is defective,
(b) Refer to the Wiring Diagram and check for proper
replace 11T080.
Module 11T080 or its cable connections:
3 - 11T080 power supply (b) If necessary, repair or replace
wiring is defective
- 11T080 ground connections the wiring/connections
- Signal line betwe)en 11T080 and node 2, of 11T080.
(connector 2, pin 8 Finally go to step 4.
- Shielding of the signal line
Final check 4
Wiring Diagram (11T080) for trouble code G00105
Fig. 7-55 Wiring Diagram (11T080) for trouble code G00105
7 - 102 PC4000-6 TS 08199-xD-GB-2


[1/4]
Trouble code G00107 - Trouble slew parking brake control 56K250a
Trouble
G00107 & G00109 G00109 - Trouble slew parking brake control 56K250b
Contents of trouble
Related information function (slew parking brake) is no longer available.
on the machine
Nominal
value
Main key switch 20S001 ON
Visually check the LEDs at 56K250a or 56K250b.
(1) LED yellow
(2) LED red
(3) A2 = GND
(4) A1 = 24V
- No power supply (A1) (5) Switch contacts (13/14)
- No ground (A2)
- Relay inoperative
- Relay output wiring 1
(13/14) defective
Specifications of the slew parking brake switch 20S029
G00107 56K250a
G00109 56K250b 20S029 in position 1 brake applied
20S029 in position 0 brake released
Both relay LEDs (yellow & red) ON
Toggle switch 20S029 and check the power supply at the relay
(G00107 56K250a / G00109 56K250b).
According to the trouble message the relay reaction is not as specified.
- Refer to the Wiring Diagram and check the relay and its wiring.
TS 08199-xD-GB-2 PC4000-6 7 - 103


[2/4]
Nominal
value
REAL TIME MONITOR - Relay Check
1. 20S001 ON
2. Engine OFF
14 Other items
Screen 2/5
5. The REAL TIME MONITOR shows "0" only, it doesn’t change from "0" to "1"
(confirmation of trouble).
Indication
Voltage Brake
REAL TIME MONITOR
1 24 V Released
0 0V Applied
Continue trouble-
(cross check)

Final check 2
7 - 104 PC4000-6 TS 08199-xD-GB-2

[3/4]
TS 08199-xD-GB-2 PC4000-6 7 - 105


[4/4]
7 - 106 PC4000-6 TS 08199-xD-GB-2


[1/4]
Trouble code G00108 - Trouble slew parking brake control Output to 56K250a
Trouble
G00108 & G00110 G00110 - Trouble slew parking brake control Output to 56K250b
- If the connection between node output and solenoid is faulty, the function (slew parking brake)
on the machine
Nominal
value
The node output signal Main key switch 20S001 ON & 20S029 in position 0
via relay to the
Refer to the Wiring Diagram and check the wiring between node output and
solenoid is disturbed 1
solenoid.
G00108 56K250a
G00110 56K250b Repair the wiring between node output and solenoid (via relay) as necessary.
REAL TIME MONITOR - Output check
1. Main key switch 20S001 ON.
2. Engine OFF.
14 Other items
Screen 2/5
4. Switch 20S029 in position 0.
5. Verify the Output Check on the REAL TIME MONITOR.
Continue trouble-
(cross check)
Digit "0" in line OUTPUT CHECK for 56K250a confirms the trouble message.
TS 08199-xD-GB-2 PC4000-6 7 - 107


[2/4]
Nominal
value
REAL TIME MONITOR - Output Signal check
Confirm the output signal from switch 20S029 over the MTC and CAN bus to
node 14 (connector 3, pin 2).
1. 20S001 ON.
2. Engine OFF.
15 Output Signals
Screen 12/24
5. Verify the Output Signals on the REAL TIME MONITOR.
If the REAL TIME MONITOR indication doesn’t change from "0" to "1"
check node 14.
Continue trouble-
(cross check)
Applied logic for 56K250a and 56K250b:

If slew parking brake switch 20S029 is in position 0
24V at the output
REAL TIME MONITOR displays 1
– Output Signal = 1 for 56K250a indicates that the signal is transferred via
MTC to the node output.
– The fault is located in the wiring between node output and solenoid.
Verify if other relevant trouble codes are set in this situation
e.g. G00043 (Trouble output short-circuit).
Locate the problem and repair as necessary.

Final check 2
7 - 108 PC4000-6 TS 08199-xD-GB-2

[3/4]
TS 08199-xD-GB-2 PC4000-6 7 - 109


[4/4]
7 - 110 PC4000-6 TS 08199-xD-GB-2

G00111 - Trouble travel parking brake control 56K251a

G00113 - Trouble travel parking brake control 56K251b
[1/1]
Trouble code G00111 - Trouble travel parking brake control 56K251a
Trouble
G00111 & G00113 G00113 - Trouble travel parking brake control 56K251b
Contents of trouble
Related information function (travel parking brake) is no longer available.
The function (travel parking brake) is not available.
on the machine
– Use the troubleshooting chart of G00107/G00109 as a guideline for troubleshooting of Relay Check
for G00111/G00113, refer to section 5.3.1 on page 5-7.
– Refer to the Wiring Diagram and check for 56K251a/56K251b.
– Use the REAL TIME MONITOR
14 Other items
Sub-screen 3/4 (Trav. park. brake)
TS 08199-xD-GB-2 PC4000-6 7 - 111

G00112 - Trouble travel parking brake control Output to 56K251a

G00114 - Trouble travel parking brake control Output to 56K251b
[1/1]
Trouble code G00112 - Trouble travel parking brake control Output to 56K251a
Trouble
G00112 & G00114 G00114 - Trouble travel parking brake control Output to 56K251b
- If the connection between node output and solenoid is faulty, the function (travel parking brake)
The function (travel parking brake) is not available.
on the machine
– Use the troubleshooting chart of G00108/G00110 as a guideline for troubleshooting of Output Check
14 Other items
Sub-screen 3/4 (Trav. park. brake)
7 - 112 PC4000-6 TS 08199-xD-GB-2

G00115 - Trouble slew hydraulic brake control 56K252a

G00117 - Trouble slew hydraulic brake control 56K252b
[1/1]
Trouble code G00115 - Trouble slew hydraulic brake control 56K252a
Trouble
G00115 & G00117 G00117 - Trouble slew hydraulic brake control 56K252b
Contents of trouble
Related information function (slew hydraulic brake) is no longer available.
The function (slew hydraulic brake) is not available.
on the machine
14 Other items
Sub-screen 4/4 (Slew hydr. brake)
TS 08199-xD-GB-2 PC4000-6 7 - 113

G00116 - Trouble slew hydraulic brake control Output to 56K252a

G00118 - Trouble slew hydraulic brake control Output to 56K252b
[1/1]
Trouble code G00116 - Trouble slew hydraulic brake control Output to 56K252a
Trouble
G00116 & G00118 G00118 - Trouble slew hydraulic brake control Output to 56K252b
- If the connection between node output and solenoid is faulty, the function (slew hydraulic brake)
The function (slew hydraulic brake) is not available.
on the machine
14 Other items
Sub-screen 4/4 (Slew hydr. brake)
7 - 114 PC4000-6 TS 08199-xD-GB-2

G00140 - Trouble monitoring X1-1 pressure

[1/3]
Trouble code
Trouble Trouble monitoring X1-1 (XLR) pressure
G00140
A malfunction in the monitoring loop for the pump regulation pressure X1 is detected.
The sensor signal is out of range (below 0.25V or higher than 9,75V)
Contents of trouble Monitoring the X1 pressure is impossible because of:
- Defective wiring or defective pressure sensor 57B085-1
- Poor terminal contact or disconnected connector in the wiring of pressure sensor 57B085-1
Related information Within a pressure range of 0 - 60 bar the sensor 57B085-1 generates a signal voltage of 0.5 - 9.5V.

Monitoring of the pump regulation pressure X1 pressure is disabled.
on the machine
Nominal
value
Disconnect the sensor connector and insert Vmin 22V
1 the Deutsch T-box. Yes Go to step 3.
Vmax 24V
Incorrect or no supply Measure the voltage between the sensor
voltage at the pressure pins A and C.
No Go to next step.
sensor 57B085-1 Is supply voltage present?
Follow the trouble-
Check if trouble code G00099 (Trouble power
2 supply) is set:
Is trouble code G00099 set?
No Go to next step.
wiring between circuit circuit in any wiring
breaker 11F013a and Refer to the Wiring Diagram and check the segment (including
X1 pressure sensor wiring segments between circuit breaker connectors) between
57B085-1 3
11F013a and connector terminal A at the circuit breaker and
(disconnection or X1 pressure sensor for continuity. No connector terminal A at
defective contact in Is continuity present? the pressure sensor.
any connector)
Locate the problem
and repair as
necessary.
Disconnection in the circuit in any wiring
shield wiring between
4 wiring segments between shield terminal and connectors) between
shield terminal
GND for continuity. shield terminal and
56X157-26 and GND No
Is continuity present? GND.
Locate the problem
and repair as
necessary.
TS 08199-xD-GB-2 PC4000-6 7 - 115

G00140 - Trouble monitoring X1-1 pressure

[2/3]
Nominal
value
Disconnect the sensor connector and insert the Vsignal
Defective pressure Yes Go to next step.
sensor 57B085-1 Deutsch T-box. 0.5 - 9.5V
5
Measure the signal voltage at connector Replace the pressure
(internal malfunction)
terminal B of the X1 pressure sensor. sensor and verify that
No
the repair was
Does the measurement meet the specification? successful.
If the continuity is not
Rmax 1Ω
as specified, any
malfunction in the
Disconnection in the wiring (including
signal wiring between connectors) between
X1 pressure sensor terminal B at the
57B085-1 and node 14 Check the wiring between terminal B at the pressure pressure sensor and
6
sensor and terminal 6 at node connector 2 for terminal 6 at node
(disconnection or
continuity. connector 2 is the
problem.
any connector)
Locate the problem and
After successful repair
go to final step 7.
Final check 7
7 - 116 PC4000-6 TS 08199-xD-GB-2


[3/3]
TS 08199-xD-GB-2 PC4000-6 7 - 117

G00141 - Trouble monitoring X2 pressure

[1/3]
Trouble code
Trouble Trouble monitoring X2 pressure
G00141
A malfunction in the monitoring loop for the X2 pressure is detected.
Poor terminal contact or any disconnected connector in the wiring of sensor 57B086.
Contents of trouble
Monitoring the X2 pressure is impossible because of:
- Defective wiring or defective sensor 57B086
Within a pressure range of 0 - 60 bar the X2 pressure sensor 57B086 generates a signal voltage
Related information
of 0.5 -9.5V.

The monitoring circuit for the X2 pressure is inoperative.
on the machine
Nominal
value
Disconnect the sensor connector and insert Vmin 22V
1 the Deutsch T-box. Yes Go to step 3.
Vmax 24V
Incorrect or no supply Measure the voltage between the sensor
voltage at the X2 terminals A and C.
pressure sensor No Go to next step.
57B086 Is supply voltage present?
Follow the trouble-
Yes shooting table for
2 supply) is set.
No Go to next step.
wiring between circuit circuit in the wiring
breaker 11F013a and Refer to the Wiring Diagram and check the (including connectors)
X2 pressure sensor wiring between circuit breaker and connector between circuit
57B086 3 breaker and cable
terminal A at the X2 pressure sensor for
(disconnection or continuity. No connector terminal A
defective contact in at the X2 pressure
any connector) sensor.
Locate the problem
and repair as
necessary.
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.
56X257-1 and GND No terminal and GND.
Locate the problem
and repair as
necessary.
7 - 118 PC4000-6 TS 08199-xD-GB-2

G00141 - Trouble monitoring X2 pressure

[2/3]
Nominal
value
Disconnect the connector from the X2 pressure Vsignal
Defective X2 pressure Yes Go to next step.
sensor 57B086 sensor and insert the Deutsch T-box. 0.5 - 9.5V
5
Measure the signal voltage at the sensor Replace the
(internal malfunction)
terminals B and C. X2 pressure sensor
No
and verify that the
Do the measurements meet the specification? repair was successful.
Disconnection in the If the resistance is too
Check for continuity in the signal wiring between
signal wiring between high, refer to the Wiring
sensor terminal B and node 14.
X2 pressure sensor and Diagram and locate the
node 14, connector 2, problem in the signal
pin 4 6 wiring of the X2
57B086 Node 14 Rmax 1Ω
terminal connector / terminal pressure sensor.
(disconnection or
defective contact in Repair as necessary.
B 2/4
any connector). After successful repair
go to final step 7.
Final check 7
TS 08199-xD-GB-2 PC4000-6 7 - 119


[3/3]
7 - 120 PC4000-6 TS 08199-xD-GB-2

G00147 - Trouble monitoring gear lubrication (PTO 1)

[1/3]
Trouble code
Trouble Trouble monitoring gear lubrication (PTO 1)
G00147
- A malfunction in the monitoring loop for the PTO gear oil pressure is detected.
Contents of trouble
- Pressure sensor 57B017-1 monitors the pressure in the PTO gear lubrication system.
Conditions for trouble message:
- The engine is standing still
- 20S001 in ON position
Example:
Pressure switch 57B017-1 signals gear oil pressure (approx. 24V), even the engine is standing still.

Related information
REAL TIME MONITOR
Condition Value State
Signal
No pressure 0V Switch closed 0
Pressure present 24 V Switch open 1
Switch point 0.5 bar

Monitoring of the PTO gear oil pressure is inoperative (binary code 010111).
on the machine
Nominal
value
Using the Deutsch T-box, measure the supply Vmin 22V
1 Yes Go to step 4.
voltage for 57B017-1 at connector 56X157,
Incorrect or no supply terminal 24. Vmax 24V
voltage at the pressure No Go to next step.
Is the correct supply voltage present?
switch 57B017-1
Follow the trouble-
Check if trouble code G00090 "No power
2 supply" is set.
No Go to next step.
Disconnection, short
circuit, or fault in the
voltage supply wiring connectors and
between circuit breaker Refer to the Wiring Diagram. resistor 56R008)
11F013 and pressure Using the Deutsch T-box, check the voltage between connector
switch 57B017-1 3
supply wiring segments between the pressure 56X157, terminal 24
(disconnection or switch and circuit breaker for continuity. No and circuit breaker.
defective contact in Is continuity present? If necessary, check the
any connector)
segments of the
voltage supply wiring
separately, locate the
problem, and repair
as necessary.
TS 08199-xD-GB-2 PC4000-6 7 - 121

G00147 - Trouble monitoring gear lubrication (PTO 1)

[2/3]
Nominal
value
The signal wiring
between pressure
Yes switch and node 14
is ok.
Go to next step.
signal wiring between
pressure switch
Check the input signal at node connector 1, wiring (including con-
57B017-1 and node 14 4
pin 8. nectors and pins)
(disconnection or between pressure
defective contact in Is the signal present?
switch and node
any connector) No connector 1, pin 8.
If necessary, check the
segments of the signal
wiring separately,
locate the problem,
and repair as
necessary.
Defective ground
Disconnect the cable connector 56X157 and Yes Go to next step.
connection at the
5 check for proper ground connection at Locate the problem
pressure switch
connector terminal 25. No and repair as
57B017-1
Is the ground connection ok? necessary.
Disconnect connector 56X157. Yes Go to next step. Rmax 1Ω

Defective pressure
switch 57B017-1 6 Measure the continuity of the pressure switch Replace the pressure
(switch does not close) between the connector pins 25 and 24. switch and verify that
No
the repair was
Is continuity present? successful.
Final check 7
7 - 122 PC4000-6 TS 08199-xD-GB-2


[3/3]
TS 08199-xD-GB-2 PC4000-6 7 - 123

G00148 - Trouble monitoring fuel level

[1/3]
Trouble code
Trouble Trouble monitoring fuel level
G00148
A malfunction in the monitoring loop of the fuel level sensor 31B063 is detected.
Monitoring of the fuel level is impossible because of:
Contents of trouble - Defective wiring or defective sensor 31B063
- Poor terminal contact or any disconnected connector in the wiring of sensor 31B063
The signal current may be out of range because the shut-off cock is closed.
- Within a pressure range of 0-0.4 bar the sensor 31B063 generates a signal voltage of 0.5 - 9.5V
Related information
- The trouble message is displayed if the signal voltage is out of range (<0.25V or >9.75V)

Risk to run out of fuel.
on the machine
Nominal
value
Open the shut-off cock between fuel tank and Yes Go to next step.
The shut-off cock fuel level sensor 31B063 to allow pressure
1 compensation. End of troubleshooting.
is closed No
Is trouble code G00148 still present? Go to final step 9.
Disconnect the cable connector from the fuel Vmin 22V
2 level sensor and insert the Deutsch T-box. Yes Go to step 4.
Vmax 24V
Incorrect or no supply Measure the supply voltage at the connector
voltage at the fuel level terminal B.
No Go to next step.
sensor 31B063 Is supply voltage present?
Follow the trouble-
3 supply) is set.
No Go to next step.
wiring between circuit circuit in any wiring
breaker 11F013a and Refer to the Wiring Diagram and check the segment (including
fuel level sensor wiring segments between circuit breaker and connectors) between
31B063 4 circuit breaker and
connector terminal B at the fuel level sensor
(disconnection or for continuity. No cable connector
defective contact in terminal B at the
Is continuity present? fuel level sensor.
any connector)
Locate the problem
and repair as
necessary.
7 - 124 PC4000-6 TS 08199-xD-GB-2

G00148 - Trouble monitoring fuel level

[2/3]
Nominal
value
shield wiring between circuit in any wiring
connector 10X140, Refer to the Wiring Diagram and check the segment (including
terminal P and GND 5 wiring segments between connector 10X140, connectors) between
(disconnection or terminal P and GND for continuity. shield terminal P and
No
defective contact in Is continuity present? GND.
any connector)
Locate the problem
and repair as
necessary.
Vmin 0.5V
Defective fuel level Disconnect the sensor connector and measure Yes Go to next step.
sensor 31B063 6 the signal voltage at connector terminal C of Vmax 9.5V
(internal malfunction) the fuel level sensor. Replace the fuel level
Does the measurement meet the sensor and verify that
No
specification? the repair was
successful.
signal wiring between circuit in the wiring
fuel level sensor Refer to the Wiring Diagram and check the (including connectors)
31B063 and connector wiring between terminal C at the fuel level between terminal C at
10X140, terminal K 7
sensor and connector 10X140, terminal K for the fuel level sensor
(disconnection or continuity. No and connector
defective contact in any Is continuity present? 10X140, terminal K.
connector)
Locate the problem
and repair as
necessary.
signal wiring of fuel Disconnection or short
level sensor 31B063 circuit in the wiring
between connector Check the wiring between connector 10X140, (including connectors)
10X140, terminal K 8 terminal K and node 2, connector 2, terminal 4 between connector
and node 2 for continuity. 10X140, terminal K
No and node connector 2,
(disconnection or Is continuity present? terminal 4.
and repair as
necessary.
Final check 9
TS 08199-xD-GB-2 PC4000-6 7 - 125

Wiring Diagram (31B063) and component location for G00148

[3/3]
Fig. 7-63 Wiring Diagram (31B063) and component location for G00148
7 - 126 PC4000-6 TS 08199-xD-GB-2

G00151 - Trouble monitoring gear (PTO) oil filter 1

[1/3]
Trouble code
Trouble Trouble monitoring gear (PTO) oil filter 1
G00151
- A malfunction in the monitoring loop for the PTO gear oil filter pressure is detected.
Contents of trouble
- Pressure sensor 57B027-1 monitors the pressure in the gear oil filter housing.
Conditions:
- 20S001 ON
- Pressure switch 57B027-1 signals pressure in the PTO gear oil filter (0 V), even the engine
is standing still.
Related information Basic sensor data (NO switch 57B027-1)
No pressure present 24 V Switch open

Pressure present 0V Switch closed
Switch point 5 bar

Monitoring of the PTO gear oil filter pressure is inoperative.
on the machine
Nominal
value
Measure the supply voltage for the pressure Vmin 22V

1 Yes Go to step 4.
switch at connector 56X157, terminal 22. Vmax 24V
Incorrect or no supply
voltage at pressure Is the correct supply voltage present? No Go to next step.
switch 57B027-1
Follow the trouble-
2 supply) is set.
No Go to next step.
Rmax
820Ω
voltage supply wiring connectors and
56F13 and pressure Check the voltage supply wiring between between connector
switch 57B027-1 3
pressure switch and the line of the circuit 56X157, terminal 22,
(disconnection or breaker for continuity. No and the circuit breaker.
defective contact in Is continuity present? If necessary, check
any connector) the segments of the
separately.
Locate the problem,
and repair as
necessary.
TS 08199-xD-GB-2 PC4000-6 7 - 127

G00151 - Trouble monitoring gear (PTO) oil filter 1

[2/3]
Nominal
value
The signal wiring
between the pressure
Yes switch and node 14,
is ok.
Go to next step.
Disconnection in the Disconnection, short
signal wiring between circuit, or fault in the
pressure switch wiring (including
Check the input signal at node 14,
57B027-1 and node 14 4 connectors and pins)
connector 1, pin 2.
defective contact in any Is the signal present? switch and node
connector) No connector 1, pin 2.
wiring separately.
Locate the problem,
and repair as
necessary.
Defective ground
Disconnect the sensor connector and check Yes Go to next step.
connection at the
5 for proper ground connection at connector Locate the problem
pressure switch
terminal 2 (via 56X157, terminal 23). No and repair as
57B027-1
Defective pressure - Disconnect connector 56X157. Replace the pressure

switch 57B027-1 switch and verify
6 - Measure the continuity of the pressure switch Yes Rmax 1Ω
that the repair was
(switch does not open) between the connector pins 1 and 2.
successful.
Is continuity present? No Go to next step.
Final check 7
7 - 128 PC4000-6 TS 08199-xD-GB-2

Wiring Diagram (57B027-1) and component location for trouble code G00151
[3/3]
Fig. 7-64 Wiring Diagram (57B027-1) and component location for trouble code G00151
TS 08199-xD-GB-2 PC4000-6 7 - 129

G00154 - Trouble monitoring return oil filter

[1/3]
Trouble code
Trouble Trouble monitoring return oil filter
G00154
- A malfunction in the monitoring loop for the return-oil chamber pressure is detected.
Contents of trouble
- The system assumes that the pressure sensor 40B163 or its wiring is defective.
Related information The message is displayed if the signal voltage is below 0.25V or higher than 9.75V

The pressure monitoring in the return-oil chamber is disturbed.
on the machine
Nominal
value
pressure sensor and insert the Deutsch T-box. Yes Go to step 4.
1 Vmax 24V
voltage in the circuit Measure the supply voltage at the pressure
of pressure sensor sensor connector, terminal A.
No Go to next step.
40B163 (return-oil Is supply voltage present?
chamber pressure) Follow the trouble-
Check if trouble code G00099 (Trouble power Yes shooting table for
2 supply) is set. trouble code G00099.
No Go to next step.
Disconnection in the Yes Go to next step. Rmax 1Ω
wiring between
pressure sensor
40B163 (return-oil
chamber pressure) and
wiring segments between pressure sensor, connectors) between
the power supply line 3
terminal A and the power supply line from the the line of the circuit
of circuit breaker
circuit breaker for continuity. No breaker and connector
11F013a
terminal A at the
(disconnection or Is continuity present?
pressure sensor.
and repair as
necessary.
7 - 130 PC4000-6 TS 08199-xD-GB-2

G00154 - Trouble monitoring return oil filter

[2/3]
Nominal
value
Disconnection in the circuit in any wiring
Disconnect the signal line of pressure sensor
signal wiring between segment of the signal
from node connector 2, terminal 8.
pressure sensor line (including
40B163 and node 11 Refer to the Wiring Diagram and check the connectors) between
connector 2, terminal 8 4 signal wiring between pressure sensor, pressure sensor
(disconnection or terminal B (via connector 40X340, terminal 13) No (return-oil chamber
defective contact in any and node 11 (connector 2, terminal 8) for pressure) and cable
connector) continuity. connector 2,
Is continuity present? terminal 8, at node 11.
Locate the problem
and repair as
necessary.
Defective ground Yes Go to next step. Rmax 1Ω
connection at Disconnection or short
connector terminal C circuit in any ground
of pressure sensor Refer to the Wiring Diagram and check the
ground wiring between pressure sensor and wiring segment
40B163 (return-oil 5 (including connector
chamber pressure) connector 40X340, terminal 14 for continuity
and proper ground connection. No 40X340) of the
(disconnection or pressure sensor.
defective contact in Are continuity and ground connection ok?
Locate the problem
any connector) and repair as
necessary.
Defective shield wiring
at the cables of Disconnection or short
pressure sensor circuit in any wiring
40B163 (return-oil
6 shield wiring for continuity and proper ground connector 40X340,
chamber pressure)
connection at connector 40X340, terminal 11. No terminal 11) of the
(disconnection or
Are continuity and ground connection ok? shield line.
and repair as
necessary.
– Insert the Deutsch T-box at the cable A sporadic malfunction Vmin 0.5V
Defective pressure connector of the pressure sensor. Yes may exist. Further
sensor 40B163
– Measure the signal voltage of the inspection is required. Vmax 9.5V
7
(return-oil chamber pressure sensor at the relating terminal Replace the pressure
pressure) at the Deutsch T-box. sensor (return-oil
No chamber pressure)
Does the measurement meet the
and verify that the
specification?
Final check 8
TS 08199-xD-GB-2 PC4000-6 7 - 131


[3/3]
7 - 132 PC4000-6 TS 08199-xD-GB-2

G00155 - Trouble monitoring leak oil filter

[1/3]
Trouble code
Trouble Trouble monitoring leak oil filter
G00155
- A malfunction in the monitoring loop for the leak-oil chamber pressure is detected.
Contents of trouble
- The system assumes that the pressure sensor 40B164 or its wiring is defective.
Related information The message is displayed if the signal voltage is below 0.25V or higher than 9.75V

The pressure monitoring in the leak-oil chamber is disturbed.
on the machine
Nominal
value
Incorrect or no supply pressure sensor and insert the T-box. Yes Go to step 4.
1 Vmax 24V
voltage in the circuit Measure the supply voltage at the connector,
of pressure sensor terminal A.
40B164 No Go to next step.
Is supply voltage present?
(leak-oil chamber
pressure) Follow the trouble-
Check if trouble code G00099 (Trouble power Yes shooting table for
2 supply) is set. trouble code G00099.
No Go to next step.
Disconnection in the Yes Go to next step. Rmax 1Ω
wiring between
pressure sensor
40B164 (leak-oil
chamber pressure)
wiring segments between the pressure sensor connectors) between
and the power supply 3
(terminal A) and the power supply line of the the line of the circuit
line of circuit breaker
circuit breaker for continuity. No breaker and connector
11F013a
terminal A at the
(disconnection or Is continuity present?
pressure sensor.
and repair as
necessary.
TS 08199-xD-GB-2 PC4000-6 7 - 133

G00155 - Trouble monitoring leak oil filter

[2/3]
Nominal
value
Disconnection in the Disconnect the signal line of the pressure circuit in any wiring
signal wiring between sensor from node 11 (connector 2, terminal 7). segment of the signal
pressure sensor
line (including
40B164 and node 11 Refer to the Wiring Diagram.
4 connectors) between
connector 2, terminal 7 Check the signal wiring between pressure pressure sensor (leak-
(disconnection or sensor, terminal B (via connector 40X340, No oil chamber pressure)
defective contact in terminal 17) and node 11 (connector 2, and cable connector 2,
any connector) terminal 7) for continuity. terminal 7 at node 11.
Is continuity present? Locate the problem
and repair as
necessary.
Defective ground Yes Go to next step. Rmax 1Ω
connection at Disconnection or short
connector terminal C circuit in any ground
of pressure sensor Refer to the Wiring Diagram.
Check the ground wiring between the pressure wiring segment
40B164 (leak-oil 5 (including connector
chamber pressure) sensor and connector 40X340, terminal 18
for continuity and proper ground connection. No 40X340) of the
(disconnection or pressure sensor.
defective contact in Are continuity and ground connection ok?
Locate the problem
any connector) and repair as
necessary.
Defective shield wiring Disconnection or short
at the cables of circuit in any wiring
pressure sensor Refer to the Wiring Diagram. segment of the shield
40B164 (leak-oil Check the shield wiring for continuity and line
chamber pressure) 6
proper ground connection at 40X340, (including connectors
(disconnection or terminal 15. No and terminal block
defective contact in Are continuity and ground connection ok? 40X340).
and repair as
necessary.
– Insert the Deutsch T-box at the cable A sporadic malfunction Vmin 0.5V
Defective pressure connector of the pressure sensor. Yes may exist. Further
sensor 40B164
– Measure the signal voltage of the inspection is required. Vmax 9.5V
7
(leak-oil chamber pressure sensor at the relating terminal Replace the pressure
pressure) of the T-box. sensor (leak-oil cham-
No ber pressure) and
Does the measurement meet the
verify that the repair
specification?
was successful.
Final check 8
7 - 134 PC4000-6 TS 08199-xD-GB-2


[3/3]
TS 08199-xD-GB-2 PC4000-6 7 - 135

G00159 - Trouble monitoring breather filter

[1/3]
Trouble code
Trouble Trouble monitoring breather filter
G00159
- A malfunction in the monitoring loop for the hydraulic oil tank breather filter is detected.
Contents of trouble - Pressure sensor 40B024 monitors the (vacuum) pressure at the breather filter,
on top of the hydraulic oil tank.
Conditions:
- 20S001 ON
- Pressure switch 40B024 signals vacuum (0V) at the breather filter, even the engine is
standing still
Basic sensor data (40B024) NO*

Related information

0.08 bar
Switch point
(vacuum)
*
*NO= Normally Open

Monitoring of the breather filter pressure is inoperative.
on the machine
Nominal
value
Prepare with main key switch 20S001 in OFF.
Measure the supply voltage for the pressure Vmin 22V

1 Yes Go to step 4.
switch at connector 40X240, terminal 10. Vmax 24V
voltage at the pressure Is the correct supply voltage present? No Go to next step.
switch 40B024
Follow the trouble-
2 supply) is set.
No Go to next step.
40R008
820Ω
wiring (including
connectors and
11F013 and pressure Check the voltage supply wiring between the
3 between connector
switch 40B024 pressure switch and the line of the circuit 40X240, terminal 10
(disconnection or breaker for continuity. No and the circuit breaker.
defective contact in Is continuity present? If necessary, check
any connector) the segments of the
separately.
Locate the problem,
and repair
as necessary.
7 - 136 PC4000-6 TS 08199-xD-GB-2

G00159 - Trouble monitoring breather filter

[2/3]
Nominal
value
The signal wiring
between pressure
Yes switch and node 11
is ok.
Go to next step.
Disconnection in the Disconnection, short
signal wiring between circuit, or fault in the
pressure switch wiring (including
40B024 and node 11 Check the input signal at node 11,
4 connectors and pins)
connector 3, pin 9.
defective contact in Is the signal present? switch and node 11,
any connector) connector 3, pin 9.
No
wiring separately.
Locate the problem,
and repair as
necessary.
Defective ground
Disconnect connector 40X240 and check for Yes Go to next step.
connection at the
5 proper ground connection at the connector Locate the problem
pressure switch
terminal 11. No and repair as
40B024
Defective pressure Replace the pressure

Disconnect connector 40X240.
switch 40B024 switch and verify that
6 Measure the continuity of the pressure switch Yes Rmax 1Ω
the repair was
(switch does not open) between the connector pins 10 and 11.
successful.
No Go to next step.
Final check 7
TS 08199-xD-GB-2 PC4000-6 7 - 137


[3/3]
7 - 138 PC4000-6 TS 08199-xD-GB-2

G00160 - Trouble monitoring engine air cleaner 1

[1/3]
Trouble code
Trouble Trouble monitoring engine air cleaner
G00160
- A malfunction in the monitoring loop for the engine air filter pressure sensors is detected.
Contents of trouble - Sensors 52B018-1 & 52B019-1 monitor the (vacuum) pressure in the inlet manifolds between
air filters and engine.
Conditions:
- 20S001 in ON position
- Pressure switch 52B018-1 and/or 52B019-1 signals vacuum (0V) in the inlet manifold below the
engine air cleaner, even the engine is standing still.
Related information Basic sensor data (52B018-1/52B019-1) NO*

Switch point >60 mbar (vacuum)
* NO= Normally Open

Monitoring of the engine air cleaners is inoperative.
on the machine
Nominal
value
Measure the supply voltage for 52B018-1 at Vmin 22V
connector 51X252, terminal 1. Yes Go to step 4.
Incorrect or no supply 1 Vmax 24V
voltage at the affected For 52B019-1 measure at terminal 3 in the
pressure switch same connector.
No Go to next step.
(52B018-1 or Is the correct supply voltage present?
52B019-1) Follow the trouble-
2 supply) is set.
No Go to next step.
TS 08199-xD-GB-2 PC4000-6 7 - 139


[2/3]
Nominal
value
51R008
820Ω
Disconnection in the wiring (including con-
voltage supply wiring nectors and resistor
between circuit breaker 51R008) between
Refer to the Wiring Diagram. connector 51X252,
11F013 and pressure
switch 52B018-1 or 3 Check the voltage supply wiring between terminal 1 (52B018-1)
52B019-1 pressure switch 52B018-1 or 52B019-1 and or terminal 3
the line of the circuit breaker for continuity. No (52B019-1) and the
(disconnection or
circuit breaker.
defective contact in Is continuity present?
any connector) If necessary, check the
segments of the
separately.
Locate the problem,
and repair as
necessary.
The signal wiring
between pressure
switch 52B018-1/
Yes 52B019-1 and node 17
is ok.
Disconnection in the Go to next step.

signal wiring between Disconnection, short
pressure switch Check the input signal at node 17, circuit, or fault in the
52B018-1/52B019-1 connector 3, pin 8 (for 52B018-1) wiring (including
and node 17 4 connectors and pins)
or
(disconnection or connector 3, pin 6 (for 52B019-1). between pressure
defective contact in switch 52B018-1/
Is the signal present? 52B019-1 and
any connector)
No node 17.
wiring separately.
Locate the problem,
and repair as
necessary.
Defective ground Disconnect connector 51X252 and check for Yes Go to next step.
connection at the proper ground connection at the connector
5 Locate the problem
pressure switch terminal 2 (52B018-1) or terminal 4
52B018-1 or 52B019-1 (52B019-1). No and repair as
necessary.
Is the ground connection ok?
7 - 140 PC4000-6 TS 08199-xD-GB-2


[3/3]
Nominal
value
Disconnect connector 51X252. Replace the defective
Defective pressure pressure switch
switch 52B018-1 Measure the continuity of the pressure
6 switches between the connector pins 1 and 2 Yes 52B018-1 or 52B019-1 Rmax 1Ω
or 52B019-1 and verify that the
(52B018-1) or between the connector pins 3
(switch does not open) and 4 (52B019-1). repair was successful.
Is continuity present? No Go to next step.

Final check 7
Wiring diagram (52B018-1 & 52B019-1) for trouble code G00160
Fig. 7-68 Wiring diagram (52B018-1 & 52B019-1) for trouble code G00160
TS 08199-xD-GB-2 PC4000-6 7 - 141

G00161 - Trouble monitoring battery voltage

[1/3]
Trouble code
Trouble Trouble monitoring battery voltage
G00161
- A malfunction in the monitoring loop for the battery voltage is detected.
Contents of trouble - The system assumes that the resistor 11T080 or the wiring circuit of the battery charging system
is defective.
If the battery voltage signal at 11T080 is outside the range of 12-39V for 5 seconds, the trouble
Related information
code is set.

Monitoring of the battery voltage is disabled.
on the machine
Nominal
value
Vmin 22V
1 Measure the input voltage at the resistor. Yes Go to step 4.
Vmax 24V
Is correct input voltage present?
No Go to next step.
Incorrect or no input
Vmin 22V
voltage (24V) at Yes Go to next step.
resistor 11T080 Vmax 24V
Check if supply voltage is present at the power
supply line 11F013a. Follow the trouble-
2
shooting chart for
Is voltage present? No trouble code G00099
"Trouble power
supply".
(+) wire between Disconnection or short
resistor 11T080 and circuit in the (+) wire
Refer to the Wiring Diagram. (including connec-
the power supply line
Check the (+) wire between resistor 11T080 tions) between the
of circuit breaker 3
and the power supply line of the circuit breaker resistor and the power
11F013a
for continuity. No supply line of the
(disconnection or
Is continuity present? circuit breaker.
and repair as
necessary.
circuit in the (-) wire
Defective ground (including connec-
Check for proper ground connection at the
connection at 4 tions) between the
(-) terminal of the resistor.
resistor 11T080 resistor and ground
No
Is the ground connection ok? (GND).
Locate the problem
and repair as
necessary.
7 - 142 PC4000-6 TS 08199-xD-GB-2

G00161 - Trouble monitoring battery voltage

[2/3]
Nominal
value
The signal voltage of VSignal min.
resistor 11T080 to Disconnect the node connector 2 and measure 12V
node 2, connector 2, 5 the signal voltage at terminal 8. Yes Go to step 7.
VSignal max.
terminal 8 is not correct Does the signal voltage meet the
or not present 39V
specification?
No Go to next step.
11T080
Yes Go to next step. 30.1kΩ+
Measure the resistance of both internal
Resistor 11T080 is 10.0kΩ
6 resistors in 11T080.
defective
Does the resistance correspond to the nominal Replace the defective
values? resistor(s) and recheck
No
function.
signal wire between circuit in the signal wire
resistor 11T080 and Check the signal wire between resistor 11T080 (including connec-
node 2, connector 2, 7 and node 2, connector 2, terminal 8 for tions) between resistor
terminal 8 continuity. 11T080 and node 2,
No connector 2,
(disconnection or Is continuity present? terminal 8.
defective contact)
Locate the problem
and repair as
necessary.
Final check 8
TS 08199-xD-GB-2 PC4000-6 7 - 143


[3/3]
7 - 144 PC4000-6 TS 08199-xD-GB-2

G00162 - Trouble monitoring charging-/discharging current

[1/3]
Trouble code
Trouble Trouble monitoring charging-/discharging current
G00162
- The system detected that the shunt resistor 71T003, or the module 51T017, or the belonging
Contents of trouble wiring is defective.
- The trouble message is displayed if the charging current is below -270A of higher than +245A.
The purpose of the module 51T017 is to monitor the charging and discharging current of the
batteries.
Battery information
Battery Location Function
71G001
Related information
71G002 Engine start
Cat walk
71G003 & miscellaneous
71G004
13G008
Cab base Stabilized voltage for MTC
13G009
Problem that appears - The monitoring circuit of the charging and discharging current for the batteries is inoperative.
on the machine - The batteries will be discharged if the charging current is too low.
Nominal
value

Switch OFF battery main switches 71Q003 & 71Q004.
71T003
4.5±0.5Ω
- Disconnect the main battery cables and Replace the shunt
The shunt resistor the signal lines (terminals B & L) from the resistor.
71T003 may be 1 shunt resistor.
Connect all cables and
defective - Then measure the resistance of the shunt recheck the monitoring
resistor. No circuit for proper
Does the measurement reading meet the function.
specification? If the repair was
successful, go to
final step 5.
Switch OFF battery main switches 71Q003 & 71Q004.
Refer to the Wiring Diagram and check the Yes Go to next step. Rmax 1Ω
following cables for continuity:
The wiring of the shunt - Between alternator 52G005 and the shunt
Locate the problem
resistor 71T003 may 2 resistor (input).
and repair as
cause the problem - Between shunt resistor (output) and all necessary.
batteries. No
After repair recheck
- Between shunt resistor (terminals B & L) and the system for proper
module 51T017, including the wire shielding. function.
Is the continuity as specified?
TS 08199-xD-GB-2 PC4000-6 7 - 145

G00162 - Trouble monitoring charging-/discharging current

[2/3]
Nominal
value
Vmin 22V
Refer to the Wiring Diagram. Yes Go to next step.
Vmax 24V
The power supply Check at the following terminals of the module:
wiring (+/-) at module Locate the problem
3 - Terminal 7 for supply voltage (B+).
51T017 may cause and repair as
the problem - Terminal 8 for proper ground connection. necessary.
No
Is the power supply wiring (+/-) of the module After repair recheck
OK? the system for proper
function.
Replace module
The signal lines Refer to the Wiring Diagram. Rmax 1Ω
Yes 51T017 and recheck
between Check the following cables for continuity: for proper function.
- shunt 71T003, - Between module pin 5, and node Locate the problem
4
- module 51T017 connector 2, pin 7. and repair as
- and node 17 necessary.
- Between module pin 4/2, and shunt No
are disturbed connection B/L. After repair recheck
Is the continuity as specified in both cables?
function.
Final check 5
7 - 146 PC4000-6 TS 08199-xD-GB-2

Wiring Diagram (battery charging current) for trouble code G00162

[3/3]
Fig. 7-70 Wiring Diagram (battery charging current) for trouble code G00162
TS 08199-xD-GB-2 PC4000-6 7 - 147

G00164 - Trouble air cleaner 1

[1/2]
Trouble code
Trouble Trouble air cleaner 1
G00164
- The message is displayed if the sensors 52B018-1 & 52B019-1 of the engine air filters detect
Contents of trouble clogged air filters.
- The system assumes that the monitoring circuits of the engine air filter sensors are not disturbed.
Sensors 52B018-1 & 52B019-1 watch the vacuum pressure in the inlet manifolds between air filters
Related information
and engine.
With clogged air filter(s) the following problems occur:

Loss in rated engine power
- Poor exhaust emission quality
- Increased fuel consumption
Problem that appears - Increased exhaust gas temperature
on the machine - 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.
Nominal
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
The engine air filters
new and a clogged outer air filter element.
are clogged
1
(inner and outer Example:
elements) Weight of a new air filter element: approx. 9 kg
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 step 2.
Final check 2
7 - 148 PC4000-6 TS 08199-xD-GB-2

View onto the engine air cleaner (G00164)

[2/2]
Fig. 7-71 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
TS 08199-xD-GB-2 PC4000-6 7 - 149

G00165 - Trouble breather filter hydraulic oil tank

[1/2]
Trouble code
Trouble Trouble breather filter hydraulic oil tank
G00165
- The trouble message is displayed if sensor 40B024 (on top of the hydraulic oil tank) detects a
clogged breather filter.
Contents of trouble
- The system assumes that the monitoring circuit of the breather filter sensor 40B024
is not disturbed.
Sensor 40B024 watches the vacuum pressure of the breather and ventilation of the hydraulic oil
Related information
tank.

A clogged breather adversely affects the circulation of the hydraulic oil in the tank.
on the machine
Nominal
value
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
is clogged If this trouble message appears frequently in-between Go to final check 2.
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.

Final check 2
7 - 150 PC4000-6 TS 08199-xD-GB-2

Label showing temperature information and defined positions (G00165)

[2/2]
Fig. 7-72 Label showing temperature information and defined positions (G00165)
(1) Hydraulic oil tank
(2) Temperature information
(3) Defined positions
TS 08199-xD-GB-2 PC4000-6 7 - 151

G00166 - Trouble oil filter gear (PTO 1)

[1/2]
Trouble code
Trouble Trouble oil filter gear (PTO 1)
G00166
Pressure sensor 57B027-1 (NO*) signals, that the filter for the PTO gear lubrication system is
Contents of trouble clogged.
*NO = Normally Open
- A problem with the pressure sensor 57B027-1 or its wiring (G00151) may also cause the trouble.
- The trouble code is not set until the hydraulic oil temperature reached T3.
Sample
Hydraulic oil: VG100
T3: 67°C
In this case the trouble code is not

set until the hydraulic oil temperature
reached 67°C.
Related information

Switch point 5 bar

Unfiltered PTO gear oil flows through the bypass of the filter.
on the machine
Nominal
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 Screw off the filter case and check for
1 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.
50S058 OFF & locked
The pressure sensor The pressure sensor has an internal stuck in closed
2 position. Remove the sensor and replace it by a new
57B027-1 is defective
one. Go to final step 3.
After that recheck the system for proper function.

Final check 3
7 - 152 PC4000-6 TS 08199-xD-GB-2

View onto the PTO 1 gear oil filter with pressure sensor 57B027-1 (G00166)
[2/2]
Fig. 7-73 View onto the PTO 1 gear oil filter with pressure sensor 57B027-1 (G00166)
TS 08199-xD-GB-2 PC4000-6 7 - 153

G00169 - Trouble return oil filter hydraulic oil tank

[1/1]
Trouble code
Trouble Trouble return oil filter hydraulic oil tank
G00169
- Pressure sensor 40B163 signals, that the back pressure in the return oil filter is higher than 2 bar.
Contents of trouble
- The system assumes that sensor 40B163 and the respective wiring are not defective.
- The Qmin / Qmax setting via VHMS must be in position AUTOMATIC.
Sample
Related information T3: 67°C
In this case the trouble code is not

set until the hydraulic oil temperature
reached 67°C.

Unfiltered return oil flows through the bypass of the filter into the hydraulic oil tank.
on the machine
Nominal
value
50S058 OFF & locked
Replace return oil
filters as described in
Remove both filter cover retainers (two-armed
the OPERATION &
The return oil filter & three-armed) on top of the 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.
50S058 OFF & locked
The pressure sensor
2 The pressure sensor has an internal stuck.
40B163 is defective Remove the sensor and replace it by a new one. Go to final step 3.
Final check 3
7 - 154 PC4000-6 TS 08199-xD-GB-2

G00170 - Trouble leak oil filter hydraulic oil tank

[1/1]
Trouble code
Trouble Trouble leak oil filter hydraulic oil tank
G00170
Contents of trouble Pressure sensor 40B164 signals, that the leak oil filter in the hydraulic tank is clogged.
- The trouble code is set if the pressure in the leak oil chamber exceeds 0.2 bar.
Sample
Related information T3: 39°C
In this case the trouble code is

not set until the hydraulic oil
temperature reached 67°C.

Unfiltered leak oil flows through the bypass of the filter into the hydraulic oil tank.
on the machine
Nominal
value
50S058 OFF & locked
Replace the leak oil
filter as described in
Remove the two-armed filter cover retainer on
the OPERATION &
The leak oil filter top of the 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.
50S058 OFF & locked
The pressure sensor The pressure sensor has an internal stuck.
2
40B164 is defective Remove the sensor and replace it by a new one. Go to final step 3.
Final check 3
TS 08199-xD-GB-2 PC4000-6 7 - 155

G00176 - Trouble battery voltage too low

[1/3]
Trouble code
Trouble 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, otherwise trouble
Related information code G00161 should be displayed.
- 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.

Another engine start may be impossible.
on the machine
Nominal
value
Vcharge
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
No and recheck for proper
specification?
charging voltage.
Using a multimeter measure the charging Vcharge
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 VHMS Monitor:
REAL TIME MONITOR
Screen 1/2
The shunt resistor

2
71T003 is defective Replace the shunt
resistor and recheck
No
for proper charging
voltage.

specification?
7 - 156 PC4000-6 TS 08199-xD-GB-2

G00176 - Trouble battery voltage too low

[2/3]
Nominal
value
Check the clamps at
Battery information the battery poles for
Battery Location Function proper contact and
secure fixation.
Any battery is defective 71G001 VBATTERY
(or batteries) Yes In case of any poor min. 10V
71G002 condition, rework the
Cat walk Battery charging max. 12V
71G003 affected battery pole
3 and reconnect clamps
REMARKS: 71G004
which are not fixed
If the machine is 13G008 Stabilized voltage correctly.
not equipped with Cab base
13G009 for MTC
maintenance-free
batteries, first check Replace any defective
the battery acid level Disconnect each battery and measure the battery/batteries
No
and correct if battery voltage. according to your
necessary. local regulations.
Does the voltage of each battery meet the
specification?
Final check 4
TS 08199-xD-GB-2 PC4000-6 7 - 157

Wiring Diagram (batteries) for trouble code G00176

[3/3]
Fig. 7-74 Wiring Diagram (batteries) for trouble code G00176
7 - 158 PC4000-6 TS 08199-xD-GB-2

G00177 - Trouble battery charging circuit

[1/2]
Trouble code
Trouble Trouble battery charging circuit
G00177
- The system detected at 51T017 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.

---
on the machine
Nominal
value
The shunt resistor Main key switch 20S001 ON - Engine OFF

71T003 is defective or Using a clamp-on ammeter, measure the current at the If the measurement
1
the battery cables are shown measuring points 1-4 in illustration Fig. 7-75 on reading is above 4A,
mixed up page 7-160. go to next step.
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
(a) Refer to the Wiring Diagram and check for proper
cable connections:
- 51T017 power supply
- 51T017 ground connections
- Signal line between 51T017 and node 17, (a) If necessary, repair
connector 2, pin 7 or replace the wir-
- Shielding of the signal line ing/connections of
- Wiring between 51T017 and 71T003 51T017.
Wiring
- Shielding of the wiring to 71T003 (b) If the function
Module 51T017 or its Diagram
3 of 51T017 is not
wiring is defective Conver-
(b) Check the converter module according to the according to the
conversion chart, sion chart
conversion chart in the Wiring Diagram.
replace the con-
verter module.

Final check 4
TS 08199-xD-GB-2 PC4000-6 7 - 159

Wiring Diagram (measuring points 1-4) for trouble code G00177

[2/2]
Fig. 7-75 Wiring Diagram (measuring points 1-4) for trouble code G00177
7 - 160 PC4000-6 TS 08199-xD-GB-2

G00178 - Trouble battery charging current too high

[1/2]
Trouble code
Trouble Trouble battery charging current too high
G00178
The system detected at 51T017 that the charging current from the alternator via the shunt resistor
Contents of trouble
71T003 is too high (higher than 200A).

Batteries may be destroyed if they are overcharged for a longer period.
on the machine
Nominal
value
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.
(a) Refer to the Wiring Diagram and check for proper
cable connections:
- 51T017 power supply
- 51T017 ground connections
- Signal line between 51T017 and node 17, (a) If necessary, repair
connector 2, pin 7 or replace the wir-
- Shielding of the signal line ing/connections of
- Wiring between 51T017 and 71T003 51T017.
Wiring
- Shielding of the wiring to 71T003 (b) If the function
Module 51T017 or its Diagram
3 of 51T017 is not
wiring is defective (b) Check the converter module according to the Conver-
according to the
conversion chart in the Wiring Diagram. sion chart
conversion chart,
replace the con-
verter module.

Final check 3
TS 08199-xD-GB-2 PC4000-6 7 - 161


[2/2]
7 - 162 PC4000-6 TS 08199-xD-GB-2

G00179 - Trouble control pressure X1-1

[1/2]
Trouble code
Trouble Trouble control pressure X1-1 (XLR)
G00179
- The message is displayed if the pump regulation pressure X1 is too high.
Contents of trouble
- The system assumes that the monitoring circuit for the X1 pressure is not disturbed.
Related information The pressure sensor 57B085-1 detected a pressure of more than 40 bar during 2 seconds.

A too high X1 pressure affects the pump regulation adversely (high stall speed).
on the machine
Nominal
value
Temp
Engine running at high idle & operation temperature. hydr.oil
>=60°C
Connect a pressure gauge (0-60 bar) to the Yes Go to next step.
test port M18 at the valve cartridge block
Replace the pressure
REMARKS: Make sure that the lever for
The X1 pressure sensor 57B085-1.
1 emergency operation at the
is too high Verify that trouble code
valve cartridge block is in
position "Electronic regulation". G00179 is not set
No
Refer to Fig. 7-77 again.
on page 7-164. If the repair was
Measure the pump regulation pressure X1. successful, go to
final step 3.
Is the X1 pressure too high (above 40 bar)?
Refer to the SERVICE MANUAL, section After successful
Wrong X1 pressure
2 ELECTRONIC PUMP REGULATION SYSTEM and adjustment go to
adjustment
follow the adjustment procedures for the X1 pressure. final step 3.
Final check 3
TS 08199-xD-GB-2 PC4000-6 7 - 163

View onto the valve cartridge block (G00179)

[2/2]
Fig. 7-77 View onto the valve cartridge block (G00179)
(1) Valve cartridge block
[M18] X1 pressure test port
[57B085-1] Pressure sensor - X1 pressure
[253.1] Emergency lever in normal operating position "Electronic pump regulation"
7 - 164 PC4000-6 TS 08199-xD-GB-2

G00180 - Trouble pilot pressure X2 too low

[1/2]
Trouble code
Trouble Trouble pilot pressure X2 too low
G00180
- The message is displayed if the pilot pressure X2 is too low.
Contents of trouble
- The pressure sensor 57B086 detected a pressure below 30 bar during 2 seconds.
Related information
- As long as the ladder is down or the refilling is extended, the X2 pressure is disabled.

A too low X2 pressure affects the hydraulic system adversely.
on the machine
Nominal
value
Temp
>=60°C
X2 pressure
45±2bar
The X2 pressure – Connect a pressure gauge (0-60 bar) to Replace the pressure
1 the pressure test port M1.2 at the valve
is too low sensor 57B086.
cartridge block.
Verify that trouble code
– Measure the pilot pressure X2. G00180 is not set
No
Is the X2 pressure too low (below 30 bar)? again.
If the repair was
successful, go to
final step 3.
Refer to the SERVICE MANUAL, section CHECKS After successful
Wrong X2 pressure
2 AND ADJUSTMENT OF PILOT PRESSURE and follow adjustment go to
adjustment
the adjustment procedures for the X2 pressure. final step 3.
Final check 3
TS 08199-xD-GB-2 PC4000-6 7 - 165

Valve cartridge block with X2 pressure sensor 57B086 & M1.2

[2/2]
Fig. 7-78 Valve cartridge block with X2 pressure sensor 57B086 & M1.2
7 - 166 PC4000-6 TS 08199-xD-GB-2

G00181 - Trouble pilot pressure X2 too high

[1/2]
Trouble code
Trouble Trouble pilot pressure X2 too high
G00181
- The message is displayed if the pilot pressure X2 is too high.
Contents of trouble
Related information The pressure sensor 57B086 detected a pressure of more than 52 bar during 2 seconds.

A too high X2 pressure affects the hydraulic system adversely.
on the machine
Nominal
value
Temp
>=60°C
X2 pressure
45±2bar
Replace the pressure
The X2 pressure Connect a pressure gauge (0-60 bar) to the
1 sensor 57B086.
is too high pressure test port M1.2 at the valve cartridge
block. Verify that trouble code
G00181 is not set
Measure the pilot pressure X2. No
again.
Is the X2 pressure too high (above 52 bar)?
If the repair was
successful, go to
final step 3.
Refer to the SERVICE MANUAL, section CHECKS After successful
Wrong X2 pressure
2 AND ADJUSTMENT OF PILOT PRESSURE and follow adjustment go to
adjustment
the adjustment procedures for the X2 pressure. final step 3.
Final check 3
TS 08199-xD-GB-2 PC4000-6 7 - 167

Valve cartridge block with X2 pressure sensor 57B086 & M1.2

[2/2]
Fig. 7-79 Valve cartridge block with X2 pressure sensor 57B086 & M1.2
7 - 168 PC4000-6 TS 08199-xD-GB-2

G00184 - Central lubrication system empty

G00187 - Slew ring gear lubrication system empty
[1/2]
Trouble code G00184 - Central lubrication system empty
Trouble
G00184 & G00187 G00187 - Slew ring gear lubrication system empty
Contents of trouble The message is displayed if the corresponding grease barrel needs refilling.
- The sensing range of the ultrasonic grease level sensors 62B108 & 62B109 is pre-adjusted
ex factory. Further settings are not possible.
Related information
- For more information about the ultrasonic grease level sensors 62B108 & 62B109 also refer to the
PARTS & SERVICE NEWS AH10510, latest version.
- Display and fade-out of this message occurs with a delay of 5 minutes.
Problem that appears - Risk, to operate the machine without grease.
on the machine - Bucket cut-off after approx. 4 hours (machine configuration).
Instruction message 20 Inform service and then press cancel button.
Nominal
value
Using the dipstick, verify if the relating grease Press the cancel
barrel needs refilling. button and refill the
Is the grease barrel empty? specified grease.
Yes
Definition of the grease levels Verify that trouble code
G00184 or G00187 is
not displayed again.
The concerned grease

barrel (CLS or SLS) 1
needs refilling
No Go to next step.
Yes Go to final step 3.

Refer to trouble code G00012/G00013 for: Verify if other relevant
The trouble message is
- Information about the LEDs at the ultrasonic trouble codes are
wrong. The concerned
sensor displayed.
grease barrel (CLS or 2
SLS) doesn’t need - Testing the sensor reaction (step 8) No If so, follow the trouble-
refilling shooting procedures
- Troubleshooting procedures
for the corresponding
Could you rectify the problem? troubleshooting chart.
Final check 3
TS 08199-xD-GB-2 PC4000-6 7 - 169

Grease level (CLS & SLS) on the REAL TIME MONITOR

[2/2]
Fig. 7-80 Grease level (CLS & SLS) on the REAL TIME MONITOR
7 - 170 PC4000-6 TS 08199-xD-GB-2

G00185 - Trouble central lubrication system

G00188 - Trouble slew ring gear lubrication system
[1/5]
Trouble code G00185 - Trouble central lubrication system
Trouble
G00185 & G00188 G00188 - Trouble slew ring gear lubrication system
Contents of trouble The grease pressure increase time (CLS or SLS) is too long (>10 minutes).
- It is not possible to build up the grease pressure (CLS or SLS) in the pre-set time frame.
Related information - For further details concerning the lubrication system refer to the SERVICE MANUAL,
section LUBRICATION SYSTEMS.
Background colour of the trouble code information: yellow
For testing and troubleshooting the pause time is automatically reduced to 30 seconds and
Action of controller the pressure holding time is automatically reduced to 15 seconds if:
- Service level, REAL TIME MONITOR for CLS/SLS is selected
- Manual lube cycle is started via 20S124 or 20S126
Problem that appears - Risk, to run the machine without CLS/SLS lubrication.
Nominal
value
Qvolume
16-19
double-
Check the performance of the relating grease strokes/
pump (CLS or SLS) and arrange preparations min
for testing the grease pressure.
Ppump drive
Grease pump: Yes Go to next step.
For detailed test & adjustment procedures hydr.pres-
malfunction, worn or 1
refer to the SERVICE MANUAL, section sure
defective
LUBRICATION SYSTEMS. 45±2bar
Make sure that the vent valve is closed. PGrease
Does the relating grease pump build up grease max.
pressure as specified? 180+5bar
Grease pump
No defective, replace
the grease pump.
The electrical function Check the electrical function of the respective Yes Go to next step.
of the vent valve is 2 vent valve solenoid.
Replace the vent valve
disturbed Is the electrical function ok? No
solenoid.
The problem is solved,
The grease may Refill the grease barrel through a filter. Yes perform the final check
3 in step 7.
be soiled Is grease pressure built up with clean grease?
No Go to next step.
Remove the mechanical part from the
electrical part of the respective vent valve. Yes Go to next step.
The mechanical
Disassemble and check the lower part and
function of the vent 4
clean as necessary.
valve is disturbed Replace the vent
Is the mechanical part of the vent valve No
valve.
blocked?
TS 08199-xD-GB-2 PC4000-6 7 - 171


[2/5]
Nominal
value
Repair or replace the mechanical part of the respective
The mechanical part vent valve as necessary.
of the vent valve is 5 Go to next step.
Clean the respective contaminated grease system.
defective
Replace the grease filter and the screen.
Refer to the SERVICE MANUAL, section Yes Go to next step.
End-of-line switch LUBRICATION SYSTEMS, and follow the
(grease main line): adjustment procedure.
6 Replace the respective
wrong adjustment No
or defective Did you need to correct any wrong end-of-line switch.
adjustment?
Final check 7 - Verify that the operation cycles of the lubrication systems correspond to the
following action chart (taken from the flowchart), refer to Fig. 7-81
on page 7-173.
Allocation of vent valves and end-of-line switches
Lubrication system Vent valve End-of-line switch

CLS 62Q507a 80B043
SLS 62Q509a 62B046
7 - 172 PC4000-6 TS 08199-xD-GB-2

Action chart for lube cycles

[3/5]
Fig. 7-81 Action chart for lube cycles
TS 08199-xD-GB-2 PC4000-6 7 - 173

View onto the vent valve (62Q507a/62Q509a)

[4/5]
Fig. 7-82 View onto the vent valve (62Q507a/62Q509a)
(1) Solenoid (5) Reset spring
(2) Valve assembly (6) Auxiliary valve cone
(3) Solenoid stem (7) Main valve cone
(4) Lever
7 - 174 PC4000-6 TS 08199-xD-GB-2

Wiring Diagram (80B043 & 62B046) for trouble codes G00185/G00188

[5/5]
Fig. 7-83 Wiring Diagram (80B043 & 62B046) for trouble codes G00185/G00188
TS 08199-xD-GB-2 PC4000-6 7 - 175


[1/3]
Trouble code G00186 - Trouble central lubrication system
Trouble
G00186 & G00189 G00189 - Trouble slew ring gear lubrication system
Contents of trouble The grease pressure decrease time (CLS or SLS) is too long (>4 minutes).
- It is not possible to release the grease pressure (CLS or SLS) in the pre-set time frame.
Related information - For further details concerning the lubrication system refer to the SERVICE MANUAL,
section LUBRICATION SYSTEMS.
For testing and troubleshooting the pause time is automatically reduced to 30 seconds and
Action of controller the pressure holding time is automatically reduced to 15 seconds if:
- Service level, REAL TIME MONITOR for CLS/SLS is selected
- Manual lube cycle is started via 20S124 or 20S126
Problem that appears - Risk, to run the machine without CLS/SLS lubrication.
Nominal
value
Locate the problem
and repair or replace
The electrical function Check the electrical function of the respective the faulty component
of the respective vent 1 vent valve solenoid and its wiring. of the wiring as
valve is disturbed No necessary.
Is the electrical function ok?
Replace the faulty
vent valve solenoid
if necessary.
- Remove the mechanical part from the electrical part
of the respective vent valve.
The mechanical part - Disassemble and check the lower part and clean
of the vent valve is 2 as necessary. Go to next step.
blocked or defective
- If it is necessary repair or replace the mechanical part.
- Clean the respective contaminated grease system.
Final check 3 - Verify that the operation cycles of the lubrication systems correspond to the
following action chart (taken from the flowchart), refer to Fig. 7-84
on page 7-177.
Allocation of vent valves
Lubrication system Vent valve

CLS 62Q507a
SLS 62Q509a
7 - 176 PC4000-6 TS 08199-xD-GB-2

Action chart for lube cycles

[2/3]
Fig. 7-84 Action chart for lube cycles
TS 08199-xD-GB-2 PC4000-6 7 - 177

View onto the vent valve (62Q507a/62Q509a)

[3/3]
Fig. 7-85 View onto the vent valve (62Q507a/62Q509a)
(1) Solenoid (5) Reset spring
(2) Valve assembly (6) Auxiliary valve cone
(3) Solenoid stem (7) Main valve cone
(4) Lever
7 - 178 PC4000-6 TS 08199-xD-GB-2

G00207 - Engine remote oil tank 1 empty

[1/1]
Trouble code
Trouble 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.
Message delay time = 2 minutes
Risk, to run out of remote engine oil.
on the machine
Nominal
Possible cause Test condition & Inspection Procedure
value
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 QSK45 and QSK60 Series Engines, section
Cummins Engine recommended fluids and lubricants.
The minimum oil quality requirement is CF-4 and higher.
TS 08199-xD-GB-2 PC4000-6 7 - 179

G00216 - Trouble software not compatible

[1/2]
Trouble code
Trouble Trouble software not compatible
G00216
Contents of trouble 5 Minutes after Main Key Switch ON the MTC software performs a software comparison.
Related information
The software comparison includes the following items (refer to the below screenshot from CoDeSys HMI):
Legend for the above sample screen:

(1) Information only
(2) Information only
(3) VHMS (KOMTRAX-Plus) controller software and monitor software are compatible (1 = 1)
(4) Monitor software and MTC software are compatible (1 = 1)
(5) Controller software and MTC software are compatible (1 = 1)
(6) MTC software and MTC machine configuration are not compatible in this sample (1 = 0)
(7) Machine configuration not correct, digit "0" is displayed (digit "1" would be correct)
REMARKS: Details of trouble message G00216 can only be seen on the screen of CoDeSys HMI Visualization software.
- Acoustic signal in the cab ON.
---
on the machine
7 - 180 PC4000-6 TS 08199-xD-GB-2

G00216 - Trouble software not compatible

[2/2]
Nominal
value
Troubleshooting procedure according to the sample screen of CoDeSys HMI on
previous page:
1. Connect your laptop with CoDeSys HMI software to the MTC.
2. Check the machine configuration according to your configuration file (pdf),
Machine configuration which is stored in the MTC.
1
setting is wrong 3. Correct the setting for machine configuration.
4. As soon as the machine configuration matches the original settings,
displayed digit "0" is replaced by digit "1".
Refer to item (7) in above sample screen.
5. If the comparison is correctly displayed as "1 = 1" trouble message G00216
is no longer displayed.
Final check 2
TS 08199-xD-GB-2 PC4000-6 7 - 181

G00218 - Switch off all motors for running transfer pump

[1/1]
Trouble code
Trouble Switch off all motors for running transfer pump
G00218
Contents of trouble This message is displayed, if the transfer pump is switched ON while the engine is running.
For operation instructions of the transfer pump refer to the OPERATION & MAINTENANCE
Related information
MANUAL section3.19.
As long as the engine is running, it is not possible to switch ON the transfer pump.
on the machine
7 - 182 PC4000-6 TS 08199-xD-GB-2

G00220 - Trouble transfer pump motor overheated

[1/2]
Trouble code
Trouble G00220 - Trouble transfer pump motor overheated
G00220
- Temperature switch 40B111 measures the temperature of the electric motor in the transfer pump.
- If the temperature reaches a limit value1), the transfer pump is switched OFF (40B111 opens)
Contents of trouble and message G00220 is displayed.
1)
Switch-off temp. 135°C
Switch-on range ≥35°C
- Temperature switch 40B111 is integrated into the transfer pump.
Related information - For the operation of the transfer pump refer to the OPERATION & MAINTENANCE MANUAL,
section 3.19.
- Acoustic signal in the cab ON.
If 40B111 switched the transfer pump OFF, the oil transfer process can not be continued.
on the machine
Nominal
value
Engine OFF - Main key switch 20S001 ON.
The setting of the Yes Go to next step.
1 Visually check the cocks for correct directions.
cock(s) may be wrong Turn the cocks into
Are the directions of cocks OK? No
their correct position.
Using the infrared thermo-gun verify the Replace the transfer
40B111 is defective or Yes
2 temperature in the area of the temperature pump.
its wiring is short-cut
switch. Replace temperature
No
Does the temperature exceed the limit value? switch 40B111.
Final check 3
TS 08199-xD-GB-2 PC4000-6 7 - 183

Wiring Diagram (transfer pump) for trouble code G00220

[2/2]
Fig. 7-86 Wiring Diagram (transfer pump) for trouble code G00220
7 - 184 PC4000-6 TS 08199-xD-GB-2

G00223 - Trouble starter control 51K001a-1

G00225 - Trouble starter control 51K001b-1
[1/1]
Trouble code G00223 - Trouble starter control 51K001a-1
Trouble
G00223 & G00225 G00225 - Trouble starter control 51K001b-1
- This message is displayed if the electronic relay 51K001a-1 or its wiring is defective (relay check).
Contents of trouble
- The troubleshooting procedure for the redundant relay 51K001b-1 is analogously.
If relay 51K001a-1 or 51K001b-1 or its wiring is defective, the electric circuit is interrupted and the
Related information function (starter) is no longer available.
The function (starter) is not available.
on the machine
– Refer to the Wiring Diagram and check for 51K001a-1/51K001b-1.
01 Engine 1
Sub-screen 6/6
TS 08199-xD-GB-2 PC4000-6 7 - 185

G00224 - Trouble starter control Output to 51K001a-1

G00226 - Trouble starter control Output to 51K001b-1
[1/1]
Trouble code G00224 - Trouble starter control Output to 51K001a-1
Trouble
G00224 & G00226 G00226 - Trouble starter control Output to 51K001b-1
- This message is displayed if the wiring between node output and solenoid (via relay 51K001a-1)
- The troubleshooting procedure for the redundant relay 51K001b-1 is analogously.
- If the connection between node output and solenoid is faulty, the function (starter)
REMARKS: G00224/G00226 is displayed at each trouble occurrence.
The function (starter) is not available.
on the machine
– Refer to the Wiring Diagram and check for 51K001a-1/51K001b-1.
01 Engine 1
Sub-screen 6/6
7 - 186 PC4000-6 TS 08199-xD-GB-2

G00231 - Trouble pilot control lever 20S019

G00232 - Trouble pilot control lever 20S020
[1/3]
Trouble code G00231 - Trouble pilot control lever 20S019
Trouble
G00231 & G00232 G00232 - Trouble pilot control lever 20S020
Contents of trouble This message is displayed if hand lever 20S019 or 20S020 has a problem.
- The zero-position contacts are integrated in the hand lever (left and right)
Related information - If 0V are present at the test contacts 2 and 3 Standard condition
If 24V are present at the test contacts 2 and 3 Trouble condition

The hand lever which is indicated in the trouble message is inoperative.
on the machine
Nominal
value
Open the REAL TIME MONITOR and check the hand
lever signal:
13 Pilot control
Screen 5/6
Refer to the Wiring

Diagram.
Visually inspect the
concerned hand lever
The hand lever or its and the respective
1
wiring is defective wiring.
Repair the wiring
or replace the faulty
hand lever.
After repair go to
Hand lever conditions: final step 2.
Indication Voltage Hand lever

REAL TIME MONITOR present condition
1 0V OK
0 24V Faulty

Final check 2
TS 08199-xD-GB-2 PC4000-6 7 - 187


[2/3]
7 - 188 PC4000-6 TS 08199-xD-GB-2


[3/3]
TS 08199-xD-GB-2 PC4000-6 7 - 189

G00233 - Trouble pilot control 11Q045

[1/2]
Trouble code
Trouble Trouble pilot control 11Q045
G00233
- The message is displayed if the pilot control circuit is disturbed.
Contents of trouble - 11Q045 is an electronic power relay.
- Its contacts 13 and 14 are monitored.
Related information This message is displayed if contacts 13 and 14 at the electronic relay are open.

- Message G00330 "Trouble pilot control 11Q111" may also be displayed if G00233 is set.
Pilot control is inoperative.
on the machine
Nominal
value
Refer to the Wiring
Visually check the power relay 11Q045. Diagram.
Standard conditions of the LEDs: Visually inspect the
Relay 11Q045 or its relay and its wiring.
wiring is defective
1 LED yellow ON OK
LED red ON OK (contacts closed) Repair the wiring
or replace the faulty
If the red LED is OFF, the relay is defective and needs relay, as necessary.
replacement. After repair go to
final step 2.
Final check 2
7 - 190 PC4000-6 TS 08199-xD-GB-2

Wiring Diagram (11Q045) for trouble code G00233

[2/2]
Fig. 7-89 Wiring Diagram (11Q045) for trouble code G00233
TS 08199-xD-GB-2 PC4000-6 7 - 191

G00234 - Trouble pilot control 11K111a

G00236 - Trouble pilot control 11K111b
[1/1]
Trouble code G00234 - Trouble pilot control 11K111a
Trouble
G00234 & G00236 G00236 - Trouble pilot control 11K111b
Contents of trouble
Related information function (pilot control) is no longer available.
The function (pilot control) is not available.
on the machine
13 Pilot control
Sub-screen 6/6
7 - 192 PC4000-6 TS 08199-xD-GB-2

G00235 - Trouble pilot control Output to 11K111a

G00237 - Trouble pilot control Output to 11K111b
[1/1]
Trouble code G00235 - Trouble pilot control Output to 11K111a
Trouble
G00235 & G00237 G00237 - Trouble pilot control Output to 11K111b
- If the connection between node output and solenoid is faulty, the function (pilot control)
on the machine
13 Pilot control
Sub-screen 6/6
TS 08199-xD-GB-2 PC4000-6 7 - 193

G00238 - Trouble supply by key switch 11Q044

[1/2]
Trouble code
Trouble G00238 - Trouble supply by key switch 11Q044 (self holding circuit).
G00238
- 11Q044 is switched by main key switch 20S001.
Contents of trouble
- 11Q044 is a main circuit breaker which is not power-supplied by 11Q100.
- If the safety circuit is closed, 11Q044 must also be closed.
Related information - The message is displayed if contacts 11 and 12 at 11Q044 are closed, and the power input at
node #2 (connector 7, pin 5) is 24V.
- The output of 11Q044 (contacts 11 & 12) is monitored via node #2, connector 7, pin 5.
- The MTC blinks out binary code 011001.
---
on the machine
Nominal
value
- Replace 11Q044
Refer to the Wiring Diagram. (contacts welded
11Q044 or its wiring is - Check if contacts 11 and 12 at 11Q044 are closed together)
1
defective (fault). or
- Verify if 24V are present at node #2, connector 7, - Repair the wiring as
pin 5 (fault). necessary
(short circuit)
Final check 2
Input signal of 11Q044 on the REAL TIME MONITOR (G00238)
Fig. 7-90 Input signal of 11Q044 on the REAL TIME MONITOR (G00238)
If 11Q044 indication on the REAL TIME MONITOR = 0 Monitoring result = OK
If 11Q044 indication on the REAL TIME MONITOR = 1 Monitoring result = Fault
7 - 194 PC4000-6 TS 08199-xD-GB-2


[2/2]
TS 08199-xD-GB-2 PC4000-6 7 - 195


[1/1]
Trouble code
Trouble Trouble hydraulic oil temperature
G00240
- Sensor 59B015 in the hydraulic oil tank signals that the hydraulic oil temperature (< T1) is far
below the operating temperature (T2).
- Below the hydraulic oil operating temperature T2 the pump regulation is automatically set
Contents of trouble
to ½Qmax.
- The system assumes that the hydraulic oil temperature sensor 59B015 and its wiring circuit are
not defective.
- Sensor 59B015 detects an hydraulic oil temperature <T1 for 5 seconds.
Related information - For the definition of the hydraulic oil temperatures T1, T2, T3, T4 refer to the below hydraulic oil
temperature table.
Action of controller - On condition that the engine is running: the fan speed is set to min. speed.
- Trouble messages G00246 and G00257 are also set automatically.
- The hydraulic oil temperature (<T1) is far below the operating temperature (T2).
- On this condition the hydraulic oil needs pre-heating or warming-up at low idle before starting to
work.
Information:
on the machine - Below the hydraulic oil operating temperature T2 the back pressure valve 40K601 is energized
(24V). The hydraulic return oil flow to the collector pipe is led directly through the filters into the
hydraulic oil tank (not through the hydraulic oil coolers).
- As soon as the hydraulic oil reaches the operating temperature, the back pressure valve 40K601
will be de-energized (0V) and the hydraulic oil flow is led through the oil coolers.
Hydraulic oil far below operating temperature!
Pre-heat hydraulic oil or warm up at low idle speed and reduced power.
Nominal
value
Engine running at low idle.
- Start to warm-up the hydraulic oil by running the engine at low idle or by pre-heating.
- As soon as the hydraulic oil temperature T1 is reached, the trouble message G00240 is no longer
displayed.
- Continue warming-up until the hydraulic oil operating temperature T2 is reached.
- If it is a problem to warm-up the hydraulic oil up to the operating temperature T2, check the setting
for the hydraulic oil specification in the service mode of VHMS.
- Also verify that the correct type of hydraulic oil is used (according to the ambient temperature).
- In case the setting for the hydraulic oil in VHMS would be wrong, correct the setting according to
the specification of the used hydraulic oil.
The hydraulic oil Hydraulic oil temperature table

temperature (< T1) is
far below the operating
temperature (T2)
7 - 196 PC4000-6 TS 08199-xD-GB-2

G00242 - Engine 1 already running

[1/1]
Trouble code
Trouble Engine 1 already running
G00242
Contents of trouble This message informs the operator that the engine is already running.
After this message is displayed, every further engine start is blocked as long as the engine is still
Related information
running.

on the machine
Instruction message 22 Engine runs (starter motor inactive).
G00243 - Fill up fuel tank

[1/1]
Trouble code
Trouble 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 ---

Risk, to run out of fuel.
on the machine
Instruction message 23 A fuel reserve only is still in the tank - Order tanker.
Nominal
value
- 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 QSK45 and QSK60 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.
TS 08199-xD-GB-2 PC4000-6 7 - 197

G00245 - Engine shutdown from ground

[1/2]
Trouble code
Trouble Engine shutdown from ground
G00245
- Machine configuration "Engine shutdown from ground" is selected.
Contents of trouble
- The engine has been stopped from the ground manually via switch 54S007 and/or 54S008.
- If switch 54S007 or 54S008 is activated from ground while the engine is running, the engine shuts
down.
Related information
- After switch 54S007 or 54S008 has been activated from ground under condition "Engine OFF &
main key switch 20S001 ON", engine start is not possible.
- The MTC blinks out binary code 011011.
Problem that appears The engine is shut off and restart is not possible until switch 54S007 and/or 54S008 is manually
on the machine switched back into its neutral position.
Instruction message 24 Engine shutdown has been actuated from ground man.
Nominal
value
Contact your supervi-
sor and clarify the
situation.
The engine shutdown Check the cause for the manually activated After the cause for
was manually activated 1 engine shutdown. Yes the engine shutdown
from ground Was switch 54S007 and/or 54S008 manually is clarified, release
activated from ground? switch 54S007 and/or
54S008 and restart
the engine.
No Go to next step.
Switche(s) may have
been activated
Yes accidently.
Actuate switch 54S007/54S008 and verify the
Go to final step 3.
input signal via VHMS:
Refer to the Wiring
No input signal on REAL TIME MONITOR. Diagram. Check switch
2 (refer to Fig. 7-92 on page 7-199) 54S007/54S008 and
the VHMS monitor
07 Manual Switch its wiring.
Screen 4/4 Locate the problem
No
and repair as
Is the input signal of the switches displayed on
necessary.
the VHMS monitor?
After repair, recheck
switches for proper
function.
Final check 3
7 - 198 PC4000-6 TS 08199-xD-GB-2

Input signal of 54S007 & 54S008 on the REAL TIME MONITOR (G00245)
[2/2]
Fig. 7-92 Input signal of 54S007 & 54S008 on the REAL TIME MONITOR (G00245)
TS 08199-xD-GB-2 PC4000-6 7 - 199

G00246 - Hydraulic oil temperature

[1/1]
Trouble code
Trouble Hydraulic oil temperature
G00246
- Sensor 59B015 in the hydraulic oil tank signals that the hydraulic oil temperature is cold,
- Below the hydraulic oil operating temperature T2 the pump regulation is automatically set to
Contents of trouble
½Qmax.
not defective.
- The sensor 59B015 detects an hydraulic oil temperature <T2 for 5 seconds.
temperature table.
- On condition that the engine is running: the fan speed is set to min. speed.
- The hydraulic oil temperature is below the operating temperature (T2).
- Below the hydraulic oil operating temperature T2 the back pressure valve 40K601 is energized
Problem that appears (24V). The hydraulic return oil flow to the collector pipe is led directly through the filters into the
on the machine hydraulic oil tank (not through the hydraulic oil coolers).
Hydraulic oil below operating temperature.
Operate with reduced power!
Nominal
value
- Keep the engine running under operating conditions.
displayed.
Hydraulic oil temperature table
The hydraulic oil is
too cold - below the
operating temperature
(T2)
7 - 200 PC4000-6 TS 08199-xD-GB-2

G00252 - Emergency shut-down at access ladder

G00254 - Emergency shut-down at hydraulic control panel
[1/2]
Trouble code G00252 - Emergency shut-down at access ladder

Trouble
G00252 ~ G00255 G00254 - Emergency shut-down at hydraulic control panel
Emergency shut-down switch was activated when the engine was running.
Emergency shut-down switch Location Trouble code

70S033a Access ladder G00252
Contents of trouble
61S033b Valve block G00253
57S033c Hydraulic control panel G00254
20S036 Operator's cab G00255
- The engine is shut off.

Related information
- Restart is impossible.
- If any of the emergency shut-down switches was activated, message G00053 Reset emergency
safety circuit is also displayed. In order tor reset the emergency condition, move the main key
Action of controller switch to OFF and wait until the MTC is totally shut down. Then turn the main key switch to ON
again.
- The MTC blinks out a binary code:
G00252 - 011100 G00253 - 011101 G00254 - 011110 G00255 - 011111
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.
Nominal
value
Rectify the cause or
the problem.
After that release the
Any emergency Check the cause for the emergency activation. Yes concerned emergency
shut-off button 1
Is any cause present? shut-down switch(es)
was activated
and reset the emer-
gency condition.
No Go to next step.
Refer to the Wiring
Diagram.
The concerned
emergency shut-off Visually inspect the concerned switch, the switch
2 concerned switch or its
button or its wiring contact, and the respective wiring.
wiring as necessary.
may be defective
After repair go to
final step 3.
Final check 3
in order to reset the binary code 011100 or 011101 or 011110 or 011111.
TS 08199-xD-GB-2 PC4000-6 7 - 201

Wiring Diagram (emergency switches) for trouble codes G00252~G00255

[2/2]
switches 54S051 and 54S052 (option)

Only present if not equipped with
Fig. 7-93 Wiring Diagram (emergency switches) for trouble codes G00252~G00255
7 - 202 PC4000-6 TS 08199-xD-GB-2

G00257 - Hydraulic oil temperature

[1/1]
Trouble code
Trouble Hydraulic oil temperature
G00257
- Sensor 59B015 in the hydraulic oil tank signals that the hydraulic oil temperature (<T1) is far
- Below the hydraulic oil operating temperature T2 the pump regulation is automatically set
Contents of trouble
to ½Qmax
not defective.
- Sensor 59B015 detects an hydraulic oil temperature <T1 for 5 seconds.
temperature table.
Action of controller - On condition that the engine is running: the fan speed is set to min. speed.
- Trouble messages G00240 and G00246 are also set automatically.
- The hydraulic oil temperature (<T1) is far below the operating temperature (T2).
- On this condition the hydraulic oil needs pre-heating or warming-up at low idle before starting to
work.
Problem that appears Information:

on the machine - Below the hydraulic oil operating temperature T2 the back pressure valve 40K601 is energized
(24V). The hydraulic return oil flow to the collector pipe is led directly through the filters into the
hydraulic oil tank (not through the hydraulic oil coolers).
Hydraulic oil far below operating temperature!
Pre-heat hydraulic oil or warm up at low idle speed and reduced power.
Nominal
value
- Start to warm-up the hydraulic oil by running the engine at low idle or by pre-heating.
displayed.
- Continue warming-up until the hydraulic oil operating temperature T2 is reached.
The hydraulic oil Hydraulic oil temperature table

temperature (<T1) is
far below the operating
temperature (T2)
TS 08199-xD-GB-2 PC4000-6 7 - 203

G00261 - Maintenance Safety Switch

[1/2]
Trouble code
Trouble Maintenance Safety Switch
G00261
- The maintenance safety switch 50S058 is switched OFF during maintenance or repair.
Contents of trouble
- Engine start is blocked for safety reasons.
Related information Switch 50S058 is the maintenance safety switch which can be secured with padlocks (supervisor).

Machine is blocked during maintenance or repair.
on the machine
Instruction message 11 Engine switched off by Maintenance Safety Switch in the engine room.
Nominal
value
Contact your
The maintenance
Check the condition of the maintenance safety supervisor and clarify
safety switch 50S058
1 switch. Yes the reason why the
is switched OFF for
Is the maintenance safety switch switched maintenance safety
service
OFF? switch is switched off.
No Go to next step.
a) Switch 50S058:
Repair or replace
as necessary.
Yes b) Wiring of 50S058:

Refer to the Wiring
Diagram. Locate the
Malfunction of the problem and repair
maintenance safety Check the function of the maintenance safety as necessary.
2
switch 50S058 or its switch and its wiring. Verify if other trouble
wiring Could you identify any trouble? codes are displayed,
which may cause the
problem.
No If any suspicious
trouble code is
displayed, follow
the relating trouble-
shooting chart.
Final check 3
7 - 204 PC4000-6 TS 08199-xD-GB-2


[2/2]
switches 54S051 and 54S052 (option)

Only present if not equipped with
TS 08199-xD-GB-2 PC4000-6 7 - 205

G00262 - Trouble screen at hydr. cooler entry clogged

[1/3]
Trouble code
Trouble Trouble screen at hydraulic cooler entry clogged
G00262
- Pressure sensors 40B166 & 40B165 signal pressures of 0-60 bar in front of and behind the
strainer in the collector pipe leading to the hydraulic oil cooler. The pressure difference represents
Contents of trouble the pressure drop in the strainer.
- The system assumes that the strainer is clogged if the pressure difference exceeds 2.5 bar.
The system assumes that the pressure sensors 40B166 & 40B165 and their wiring are
Related information
not defective.

Risk, to run the machine with insufficient cooling of the hydraulic oil.
on the machine
Nominal
value
Replace the faulty
Pressure sensors Check the pressure sensors for proper pressure sensor and
Yes
40B166 & 40B165 may 1 function. recheck for proper
have a malfunction Is a pressure sensor faulty? function.
No Go to next step.
The strainer in the - Remove the oil strainer in the collector pipe.
collector pipe (oil flow
2 - Clean or replace the strainer as necessary.
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.
Final check 3
40B166 and 40B165 on the REAL TIME MONITOR 03 Hydraulic (G00262)
Fig. 7-95 40B166 and 40B165 on the REAL TIME MONITOR 03 Hydraulic
7 - 206 PC4000-6 TS 08199-xD-GB-2

Location of 40B166 and 40B165 at the hydraulic oil tank (G00262)

[2/3]
Fig. 7-96 Location of 40B166 and 40B165 at the hydraulic oil tank
TS 08199-xD-GB-2 PC4000-6 7 - 207

Wiring Diagram (40B166 & 40B165) for trouble code G00262

[3/3]
Fig. 7-97 Wiring Diagram (40B166 & 40B165) for trouble code G00262
7 - 208 PC4000-6 TS 08199-xD-GB-2

G00308 - Trouble CAN-Bus or CAN-Hardware

[1/3]
Trouble code
Trouble Trouble CAN-Bus or CAN-Hardware
G00308
If this message appears, the internal CAN bus (between MTC and nodes) has a problem.
Other faults which may cause this trouble message are:
Contents of trouble - Defective or disconnected end resistor (40R101 / 20R101).
- Wrong setting of the DIP switches at any node.
- Defective node unit (hardware).
To identify the trouble location in the CAN bus quickly, use the following system information in order
to receive essential details:
1) Open the REAL TIME MONITOR (VHMS)
Related information 05 Electrical Equipm.
Screen 3/3
2) Binary blink codes at the MTC.
3) CoDeSys HMI visualization (CAN bus overview).
- The MTC blinks out binary code 111111 plus an add-on binary code which indicates details about
the kind of trouble (refer to "Table of Add-On Binary Codes for G00308" on page 6-16).
- Acoustic signal ON.
- Engine shut-down.
- Engine restart is blocked.
on the machine
- An emergency operation mode or a bypass function are not available.
Stop the engine.
- Inform service.
For the troubleshooting procedure (G00308) go to next page.
– For further information on G00308 also refer to "CAN-Bus trouble or Node Output Trouble" on page 5-2.
– For further information on CAN bus basics and "How to crimp" repair instructions refer to the
SERVICE MANUAL chapter 14.
TS 08199-xD-GB-2 PC4000-6 7 - 209


[2/3]
Nominal
value
Method 1
Troubleshooting on the basis of REAL TIME MONITOR
information.
Screen 3/3
With the help of beside

information, locate the
problem in the CAN
bus.
Legend: Start troubleshooting at
node 14, which is the
(1) CAN-NODE ERROR TYPE indications nearest affected node
Cable disconnection in
1
the internal CAN bus "0" No disconnection in the CAN bus OK to the MTC.
"1" Disconnection the CAN bus Fault After repair, if neces-
"2" Short circuit in the CAN bus Fault sary continue trouble-
shooting at other
indicated nodes which
(2) CAN-NODE NUMBER are farther away from
the MTC.
In case of trouble in the CAN bus, the number of
that node with problems is indicated, which is Repair as necessary.
nearest to the MTC.
For the sequence of nodes in the CAN bus system
refer to section 5.1 on page 5-2.
If "0" is indicated, the system is OK.
The above sample screen shows:

(1) A disconnection in the CAN bus is detected.
(2) Node 14 is the nearest node to the MTC,
which is affected by the disconnection fault.
It may be possible that nodes behind node 14 are
affected as well.
7 - 210 PC4000-6 TS 08199-xD-GB-2


[3/3]
Nominal
value
Method 2
Troubleshooting by using the MTC blink codes. With the help of beside
For further information on the binary blink codes refer
problem in the CAN
to the OPERATION & MAINTENANCE MANUAL:
bus.
Start troubleshooting
This method is used if: at the indicated node
- VHMS is not updated and the REAL TIME MONITOR which is nearest to
Cable disconnection in screen 3/3, which is used in step 1, is not available. the MTC.
2
the internal CAN bus
- The VHMS monitor is OFF. Repair as necessary
After repair, if neces-

Procedure: sary continue trouble-
shooting at other
- Read out the binary blink codes at the MTC.
indicated nodes which
- Put the binary codes in the system order, according to are farther away from
"Sequence of the CAN nodes at the CAN bus" on the MTC.
page 5-6.
Repair as necessary.

Method 3
Troubleshooting on the basis of CoDeSys HMI
Cable disconnection in
3 Visualization.
the internal CAN bus
The following sample screen "AC01 overview
CANopen Bus" shows all nodes which are
disconnected from the CAN bus.
With the help of beside

problem in the CAN
bus.
Start troubleshooting at
node 14 which is near-
est to the MTC.
Repair as necessary
After repair at node 14
continue troubleshoot-
ing at node 11 which is
farther away from the
MTC than node 14.
Repair as necessary.
(1) Trouble at node 14 (red marked)

continued 3 (2) Trouble at node 11 (red marked)
Node 14 is closer to the MTC than node 11.
TS 08199-xD-GB-2 PC4000-6 7 - 211

G00309 - Trouble ladder up 56K253a

G00311 - Trouble ladder up redundant 56K253b
[1/1]
Trouble code G00309 - Trouble ladder up 56K253a
Trouble
G00309 & G00311 G00311 - Trouble ladder up redundant 56K253b
Contents of trouble
Related information function (ladder up) is no longer available.
The function (ladder up) is not available.
on the machine
11 Ladder
Sub-screen 4/5
7 - 212 PC4000-6 TS 08199-xD-GB-2

G00310 - Trouble ladder up Output to 56K253a

G00312 - Trouble ladder up redundant Output to 56K253b
[1/1]
Trouble code G00310 - Trouble ladder up Output to 56K253a
Trouble
G00310 & G00312 G00312 - Trouble ladder up redundant Output to 56K253b
- If the connection between node output and solenoid is faulty, the function (pilot control)
on the machine
11 Ladder
Sub-screen 3/5
TS 08199-xD-GB-2 PC4000-6 7 - 213

G00313 - Trouble ladder down 56K254a

G00315 - Trouble ladder down redundant 56K254b
[1/1]
Trouble code G00313 - Trouble ladder down 56K254a
Trouble
G00313 & G00315 G00315 - Trouble ladder down redundant 56K254b
Contents of trouble
Related information function (ladder down) is no longer available.
The function (ladder down) is not available.
on the machine
11 Ladder
Sub-screen 4/5
7 - 214 PC4000-6 TS 08199-xD-GB-2

G00314 - Trouble ladder down Output to 56K254a

G00316 - Trouble ladder down redundant Output to 56K254b
[1/1]
Trouble code G00314 - Trouble ladder down Output to 56K254a
Trouble
G00314 & G00316 G00316 - Trouble ladder down redundant Output to 56K254b
- If the connection between node output and solenoid is faulty, the function (ladder down)
The function (ladder down) is not available.
on the machine
11 Ladder
Sub-screen 3/5
TS 08199-xD-GB-2 PC4000-6 7 - 215

G00317 - Trouble service arm up 56K255a

G00319 - Trouble service arm up redundant 56K255b
[1/1]
Trouble code G00317 - Trouble service arm up 56K255a
Trouble
G00317 & G00319 G00319 - Trouble service arm up redundant 56K255b
Contents of trouble
Related information function (service arm up) is no longer available.
The function (service arm up) is not available.
on the machine
12 Service arm
Sub-screen 4/5
7 - 216 PC4000-6 TS 08199-xD-GB-2

G00318 - Trouble service arm up Output to 56K255a

G00320 - Trouble service arm up redundant Output to 56K255b
[1/1]
Trouble code G00318 - Trouble service arm up Output to 56K255a
Trouble
G00318 & G00320 G00320 - Trouble service arm up redundant Output to 56K255b
- If the connection between node output and solenoid is faulty, the function (service arm up)
The function (service arm up) is not available.
on the machine
12 Service arm
Sub-screen 3/5
TS 08199-xD-GB-2 PC4000-6 7 - 217

G00321 - Trouble service arm down 56K256a

G00323 - Trouble service arm down redundant 56K256b
[1/1]
Trouble code G00321 - Trouble service arm down 56K256a
Trouble
G00321 & G00323 G00323 - Trouble service arm down redundant 56K256b
Contents of trouble
Related information function (service arm down) is no longer available.
The function (service arm down) is not available.
on the machine
12 Service arm
Sub-screen 4/5
7 - 218 PC4000-6 TS 08199-xD-GB-2

G00322 - Trouble service arm down Output to 56K256a

G00324 - Trouble service arm down redundant Output to 56K256b
[1/1]
Trouble code G00322 - Trouble service arm down Output to 56K256a
Trouble
G00322 & G00324 G00324 - Trouble service arm down redundant Output to 56K256b
- If the connection between node output and solenoid is faulty, the function (service arm down)
The function (service arm down) is not available.
on the machine
12 Service arm
Sub-screen 3/5
TS 08199-xD-GB-2 PC4000-6 7 - 219

G00325 - Trouble service arm Input

G00326 - Trouble ladder Input
G00327 - Trouble parking brake Input
G00328 - Trouble start Input
[1/3]
Trouble code G00325 Trouble service arm Input
G00326 Trouble ladder Input
G00325 G00327 Trouble
G00327 Trouble parking brake Input
G00326 G00328 G00328 Trouble start Input
These trouble codes monitor the primary or redundant input of the switches at the nodes.
Switch location and trouble codes:
Trouble code Switch Location
Contents of trouble G00325 55S087 Refilling arm

G00326 70S084 Access ladder
G00327 20S029 Cab
G00328 20S004 Dashboard in cab
Related information The trouble code is displayed if the primary or redundant switch input is missing.

While the trouble code is set, the respective function can not be switched / activated.
on the machine
Nominal
value
12 Service arm
Screen 1/5
1. Refer to the Wiring

Diagram.
2. Visually inspect the
concerned switch,
the switch contact,
Displayed:
and the respective
G00325 1 wiring.
Trouble service arm
3. Locate the problem.
Input
4. Repair or replace
the concerned
switch or its wiring
as necessary.
If the displayed value is "1" the function is OK/available.
5. After repair go to
If G00325 is displayed, the input signal of 55S087 or final step 2.
55S087r is missing. In this case "0" is indicated on
the REAL TIME MONITOR, and the function is not
available.
7 - 220 PC4000-6 TS 08199-xD-GB-2


[2/3]
Nominal
value
11 Ladder
Screen 1/5

Diagram.
concerned switch,
the switch contact,
Displayed: and the respective
G00326 1 wiring.
Trouble ladder Input 3. Locate the problem.
the concerned
as necessary.
If the displayed value is "1" the function is OK/available.
5. After repair go to
If G00326 is displayed, the input signal of 70S084_UP final step 2.
or 70S084rUP is missing. In this case "0" is indicated
on the REAL TIME MONITOR, and the function is not
available.

07 Manual Switch
Screen 2/4

Diagram.
concerned switch,
the switch contact,
Displayed:
and the respective
G00327 1 wiring.
Trouble parking brake
3. Locate the problem.
Input
the concerned
If the displayed value is "1" the function is OK/available. switch or its wiring
If G00327 is displayed, the input signal of 20S029 or as necessary.
20S029r is missing. In this case "0" is indicated on 5. After repair go to
the REAL TIME MONITOR, and the function is not final step 2.
available.
Indication
Switch condition Brake
REAL TIME MONITOR
1 ON Released
0 OFF Applied
TS 08199-xD-GB-2 PC4000-6 7 - 221


[3/3]
Nominal
value
07 Manual Switch
Screen 1/4

Diagram.
concerned switch,
the switch contact,
Displayed: and the respective
G00328 1 wiring.
Trouble start Input 3. Locate the problem.
the concerned
During engine start the indication for 20S004-1 and as necessary.
20S004r-1 should be "1". 5. After repair go to
If G00328 is displayed, the input signal of 20S004-1 or final step 2.
20S004r-1 is missing. In this case "0" is indicated on
the REAL TIME MONITOR, and the function is not
available (engine start impossible).

Final check 2
7 - 222 PC4000-6 TS 08199-xD-GB-2


[1/3]
Trouble code
Trouble Trouble pilot control 11Q111
G00330
- The message is displayed if the pilot control circuit is disturbed.
Contents of trouble
- Contacts 13 and 14 of 11Q111 are monitored by 11K126.
- 11Q111 is the main contactor for the pilot control circuit.
- With 11K126 the signal contacts 13 and 14 of 11Q111 are monitored for "welded together" or
Related information
"sticking together".
- Only contacts 13 and 14 of 11Q111 are used for pilot control supervision.
Action of controller - Message G00233 "Trouble pilot control 11Q045" is also displayed if a fault at 11Q111 is detected.
Both messages (G00330 and G00233) are always displayed together.
Pilot control is inoperative.
on the machine
Nominal
value
Check the condition (0 or 1) of the monitoring relay
11K126 on the REAL TIME MONITOR.

13 Pilot control
Screen 5/6
11Q111 or its wiring If "1" is displayed

1 repair the wiring
is defective
or replace 11Q111
if necessary.
Indication "0" means: Pilot control is active

Indication "1" means: Pilot control is inactive (fault)
TS 08199-xD-GB-2 PC4000-6 7 - 223


[2/3]
Nominal
value
Visually check 11K126.
Refer to the Wiring

Diagram and locate the
11K126 or its wiring
2 problem.
is defective
Replace or repair the
relay or its wiring as
necessary
(1) LED yellow (4) A1 = 24V

(2) LED red (5) Switch contacts (13/14)
(3) A2 = GND
Standard conditions of the LEDs:

0V at relay 11K126
24V at relay 11K126

LED orange 24V input ON
LED red 24V output ON

Final check 3
7 - 224 PC4000-6 TS 08199-xD-GB-2

Wiring Diagram (11Q111/11K126) for trouble code G00330

[3/3]
Fig. 7-98 Wiring Diagram (11Q111/11K126) for trouble code G00330
TS 08199-xD-GB-2 PC4000-6 7 - 225

G00331 - Automatic after_running engine 1

[1/1]
Trouble code
Trouble Automatic after_running engine 1
G00331
- Engine after-run is a cool down period for Diesel engines.
It is an option in the machine configuration menu (CoDeSys HMI).
Contents of trouble
- When the engine stop button 20S005-1 is pressed, this message remembers the operator
that the engine needs to run at low idle for cooling down before the engine is shut-down.
Related information - If this message is set, a 5 minutes "Diesel cooling down period" will follow up.

- The cooling down period over 5 minutes is a programmed delay.
- After the engine cooling down period is completed, message G00352 (Engine 1 standstill)
is displayed for 5 seconds.
---
on the machine
Instruction message 57 Cool down period !
7 - 226 PC4000-6 TS 08199-xD-GB-2

G00333 - Trouble battery charger relay

[1/2]
Trouble code
Trouble Trouble battery charger relay
G00333
- Relay 11Q122 switches the stabilized power supply.
Contents of trouble
- Power supply comes from the circuit breaker 11F019.
This trouble message is displayed, if the wiring circuit from 11F019 via 11Q122 (contacts 11 & 12)
Related information
to node 2 (connector 1, pin 5) is disturbed.
Problem that appears - Batteries are not charged properly.

on the machine - Running the risk of flat batteries.
Nominal
value
Refer to the Wiring Diagram and check the

wiring circuit from 11F019 to:
Relay 11Q122 or its Locate the problem. Node 2
1 → 11Q122 (contacts 11 & 12) Repair the wiring connector 1
wiring is defective
→ node 2 (connector 1, pin 5) or replace the relay pin 5
as necessary. 24V
If the condition is normal, 24V are present at node 2
(connector 1, pin 5)

Final check 2
TS 08199-xD-GB-2 PC4000-6 7 - 227


[2/2]
7 - 228 PC4000-6 TS 08199-xD-GB-2

G00351 - Engine 1 running

[1/1]
Trouble code
Trouble Engine 1 running
G00351
Contents of trouble When the engine starts running this message is displayed for 5 seconds.
- This is an informational message.

Related information
- No further action is required.
Action of controller ---

---
on the machine
Instruction message --- ---
G00352 - Engine 1 standstill

[1/1]
Trouble code
Trouble Engine 1 standstill
G00352
Contents of trouble When the engine is shut down this message is displayed for 5 seconds.
- This is an informational message.

Related information
- No further action is required.
Action of controller ---

---
on the machine
Instruction message ---
TS 08199-xD-GB-2 PC4000-6 7 - 229

G00417 - Communication failure PLC [MTC] <=> VHMS-controller

[1/1]
Trouble code
Trouble Communication failure PLC [MTC] <=> VHMS-controller
G00417
Contents of trouble The communication between MTC and VHMS controller is impossible.
- Communication between MTC and VHMS controller takes place via a serial connection.
Related information - At the MTC the serial cable is connected to the COM2 port.
- At the VHMS controller the serial cable is connected to the CN3A port.
Problem that appears Data exchange between MTC and VHMS controller, e.g. the monitoring function and the memory
on the machine function, are disabled.
Nominal
value
Disconnection in the - Visually check the serial harness and its Yes Go to next step.
serial wiring between connectors.
Reconnect the serial
MTC and VHMS - Verify that the serial connector at the MTC connector orderly to
1
controller or the contact side is connected to the COM2 port. the COM2 port of the
in any connector is No
Is the serial harness in proper condition and is MTC or locate the
defective problem and repair as
the connector at the MTC side plugged into the
COM2 port? necessary.
Check the MTC & Rmax 1Ω
VHMS controller
programs for
compatibility
via CodeSys.
The serial cable Disconnect the serial connectors from MTC If further information is
may be defective Yes
2 and VHMS controller and measure the wiring required:
(no continuity) harness for continuity. Please note the serial
Is continuity present? numbers of VHMS
monitor & controller
and contact your
dealer or KMG.
Replace the CAN bus
No
harness.
Final check 3
Serial harness and ports between MTC and VHMS controller
Fig. 7-100 Serial harness and ports between MTC and VHMS controller
7 - 230 PC4000-6 TS 08199-xD-GB-2

G00420 - Connector sel error

[1/1]
Trouble code
Trouble Connector sel error
G00420
- The cable connectors at the VHMS controller are mixed up.
It is also possible that single wires of any wire harness at the VHMS controller are connected to
Contents of trouble wrong connector pins.
- The wiring to the VHMS controller may be damaged (or short cut).
- It is necessary to check the repair history.
Related information - In case any repair has been done at the VHMS wiring, the wiring needs a double-check.
For detailed information on the wiring of the VHMS controller refer to the SERVICE MANUAL,
chapter 14.6 Wiring of the VHMS-Controller.

The monitoring system is disturbed.
on the machine
Nominal
value
The cable connectors Refer to the Wiring Diagram and to the S/M Yes Go to next step. SERVICE
at the VHMS controller 1 and check the cable connectors at the VHMS MANUAL
may be mixed up. controller for their correct connection order. Plug in the connectors chapter
No
in their correct order. 14.6
Are all connectors orderly plugged in?
In case any repair has been done at the Yes Go to next step.
Cables may be system before, check if all cables are SERVICE
connected to wrong 2 connected to their conforming connector pins. MANUAL
connector pins Refer to the Wiring Diagram and to the S/M. Reconnect the cables
chapter
No to their conforming
Are all cables connected to their conforming 14.6
pins.
pins?
Refer to the Wiring Diagram and check the cables
The wiring at the Replace any defective
and their connectors at the VHMS controller for any
VHMS controller is 3 component or repair Wiring
damage.
damaged (or short cut) any wiring malfunction Diagram
Disconnect the connectors from the VHMS controller as necessary.
and measure the wire harnesses for continuity.
Final check 4
TS 08199-xD-GB-2 PC4000-6 7 - 231

G00421 - Farm sys error

[1/1]
Trouble code
Trouble Farm sys error
G00421
- The firmware of the VHMS controller has a problem.
Contents of trouble
- A new upload is necessary or the VHMS controller needs replacement.
- The operation system has a basic problem.
Related information
- For further information contact your dealer or KMG.
- No VHMS/monitoring operation.
The VHMS system is inoperative.
on the machine
Nominal
value
The firmware has
1 Upload new firmware or replace the VHMS controller.
a problem
Final check 2
7 - 232 PC4000-6 TS 08199-xD-GB-2

G00422 - Can-net sys (J1939)

[1/1]
Trouble code
Trouble Can-net sys (J1939)
G00422
The VHMS controller does not receive any signal from QUANTUM controller (engine control)
Contents of trouble
via CAN bus no. 0.
Related information Engine speed >300 1/min

Real time monitoring of the engine is not possible.
on the machine
Nominal
value
The connection Main key switch 20S001 ON.
between VHMS and
Check wiring, connectors, and pins between VHMS and the engine control
the engine control 1 Wiring
system QUANTUM for proper order and connection.
system QUANTUM Diagram
is inoperative Repair or replace components according to the Wiring Diagram.
Final check 2
TS 08199-xD-GB-2 PC4000-6 7 - 233

G00423 - Application sys error

[1/1]
Trouble code
Trouble Application sys error
G00423
- The software application of to the VHMS controller has a problem.
Contents of trouble
- A new software release is necessary.
Related information The VHMS software is inoperative.
- No VHMS/monitoring operation.
- Background colour of the trouble code information: yellow.
The VHMS system is inoperative.
on the machine
Nominal
value
The software has A new release of the VHMS software is necessary - change VHMS controller.
1
a problem Contact your dealer for further details.
Final check 2
7 - 234 PC4000-6 TS 08199-xD-GB-2

G00425 - Settings impossible to take over into the PLC

[1/2]
Trouble code
Trouble Settings impossible to take over into the PLC [MTC]
G00425
- It is impossible to take over the settings into the MTC memory, which are input via the
Contents of trouble VHMS monitor.
- That means: any modification of the settings is impossible.
After the system failed 10 times to build up a connection between
VHMS monitor → VHMS controller → MTC, trouble code G00425 is displayed.
Related information REMARKS: Trouble codes G00417 and G00491 may be displayed as well. In case these trouble
codes are displayed at the same time, first follow the instructions of G00417 and/or
G00491 before starting troubleshooting according to G00425.

It is impossible to modify any settings via the VHMS monitor.
on the machine
Nominal
value
On condition that
trouble codes G00417 Program re-load (MTC / VHMS controller) or replacement of the units is necessary.
& G00491 are not
displayed, any If further information is required in this case:
software or hardware Note the serial numbers of the VHMS controller and VHMS monitor and contact your
problem may be dealer or KMG.
present
Final check
TS 08199-xD-GB-2 PC4000-6 7 - 235

Wiring Diagram overview for G00425: VHMS monitor → VHMS controller → MTC
[2/2]
Fig. 7-101 Wiring Diagram overview for G00425: VHMS monitor → VHMS controller → MTC
7 - 236 PC4000-6 TS 08199-xD-GB-2

G00491 - Communication failure MH800 <=> VHMS-Controller

[1/2]
Trouble code
Trouble Communication failure MH800 <=> VHMS-Controller
G00491
Contents of trouble The CAN bus (#0) communication between VHMS monitor and VHMS controller is inoperative.
Communication between VHMS monitor and VHMS controller takes place via CAN bus #0.
At the VHMS monitor the CAN bus is connected to the CN2 port via connectors:
Related information
20X335e, 20X335d, 10X335c, 10X335b, and the end resistor 10R101 at connector 10X300a.
At the VHMS controller the CAN bus is connected to the CN4A port.

Communication between VHMS monitor and VHMS controller is impossible.
on the machine
Nominal
value
- Visually check the condition of the CAN bus Yes Go to next step.
harness.
CAN bus wiring - Visually check all connectors/pins for proper
Locate the problem
between crimping and connection.
and repair as
VHMS monitor and 1 - Make sure that the cables are fixed in the necessary.
VHMS controller, correct sequence inside the connectors. No If any CAN bus
or the contact in any Is the CAN bus harness in good condition? segment is damaged,
connector is defective.
Is the contact of connectors/pins alright? replace the relating
cable segment.
Is the cable allocation in the connectors
correct?
Re-program MH801 CAN bus:
and/or the VHMS Rmax 1Ω
controller, or replace
- Separate the CAN bus segments and 10R101:
the units if necessary.
measure their continuity. 120Ω
The CAN bus harness If further information is
or the belonging - In addition separate resistor 10R101 from Yes required:
resistor 10R101 connector 10X300a and measure its Please note the serial
may be defective 2
resistance. numbers of VHMS
(no continuity, wrong Is the continuity of the CAN bus segments monitor & controller
resistance) alright? and contact your
dealer or KMG.
Does the resistance of 10R101 meet the
specification? Replace the defective
CAN bus segment or
No
the end resistor
10R101 as necessary.
Final check 3
TS 08199-xD-GB-2 PC4000-6 7 - 237

Wiring Diagram overview for G00491: VHMS monitor (MH801) → VHMS controller
[2/2]
Fig. 7-102 Wiring Diagram overview for G00491: VHMS monitor (MH801) → VHMS controller
7 - 238 PC4000-6 TS 08199-xD-GB-2

TS 08199-xD-GB-2 PC4000-6 7 - 239

7 - 240 PC4000-6 TS 08199-xD-GB-2

Troubleshooting by Symptoms
8 TROUBLESHOOTING BY
SYMPTOMS
TS 08199-xD-GB-2 PC4000-6 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).
Related information - The safety lock lever is in down position during engine start.
- 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).
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
value
Main key switch 20S001 OFF &
Maintenance safety switch 50S058 locked.
Vbatt >24V
Neglected battery (under
maintenance. load no
Check the capacity and condition of batteries
Internal short circuit in 71G001–71G004. drop below
1 Replace the concerned 20V)
any battery or low Yes
Also check the capacity and condition of battery/batteries.
battery voltage Electrolyte
batteries 13G008 & 13G009 in the cab base.
(below 17 V) specific
Is any battery defective? gravity
>1.26
No Go to next step.
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.
Safety lock switch Refer to the Wiring Diagram. Yes Go to next step.
(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 PC4000-6 TS 08199-xD-GB-2
Troubleshooting by Symptoms Symptoms of the Engine and Related Electrical System
SEL001 - Engine does not start (engine does not rotate)

[2/5]
Nominal
value
Main key switch 20S001 ON &
Engine start switch 20S004-1 activated.
Refer to Wiring
When the start switch 20S004-1 is activated, Diagram.
the pre-lube pump 52G006-1 must start and Check the following
run until an oil pressure of 0.17 bar is built up components and the
in the engine. relating wiring:
The pre-lube process is
As soon as the specified engine oil pressure is - Pre-lube pump
disturbed
4 reached at the pressure switch 52B093-1, the 52G006-1
(it is not started or pre-lube switch 52K030-1 initiates the start sig- Wiring
stopped) No - Engine oil Diagram
nal to the starter relays 52Q002a-1 and
pressure switch
52Q002b-1 of the starter motors.
52B093-1 (incl.
Refer to the Wiring Diagram and check the switch function)
pre-lube process.
- Pre-lube timing relay
Is the pre-lube process ok 52K030-1
(including pre-lube start and stop)?
- Starter relays
52Q002a-1 and
52Q002b-1
Engine start switch 20S004-1 activated.
Component's lifetime Replace the starter
exceeded Check the relays 52Q002a-1 & 52Q002b-1 for Yes
Vbatt (approx. 24 V) input/power supply. motors.
(starter motors internal 5 Vbatt
Refer to the Wiring
disconnection or short Is Vbatt present at the input and output of these (approx.
Diagram.
circuit) relays? No 24V)
Repair/ replace the
Is Vbatt present at the starter motors? wiring as necessary.
Battery switches 71Q003 & 71Q004 OFF.
Replace the starter
motors and recheck
Yes
Component's lifetime function.
exceeded Check the engine
(starter motors internal 6 Disassemble or replace both starter motors flywheel for free
disconnection or and inspect them. mechanical rotation.
damage) Is any mechanical fault detectable? Also refer to the
No Cummins Trouble-
shooting and Repair
Manual.
necessary.
Final check 7
Start the machine and verify that the repair was successful.
TS 08199-xD-GB-2 PC4000-6 8 -3
Wiring Diagram 1 (engine start) for trouble code SEL001

[3/5]
Fig. 8-1 Wiring Diagram 1 (engine start) for trouble code SEL001
8 -4 PC4000-6 TS 08199-xD-GB-2
[4/5]
Legend for Fig. 8-1
(previous page)
52B093-1 Engine oil pressure switch

52G006-1 Pre-lube pump
52K030-1 Pre-lube timing relay
52M001-1 Starter 1
52M002-1 Starter 2
52Q002a-1 Starter relay 1
52Q002b-1 Starter relay 2
52Q030a-1 Pre-lube pump relay
71G001 Battery
71G002 Battery
71G003 Battery
71G004 Battery
71Q003 Battery switch (for starter 52M001-1)
71Q004 Battery switch (for starter 52M002-1)
Legend for Fig. 8-2
(following page)
A (13G008 & 13G009) Controller batteries (for stabilizing the control voltage)
A (13Q003) Battery switch for the controller batteries
B (20S004-1) Engine start switch
C (51K001a-1) Engine start relay motor 1
D (51K001b-1) Engine start relay motor 1 (redundant)
TS 08199-xD-GB-2 PC4000-6 8 -5
Wiring Diagram 2 (engine start) for trouble code SEL001

[5/5]
Fig. 8-2 Wiring Diagram 2 (engine start) for trouble code SEL001
8 -6 PC4000-6 TS 08199-xD-GB-2
SEL002 - Engine stops while in operation

[1/3]
Trouble code
Trouble Engine stops while in operation
SEL002
- During operation the engine suddenly stops.
Contents of trouble
- A corresponding trouble message 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.

- Engine restart is impossible (engine rotates but does not start).
on the machine
- No exhaust smoke visible.
Engine shut-down due to:
- Lack of fuel in the fuel tank or contamination
Possible causes
- Racor (water separator) and/or fuel filter clogged
- Internal (or mechanical) fuel pump problems or wear
Nominal
value
Refer to the
Cummins
Engine
Manual for
fuel specifi-
cations.
- Check the fuel level
Check the level in the fuel tank. and refuel if neces-
sary.
Lack of Diesel fuel Check the fuel solenoid valve 31Q599 for
1 proper function (31Q599 must be open during - Inspect the fuel tank
at the fuel filters and the bottom fuel
engine start).
line connection for
Is fuel supply present at the Racor and at the contamination.
fuel filters? No
- Check 31Q599 for
proper function and
repair if necessary.
- Check the fuel supply
line for free passage
and repair if neces-
sary.
Refer to the
Cummins
Check the Racor and/or fuel filters for Bleed the fuel pump Engine
Yes
contamination. If necessary clean the Racor and restart the engine. Manual for
Lack of Diesel fuel and/or replace the filter elements. fuel specifi-
2
at the fuel pump Replace the fuel filter on the engine side. cations.
Check the fuel shut-off circuit for proper func- Check the supply
tion. hoses and unions for
No free passage and
Is fuel present at the fuel pump? repair if necessary.
Go to next step.
TS 08199-xD-GB-2 PC4000-6 8 -7
SEL002 - Engine stops while in operation

[2/3]
Nominal
value
Inform the Cummins Service. &
Main key switch 20S001 ON. &
Connect the Cummins tester and start the "Insite" software.
Repair as necessary Refer to the
and recheck the Cummins
Yes
system for proper specifica-
function. tions.
- Check the fuel speci-
Mechanical problems fication and measure
3 Monitor and check the starting process
at the fuel system the water content in
(fuel supply) with the "Insite" software.
the Diesel fuel.
Could you locate the problem?
- Inspect the fuel
No
system together
with the Cummins
Service.
- Repair or replace as
necessary.
Final check 4
8 -8 PC4000-6 TS 08199-xD-GB-2
View onto the fuel system water separator (SEL002)

[3/3]
Fig. 8-3 View onto the fuel system water separator (SEL002)
Legend for Fig. 8-3
(1) Fuel tank
(2) Fuel shut-off solenoid valve (31Q599)
(3) Water separator filter
(4) Fuel filters
TS 08199-xD-GB-2 PC4000-6 8 -9
SEL003 - Engine speed is hunting during boom-up movement

[1/1]
Trouble code
Trouble Engine speed is hunting during boom-up movement
SEL003
- At high 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 hydraulic control system
- Improper function of the pump regulation system
- Active / inactive trouble codes stored in the Quantum ECM memory disturb the RPM control
Possible causes - Lack of fuel
- Wrong RPM adjustments
Nominal
value
Connect the Cummins tester and check with the "Insite" software tool.
Active / inactive Refer to the
Check for pending active / inactive trouble Go to the final step Cummins
trouble codes stored codes and delete the error memory com- and then release the Engine
in the Quantum ECM 1 pletely. Yes
shovel back to Manual for
memory disturb the fuel specifi-
Then recheck the engine running condition. operation.
RPM control cations.
Is the hunting problem solved?
No Go to next step.
The engine is hunting Refer to the
during boom up Replace the fuel filter Cummins
2 Check all Racors / fuel filters elements and clean the Engine
movement. Yes
for contamination. Racor housing as Manual for
Lack of fuel necessary. fuel specifi-
Is any filter clogged?
cations.
No Go to next step.
Connect the Cummins tester and check with the "Insite" software tool.
Refer to the
Go to the final step Cummins
At "high idle" the and then release the Engine
engine speed is lower Check and adjust the specified RPM. Yes
shovel back to operaK- Manual for
than specified 3 Also refer to the SERVICE MANUAL and Ttion. fuel specifi-
cations.
Wrong RPM adjust- to the PM-CLINIC sheets.
ments Together with the
Was the RPM adjustment successful?
Cummins Service work
No
out the complete Fuel
System sheet.
Final check 4
8 - 10 PC4000-6 TS 08199-xD-GB-2
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.

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
value
Engine stop switch 20S005-1 activated
Refer to the Wiring
Diagram. Vmin 22V
When the engine stop
Locate the problem
switch 20S005-1 is Check the circuits of 20S005-1 and the engine
1 and repair as
pressed, the engine Yes
stop via node 20K309 for proper function. necessary.
stop is not activated
Is any problem present? After that recheck Vmax 24V
the system for
proper function.
No Go to next step.
Engine stop switch 20S005-1 activated
necessary.
Yes After that recheck Cummins
the system for
It is not possible to proper function.
activate the shut-off Inform the Cummins Service.
Using the Cummins
function (QSK60, 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.
Final check 3
TS 08199-xD-GB-2 PC4000-6 8 - 11
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.

A sufficient loading or moving is not possible.
on the machine
General causes for lack of output power:
- Insufficient air intake
- Insufficient fuel supply
- Racor or fuel filter clogged
Possible causes
- Improper fuel injection condition
- The used fuel does not meet the specifications
- Overheating (in case of overheating combined with loss of power carry out troubleshooting
for overheating)
Nominal
value
Test conditions according to the kind of inspection, when following the
judgment table information.
- Inspect the
suspicious system,
unit, or component
Engine lacks output for malfunction and
1 repair or replace as
(no power) Refer to the following judgment table and identify
the appropriate trouble cause(s). necessary.
- After that recheck the
system for proper
function.
- Go to final step 2.
Final check 2
8 - 12 PC4000-6 TS 08199-xD-GB-2
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
TS 08199-xD-GB-2 PC4000-6 8 - 13
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)
Problem that appears - Reduced engine efficiency

on the machine - Poor emission quality
General causes for black exhaust smoke:
Possible causes - Insufficient air intake
- Excessive fuel injection
Nominal
value
- 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).
system for proper
function.
Final check 2
8 - 14 PC4000-6 TS 08199-xD-GB-2
SEL006 - Exhaust smoke is black

[2/2]
Air leakage between turbocharger & cyl. head
Defective contact of valve and valve seat

Clogged injector, wrong spray pattern


Clogged air cleaner elements
Crushed, clogged muffler

Legend

Suddenly became black ◙
Colour of exhaust gas Gradually became black ◙ ◙ Ο
Questions

Suddenly ◙ Ο Ο
Power was lost
Gradually Ο Ο Ο Ο
Non-specified fuel is being used Ο
Air cleaner clogging warning is displayed ◙
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

When the "delivery test" is made, wrong injection timing is found
Injection pump test shows, that the injection amount is wrong
When muffler is removed, exhaust gas colour returns to normal ●
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
Clean
TS 08199-xD-GB-2 PC4000-6 8 - 15
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)
Problem that appears - Low output power.

on the machine - Risk of an engine breakdown.
Possible causes See the following judgment table.
Nominal
value
- 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).
system for proper
function.
Final check 2
8 - 16 PC4000-6 TS 08199-xD-GB-2
SEL007 - Oil consumption is excessive

[2/2]
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
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

Questions
Oil consumption suddenly increased ◙

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 ◙

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
TS 08199-xD-GB-2 PC4000-6 8 - 17
SEL008 - Oil becomes contaminated quickly

[1/2]
Trouble code
Trouble Oil becomes contaminated quickly
SEL008
Contents of trouble The engine oil becomes contaminated quickly
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
value
- Inspect the
suspicious system,
unit, or component
The engine oil is for malfunction and
contaminated quickly Refer to the following judgment table and identify
system for proper
function.
Final check 2
8 - 18 PC4000-6 TS 08199-xD-GB-2
SEL008 - Oil becomes contaminated quickly

[2/2]
Defective seal at turbocharger turbine end

Clogged breather or breather hose
Clogged turbocharger drain pipe

Worn valve, valve guide
Exhaust smoke is black

Legend
Defective safety valve

Clogged oil filter


Questions
Degree of use of the machine Operated for a long period ◊ ◊ ◊

Non-specified engine oil is used O
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 ◙
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
TS 08199-xD-GB-2 PC4000-6 8 - 19
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
SDA 16 V 160
PC4000-6 1400 209 238 255 282 340
(QSK60)
- Engine oil consumption about 0.25% 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 3600 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)
Possible causes - Improper fuel injection condition
- Excessive fuel injection amount
Nominal
value
- Inspect the
suspicious system,
unit, or component
Fuel consumption for malfunction and
highly exceeds the 1 repair or replace as
Refer to the following judgment table and identify the
standard values necessary.
appropriate trouble cause(s).
system for proper
function.
Final check 2
8 - 20 PC4000-6 TS 08199-xD-GB-2
SEL009 - Fuel consumption is excessive

[2/2]
External leakage at fuel piping, fuel filter

Fuel leakage inside the cylinder head
Defective injector holder, spray
Legend
Defective fuel pump


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
TS 08199-xD-GB-2 PC4000-6 8 - 21
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 sputters 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
- Engine generates excessive heat
on the machine
- Excessive smoke coming out of the mufflers
Possible causes See the following judgment table.
Nominal
value
- Inspect the
suspicious system,
Oil is in the engine unit, or component
coolant, or the coolant for malfunction and
spurts back, or the 1 repair or replace as
Refer to the following judgment table and identify
coolant level goes necessary.
down
system for proper
function.
Go to final step 2.
Final check 2
8 - 22 PC4000-6 TS 08199-xD-GB-2
SEL010 - Oil is in engine coolant

[2/2]
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

Questions

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
TS 08199-xD-GB-2 PC4000-6 8 - 23
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
First verify the proper function of the "Oil Management Centinel System" and the "Reserve Pump
Related information
System" (refer to the OPERATION & MAINTENANCE MANUAL and to the SERVICE MANUAL).
Oil spills out of the engine breather hose.
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 (e.g. Reserve System) gets into the engine oil.
Nominal
value
- Inspect the
suspicious system,
unit, or component
The engine oil level for malfunction and
rises Refer to the following judgment table and identify
- After that recheck
the system for
proper function.
Go to final step 2.
Final check 2
8 - 24 PC4000-6 TS 08199-xD-GB-2
SEL011 - Oil level rises

[2/2]
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

Questions

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
TS 08199-xD-GB-2 PC4000-6 8 - 25
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 monitor panel coolant temperature gauge is in normal range,

Related information
start troubleshooting with a temperature gun and verify the adequate coolant temperature.
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
value
- Inspect the suspi-
cious system, unit, or
The engine coolant component for mal-
temperature becomes 1 function and repair or
Refer to the following judgment table and identify replace as necessary.
too high (overheating)
system for proper
function.
Go to final step 2.
Final check 2
8 - 26 PC4000-6 TS 08199-xD-GB-2
SEL012 - Coolant temperature becomes too high (overheating)

[2/2]
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
Low or no fan RPM


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 ◙
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 ●
Troubleshooting
temperature
When coolant temperature is measured, it is normal ●
When measurement is made with the radiator cap tester, set pressure is found ●
to be low (pressure is not kept)
Remove oil pan and inspect directly ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct or
Remedy
Correct
Correct
replace
TS 08199-xD-GB-2 PC4000-6 8 - 27
Symptoms of the Hydraulic System Troubleshooting by Symptoms
8.2 SYMPTOMS OF THE HYDRAULIC SYSTEM
(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.
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 → hydraulic oil temperature at least T3.
- 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.
- Using a stop watch, test the cycle times of the work equipment (beginning at the 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 values.
- When carrying out tests use the recommended adjustment values only.
The work performance of the shovel is poor and/or too slow.
on the machine
- Wrong position of the change-over valve lever (253.1) for the hydraulic pump regulation mode
at the valve and filter plate
- Wrong adjustment of the pump regulation system
Possible causes - Wrong Energy Efficiency adjustment
- Wrong hydraulic adjustments (SRV, MRV) or defective valves
- Any hydraulic cylinder defective (internal leak)
- Low engine power output
Nominal
value
Wrong position of the Check the emergency lever position at the Move the emergency
emergency lever valve and filter plate. lever (253.1) to E
1
(253.1) at the valve No position and bring
and filter plate Is the emergency lever set to E position?
the machine back
to operation.
Follow the respective requirements of the SERVICE MANUAL.
Readjust the pump regulation system Yes Go to next step.
according to the procedures given in the
Wrong adjustment of Adjust the pump
SERVICE MANUAL (the emergency lever SERVICE
the pump regulation 2 regulation system
253.1 at the valve and filter plate must be MANUAL
system according to the PM-
set to E position in any case). No PM-CLINIC
CLINIC sheet and
Is the pump regulation system working as described in the
correctly? SERVICE MANUAL.
The basic pump regulation adjustment is Yes Go to next step. PM-CLINIC
successfully completed. All values correspond
to the PM-CLINIC sheet.
Now check the additional pump regulation of
Wrong Energy Adjust according to the SERVICE
3 the Energy Efficiency system.
Efficiency adjustment PM-CLINIC sheet and MANUAL
Carry out the test of the sprocket revolution No
time according to the PM-CLINIC sheet as described in the
PM-CLINIC
(item 37). SERVICE MANUAL.
Do the measured time values meet the
specification?
8 - 28 PC4000-6 TS 08199-xD-GB-2
Troubleshooting by Symptoms Symptoms of the Hydraulic System
(especially the "boom up" function)
[2/2]
Nominal
value
Adjust valves as
Check the adjustments of the SRV (Safety SRV
Wrong hydraulic necessary according
Relief Valves) and MRV (Main Relief Valves) 350±5bar
adjustments to the PM-CLINIC
4 according to the SERVICE MANUAL and the Yes
(SRV, MRV) sheet and as MRV
PM-CLINIC sheet.
or defective valves described in the 310+5bar
Is any valve adjustment below the default SERVICE MANUAL.
value?
No Go to next step.
After the correct adjustment of the pump regu- If any cylinder leakage
lation system, including Energy Efficiency, is is found replace the
Yes
completed, the work attachment is still too defective hydraulic
Any hydraulic cylinder slow, especially the "boom up" function. cylinder.
5
defective (internal leak) Using an infrared thermometer, check the
boom cylinder temperature (refer to "Cylinder
bypass test" in this manual) in order to locate No Go to next step.
an internal leakage.
Could you determine any abnormality?
After inspection clean
Perform the engine Power Check according the Racor and/or
the PM-CLINIC sheet. replace the fuel filter
elements as
Even all adjustments are correctly done and necessary. PM-
Yes
Low engine power even they correspond to the default values, the CLINIC
6 Recheck the engine
output engine stall speed drops below the specified
speed of the PM-CLINIC Power Check. stall speed according
to the PM-CLINIC
Check the engine fuel supply system for Power Check.
sufficient fuel delivery capacity.
Call the Cummins
Is any Racor (separator) or fuel filter clogged? No service for a complete
engine check up.
Final check 7
TS 08199-xD-GB-2 PC4000-6 8 - 29
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 compound
Contents of trouble movements of the attachment.
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 (hydraulic oil temperature at least T3).
- Recheck yourself all oil levels and functions and inspect for any leakage.
Related information - Before starting any adjustment work, operate the shovel yourself and test all affected functions.
Check for noise or abnormal reactions.
- Using a stop watch, test the cycle times of the work equipment (beginning at the 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 values.
- When carrying out tests use the recommended adjustment values only.
The work performance of the shovel is poor and/or too slow.
on the machine
- The engine stalls too much.
Possible causes
- Wrong adjustment of the pump regulation system or the Energy Efficiency.
Nominal
value
Check the engine stall speed according the Clean the Racor,
PM-CLINIC sheet. replace the fuel filter,
Even all adjustments are correctly done and or air filter if clogged.
even they correspond to the default values, the Yes Then recheck the stall PM-CLINIC
engine stall speed drops below the stall speed speed according to the
The engine stalls limits. PM-CLINIC data
1
too much sheet.
Check all air filters for cleanness and check
the cyclone dust streamer for proper function.
Check the engine fuel supply system for Call the Cummins
sufficient fuel delivery capacity. No service for a complete
engine check up.
Is any Racor (separator), fuel filter, or air filter
clogged?
8 - 30 PC4000-6 TS 08199-xD-GB-2
SHY002 - Engine speed sharply drops or engine stalls too much

[2/2]
Nominal
value
Check the bucket size
and weight.
Check the density

(specific weight) of the
material and compare
to the bucket size and SERVICE
Check the position of the emergency lever on the mounted wear MANUAL,
the valve and filter plate. package on the bucket
For the adjustment of the regulation system Yes (overload). PM-
Wrong adjustment of the lever must be in position for electronic CLINIC
the pump regulation pump regulation (E). Confirm the actual data sheet,
2
system or the Energy Adjust the pump regulation (Energy Efficiency) operating altitude
Efficiency. system according to the SERVICE MANUAL (higher than 3600 m?). PARTS &
and make sure to meet the correct values. SERVICE
Also refer to the latest NEWS
Is the pump regulation system working version of PARTS & AH05515
correctly? SERVICE NEWS (latest ver-
AH05515. sion)
Adjust the pump
regulation system
according to the
No
PM-CLINIC sheet and
as described in the
SERVICE MANUAL.
Final check 3
TS 08199-xD-GB-2 PC4000-6 8 - 31
SHY003 - No work equipment, travel or swing movement

[1/1]
Trouble code
Trouble No work equipment, travel or swing movement
SHY003
- Work equipment, travel or swing movement is impossible.
Contents of trouble
- 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.
No movement is possible.
on the machine
- 11K111a and 11K111b are inoperative or burnt.
Possible causes
- Pilot pressure is not available (PPC pump defective).
Nominal
value
- Check the circuits of 11K111a and 11K111b Repair or replace
Relays 11K111a and for proper function. relays 11K111a & Output
Yes
11K111b are 1 - Check the function of relays 11K111a and 11K111b and/or their 24V
inoperative or burnt 11K111b manually. sockets if damaged.
Could you identify any problem in the electrical No Go to next step.

system?
X4=60bar
Check for proper
X2=45bar
Yes movement of the
- Check the pilot pressure at the valve and work equipment. SERVICE
cartridge block as described in the MANUAL
Pilot pressure is
not available 2 SERVICE MANUAL. Check the drive input
(PPC pump defective) of pilot pump.
- Make sure that the pilot pressure is in the
specified working range. Check the pilot pump
No for damage (internal
Is specified pilot pressure available?
fault).
necessary.
Final check 3
8 - 32 PC4000-6 TS 08199-xD-GB-2
SHY004 - Work equipment has too much hydraulic drift

[1/2]
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.
- According to section "Cylinder bypass test" check and measure the existing drift at the
cylinder circuit. Locate the affected hydraulic circuit.
Related information
- Install pressure gauges at the main blocks of the affected circuit and monitor the pilot pressure
for the respective main spool.
Problem that appears - Risk, to loose control of the shovel operation.
on the machine - Damage or breakdown is possible due to contacting dump trucks.
- No or incorrect main spool movement (neutral spring damaged).
Possible causes - FSA - Floating valve internal leak or damage.
- Hydraulic cylinder damaged (internal leak).
Nominal
value
All PPC sections on the main blocks equipped with pressure gauges.
35-45bar
at the main
block
spools
(when the
lever is
moved "full
No or incorrect main On the main blocks check all functions of the stroke").
spool movement work equipment for increasing and decreasing
1 Check the pilot pres-
(neutral spring times of the pilot pressure control, simultane-
ously to the lever movements. sure at the remote
damaged)
control valves.
Is the pilot pressure increasing and decreasing
simultaneously? Check the remote
control valves for
No proper function
(electrical signal from
the lever - via amplifier
& ramp time module -
to the remote control
valve).
All PPC sections on the main blocks equipped with pressure gauges.
In the floating valves 60Q632, 60Q633, Replace the affected
60Q634 (stick in) or 61Q635 and main block valve and adjust as SERVICE
FSA - Floating valve (spool boom down) any leakage or damage of Yes described in the MANUAL
2
internal leak or damage the inner spool is possible. SERVICE MANUAL PM-CLINIC
Inspect the floating valves as described in the and PM-CLINIC.
SERVICE MANUAL.
No Go to next step.
Can you identify any leakage or damage?
TS 08199-xD-GB-2 PC4000-6 8 - 33
SHY004 - Work equipment has too much hydraulic drift

[2/2]
Nominal
value
Replace any defective
cylinder by a new one.
Bleed the new
hydraulic cylinder(s). Minimum
Yes Perform the bypass test period
test again in order to 20 minutes
The function of the main blocks is ok.
make sure that no
Hydraulic cylinder Refer to section "Cylinder bypass test" and other cylinder is
damaged 3 check the suspicious cylinders for defective affected.
(internal leak) internal seals. Check the SRV and
Can you find significant temperature suction valves for
differences during the cylinder bypass test? proper function.
Repair or replace if
No necessary, and after
that, verify that the
hydraulic drift of the
work equipment meets
the specified range.
Final check 4
8 - 34 PC4000-6 TS 08199-xD-GB-2
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 attachment.
Contents of trouble
- 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 controlled and adjusted via the
Related information
Ramp Time Modules.
Due to a big time lag the machine can not be operated according to proper quality standards.
on the machine
Possible causes Wrong adjustment of the Ramp Time Modules.
Nominal
value
Perform the complete
measurements for the Standard
electrical levers, Value
including the amplifier Table
Perform the basic adjustments of the Ramp test. Wiring
Time Modules according to the procedures Yes Refer to the SERVICE Diagram
Wrong adjustment described in the SERVICE MANUAL. MANUAL. SERVICE
of the Ramp Time 1
Modules For the standard value table refer to your Refer to the latest MANUAL
Wiring Diagram. version of PARTS & PARTS &
Do the adjustment values meet the specified SERVICE NEWS SERVICE
range? AH09525. NEWS
Perform the basic AH09525
adjustments according (latest
No
to the data in your version)
Wiring Diagram.
Final check 2
TS 08199-xD-GB-2 PC4000-6 8 - 35
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 Hydraulic Diagram.
- The left and right track wear measurements are on the same level.
- During machine traveling the shovel deviates to one side.
- The operator has to stop the shovel after a couple of meters in order to correct the direction
on the machine
of travel to straight forward.
- Defective hydraulic travel motor.
Possible causes
- Internal leak in the rotary joint.
Nominal
value
- Disconnect the ports
A and B at the travel
motors (in order to
exclude the travel
motors).
Connect high pressure gauges (400 bar) to the - Plug the hoses and SRV
main blocks. the inlet ports of the 310bar
Defective hydraulic Yes travel motors.
Disconnect the parking brake solenoid valve MRV
travel motor - Now check the 315bar
1 57Q516 in order to close the brake.
Internal leak in the pressure again.
rotary joint Actuate the travel pedals and read the current
pressure at the gauges. - If the pressure values
are still the same as
Is there any pressure difference between left before, replace the
and right, or loss of pressure? travel motor(s).
If the pressure values
are not the same as
No before, replace the
rotary joint due to an
internal leakage.
Final check 2
8 - 36 PC4000-6 TS 08199-xD-GB-2
SHY007 - Hydraulic system has lack of power (Energy Efficiency)

[1/2]
Trouble code
Trouble Hydraulic system has lack of power (energy efficiency)
SHY007
- The hydraulic system has a lack of power.
Contents of trouble - The PM-CLINIC procedures were performed successfully.
- The values of engine power output are ok.
- The energy efficiency is an improvement and was implemented on your shovel in a
Related information field campaign.
- Follow the adjustment procedures in the SERVICE MANUAL, section "Energy Efficiency".
The movement speed of the attachment and during traveling is too slow.
on the machine
Possible causes Defective valve or wrong adjustment of the Energy Efficiency.
Nominal
value
Check and adjust the energy efficiency according to the SERVICE MANUAL,
section "Energy Efficiency".
Inspection of the solenoid functions
If any individual movement is selected (single movement), the pumps will deliver The basic
the maximum flow, with one exception. setting
Pump 1 will deliver the half flow only if high speed swing is selected. (bench
This fact is important for PM-CLINIC and other tests. setting)
a) Individual movements of the Attachment are selected: of the
Defective valve or PST valve
wrong adjustment of 1 → 57K646 OFF + 57K647 OFF + 57K648 OFF + 57K626 ON is 18 bar.
the Energy Efficiency b) Only travel is selected: The
→ 57K646 OFF + 57K647 OFF + 57K648 OFF + 57K626 ON sprocket
rotation
c) Only swing (low speed) is selected: times
→ 57K646 ON + 57K647 OFF + 57K648 ON + 57K626 ON meet the
nominal
d) Only swing (high speed) is selected: values.
→ 57K646 ON + 57K647 OFF + 57K648 OFF + 57K626 OFF
Go to next step.
TS 08199-xD-GB-2 PC4000-6 8 - 37
SHY007 - Hydraulic system has lack of power (Energy Efficiency)

[2/2]
Nominal
value
Pump flow control test values

Sprocket Sprocket
57K646 57K647 57K648 57K626 right left
No. Function
[Volt] [Volt] [Volt] [Volt] Time/5 rev Time/5 rev
[s] [s]
Travel
1 0 0 0 24 50 ± 1 50 ± 1
right only
Travel
right &
2 24 24 24 24 65 ± 1 65 ± 1
swing (low
speed)
The basic
Travel
setting
right &
3 24 0 0 0 65 ± 1 65 ± 1 (bench
swing (fast
setting)
speed)
of the
Travel left PST valve
4 0 0 0 24 50 ± 1 50 ± 1
Check of the sprocket only is 18bar.
2
rotation times Travel left
& swing The
5 24 24 24 24 65 ± 1 65 ± 1
(low sprocket
speed) rotation
Travel left times
& swing meet the
6 24 0 0 0 65 ± 1 65 ± 1 nominal
(fast
speed) values.
Information for testing
– Select the swing speed between low and high with 20S154
at the left control lever.
– The 5 revolutions of the sprocket within 65 seconds are
mandatory to determine the optimized pump flow.
– The pressure control valve (152) is factory pre-adjusted to 18 bar.
If necessary adjust or repair the system.

Final check 3
8 - 38 PC4000-6 TS 08199-xD-GB-2
SHY008 - Machine does not swing

[1/1]
Trouble code
Trouble Machine does not swing
SHY008
- The machine does not swing when the lever is moved.
- The swing parking brake is released (otherwise a corresponding info message is displayed on the
Contents of trouble
VHMS monitor)
- All other operating functions are going well.
- The electrical lever signal on the amplifier and ramp time modules is present
Related information (otherwise a corresponding error message is displayed on the VHMS monitor).
- No swing movement (left or right) is possible.
No swing movement is possible.
on the machine
Possible causes No pressure increase at the 2-stage valve(s).
Nominal
value
Swing parking brake switch 20S029 ON.
Attachment in ground position.
Follow the instructions for testing and adjusting
the swing circuit as described in the SERVICE
MANUAL. Reconnect the pilot
pressure hoses to the
For better adjustment of the 2-stage valves
Yes 2-stage valves and put For the
disconnect and plug the pilot lines of the target
the shovel back to
2-stage valves. values
operation.
1. Adjustment of the 330 bar stage refer to
No pressure increase PM-CLINIC
1 2. Adjustment of the 130 bar stage
at the 2-stage valve sheets.
REMARKS: Remember that there are 2 For the

swing gearboxes with mounted adjust-
swing motors and the 2-stage ment pro-
valves. Replace both 2-stage cedures
Both valves need to have the No valves and perform the refer to the
same pressure (synchronisa- basic adjustments. SERVICE
tion). MANUAL.
Could you successfully adjust the 2-stage

valves?
Final check 2
TS 08199-xD-GB-2 PC4000-6 8 - 39
SHY009 - Swing acceleration is poor

[1/2]
Trouble code
Trouble Swing acceleration is poor
SHY009
- The machine swing acceleration is poor (too long acceleration time or too short acceleration time).
- The swing parking brake is released (otherwise a corresponding info message is displayed on the
Contents of trouble
VHMS monitor).
- All other operating functions are going well.
- For the basic adjustment procedures refer to the SERVICE MANUAL,
Related information section "Checks and adjustments for the swing circuit".
- For the target adjustment values refer to PM-CLINIC sheets.
The swing acceleration is poor and any fast swing & load movement is not possible.
on the machine
- The 2-stage valve is defective or its adjustment is wrong.
- The swing brake valve is defective (internal leak in the anti-cavitation/suction valves).
Possible causes
- The O-ring at the spacer plate is leaking (oil flows from A to B side).
- The swing motor is defective (internal leakage).
Nominal
value
Engine running at high idle &
Swing lock switch 20S029 ON.
Replace both 2-stage
valves and perform the
basic adjustments.
The 2-stage valve Perform the basic adjustments of the swing
is defective or its 1 circuit according the SERVICE MANUAL If - after replacement of SERVICE
adjustment is wrong and the PM-CLINIC sheets. the 2-stage valves - MANUAL
No the swing acceleration PM-CLINIC
Could you adjust the correct swing
is still poor, replace the
acceleration (swing cycle time)?
complete swing brake
valve blocks on top of
the swing motors.
Refer to next step.
Perform the following steps according to the

Safety Notes in the SERVICE MANUAL.
Disconnect the high pressure hoses from the
Bring the shovel back
swing brake block. Yes
to operation.
The swing brake valve NOTE! Before mounting the new block
is defective in the next work step, also see
(internal leak in the 2 step 3 in this troubleshooting SERVICE
anti-cavitation/suction chart. MANUAL
valves) Replace the complete block with new 2-stage PM-CLINIC
valves and O-rings.
Then perform the basic adjustments according
to the SERVICE MANUAL and the PM-CLINIC No Go to next step
sheets.
Could you now adjust the correct swing
acceleration (swing cycle time)?
8 - 40 PC4000-6 TS 08199-xD-GB-2
SHY009 - Swing acceleration is poor

[2/2]
Nominal
value
Check the spacer plate
for indications of
corrosion or pitting.
If necessary replace
the spacer plate.
Check the O-rings on the spacer plate and on Replace the O-rings SERVICE
the lower side of the swing brake block. and mount the swing MANUAL
No brake valve. PM-CLINIC
Are these O-rings ok?
Then perform the basic
adjustments for the
swing system
according to the
SERVICE MANUAL
The O-ring at the and the PM-CLINIC
spacer plate is leaking sheets.
3
(oil flows from A to B
side)
Legend
(1) Swing brake valve
(2) O-ring
(3) Spacer plate
(4) Swing motor

For testing the leak oil keep the engine running at high idle.
– Check the leak oil flow at the swing Replace the defective
Yes
motors. swing motor(s).
– Disconnect the leak oil hose from each Go to troubleshooting
swing motor and plug the hose opening. chart SME006 in the
The swing motor is – Mount an external hose to the swing following section
defective 4 motor leak oil port and drain the leak oil "Symptoms of the
(internal leakage) into a suitable container Mechanical System".
(min. volume: 20 liters). No Check the swing motor
– Operate the swing movement for 1 minute drive shaft input at the
and measure the leak oil amount swing gearbox.
(approx. 5 liters/min). If any malfunction
– Does the amount of leak oil exceed the is found, repair as
above recommendation? necessary.
Final check 5
TS 08199-xD-GB-2 PC4000-6 8 - 41
SHY010 - Excessive overrun when stopping swing

[1/2]
Trouble code
Trouble Excessive overrun when stopping swing
SHY010
Contents of trouble There is an excessive overrun when the swing movement of the superstructure is stopped.
- If during swing movement the control lever is moved into neutral position, the superstructure
swing movement should be stopped within an angle of 70°.
Related information
- If the superstructure does not stop within this angle, the superstructure overrun can be considered
as to be excessive.
Problem that appears The swing deceleration is poor (too long) and a correct positioning of the attachment
on the machine is not possible.
- The 2-stage valve is defective or its adjustment is wrong.
- The swing brake valve is defective (internal leak in the anti-cavitation/suction valves).
Possible causes
- The O-ring at the spacer plate is leaking (oil flows from A to B side).
- The swing motor is defective (internal leakage).
Nominal
value
Swing lock switched ON.
Replace both 2-stage
valves and perform the
basic adjustments.
The 2-stage valve Perform the basic adjustments of the swing
is defective or its 1 circuit according the SERVICE MANUAL If - after replacement of SERVICE
adjustment is wrong and the PM-CLINIC sheets. the 2-stage valves - MANUAL
No the swing deceleration PM-CLINIC
Could you adjust the correct swing
is still poor, replace the
deceleration?
complete swing brake
valve blocks on top of
the swing motors.
Refer to next step.
Perform the following steps according to the

Safety Notes in the SERVICE MANUAL.
Disconnect the high pressure hoses from the
Bring the shovel back
swing brake block. Yes
to operation.
The swing brake valve NOTE! Before mounting the new block
is defective in the next work step, also see
(internal leak in the 2 step 3 in this troubleshooting SERVICE
anti-cavitation/suction chart. MANUAL
valves) Replace the complete block with new 2-stage PM-CLINIC
valves and O-rings.
Then perform the basic adjustments according
to the SERVICE MANUAL and the PM-CLINIC No Go to next step
sheets.
Could you now adjust the correct swing
deceleration?
8 - 42 PC4000-6 TS 08199-xD-GB-2
SHY010 - Excessive overrun when stopping swing

[2/2]
Nominal
value
Check the spacer plate
for indications of
corrosion or pitting.
If necessary replace
the spacer plate.
Check the O-rings on the spacer plate and on SERVICE
Replace the O-rings
the lower side of the swing brake block. MANUAL
No and mount the swing
Are these O-rings ok? brake valve. PM-CLINIC
Then perform the basic

adjustments for the
swing system
according to the
SERVICE MANUAL
The O-ring at the and PM-CLINIC.
spacer plate is leaking
3
(oil flows from A to B
side)
Legend
(1) Swing brake valve
(2) O-ring
(3) Spacer plate
(4) Swing motor

For testing the leak oil, keep the engine running at high idle.
– Check the leak oil flow at the swing Replace the defective
Yes
motors. swing motor(s).
– Disconnect the leak oil hose from each Go to troubleshooting
swing motor and plug the hose opening. chart SME006 in the
The swing motor is – Mount an external hose to the swing following section
defective 4 motor leak oil port and drain the leak oil "Symptoms of the
(internal leakage) into a suitable container Mechanical System".
(min. volume: 20 liters). No Check the swing motor
– Operate the swing movement for 1 minute drive shaft input at the
and measure the leak oil amount swing gearbox.
(approx. 5 liters/min). If any malfunction
Does the amount of leak oil exceed the above is found, repair
recommendation? as necessary.
Final check 5
TS 08199-xD-GB-2 PC4000-6 8 - 43
SHY011 - Floating system without function

[1/1]
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".
- Floating valve 61Q635 is installed in the boom circuit.
Related information - Floating valves 60Q632, 60Q633, 60Q634 are installed in the stick circuit.
- The electric circuit is faultless, but the floating system is inoperative and/or its deactivation
is impossible (the spools in the hydraulic valves 60Q632-60Q634 or 61Q635 do not move).
No floating function for "Stick In" and/or "Boom Down".
on the machine
Possible causes The spools in the floating valves are mechanically stuck.
Nominal
value
The attachment must be in down and full reach position.
Replace or repair the

The spools in the – Find out in which circuit the problem occurs defective valve.
floating valves are 1 ("Stick In" and/or "Boom Down").
Then perform the basic SERVICE
mechanically stuck – Check the electrical signals at the solenoid valves. adjustment. MANUAL
– Disassemble the defective floating valve and Refer to the SERVICE PM-CLINIC
check the state of the inner spool and spring. MANUAL and to the
PM-CLINIC sheets.

Final check 2
8 - 44 PC4000-6 TS 08199-xD-GB-2
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.
- Any malfunction of the hydraulic circuit is possible.
on the machine
- Overheating of the hydraulic oil is possible.
- 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
value
Perform a sectional troubleshooting and check SERVICE
Wrong adjustment or Adjust or replace as MANUAL
the adjustment of SRV and MRV. Yes
malfunction of SRV 1 necessary.
Follow the instructions and specifications in PM-CLINIC
or MRV. the SERVICE MANUAL and PM-CLINIC
sheets. No Go to next step.
Could you find any functional problem?
Malfunction of any
Replace or repair as
throttle valve or Yes
Check the suspicious hydraulic circuit for noise necessary.
suction valve at the 2
main blocks or at and locate the problem (temperature differ- Perform the complete
the manifold ence) with the infrared thermometer gun. No PM-CLINIC PM-CLINIC
procedures
Final check 3
TS 08199-xD-GB-2 PC4000-6 8 - 45
SHY013 - Track tensioning system without function

[1/1]
Trouble code
Trouble Track tensioning system without function
SHY013
Contents of trouble The automatic track tensioning system does not work.
- The automatic track tensioning system works under the following condition: the engine is running
at high idle and the ladder is in up position.
Related information - During a travel distance of approx. 20 m the track tension is built up automatically.
- When the engine is 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.
Problem that appears - If the track tensioning is too low, the wear-out on track pads and sprockets increases.
on the machine - Track-off may occur during traveling or any movements due to loose tracks.
- No or too low track tensioning pressure.
Possible causes - Accumulators insufficiently charged or defective.
- Defective track tensioning cylinder(s).
Nominal
value
Ladder in up position.
Test and adjust the track tensioning pressure SERVICE
Bring the machine MANUAL
No or too low track according to the instructions and specifications Yes
1 back to operation.
tensioning pressure in the SERVICE MANUAL and PM-CLINIC PM-CLINIC
sheets.
Is adjustment possible and does the track No Go to next step.
tensioning system work orderly?
SERVICE
Test and adjust the charging of the
MANUAL
accumulators according to the instructions and
Accumulators PARTS &
specifications in the SERVICE MANUAL.
insufficiently charged 2 Bring the machine SERVICE
Also refer to the latest version of PARTS & Yes
or defective back to operation. NEWS
SERVICE NEWS AH03533.
AH03533
Is the function "Charging the Accumulators" (latest
possible and does the track tensioning system version)
work orderly? No Go to next step.
Ladder in up position.
Check the track
tensioning cylinders for
swollen partitions.
The tests and adjustments in steps 1 and 2
have been completed successfully (that Yes If necessary repair or
means a track tensioning pressure of 35 bar is replace the barrels -
present and the accumulators are charged alternatively replace
Defective track
3 orderly). But the track tensioning cylinders can complete track
tensioning cylinder(s)
not hold the supplied pressure. tensioning cylinders.
Disassemble the track tensioning cylinders Replace the seals.
and check the seals at the pistons. Replace the track
Are the seals in the track tensioning cylinders tensioning block
No no. 130 (car body)
defective?
and flush the pipes
and hoses of the track
tensioning lines.
Final check 4
8 - 46 PC4000-6 TS 08199-xD-GB-2
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 X2 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 X2 pressure.
- Too low SRV pressure, or the valve is defective.
Possible causes - Valve 57Q623a/b mechanically stuck.
- The ladder cylinder has an internal leakage (piston seal defective).
- The ladder bearing is defective or it is tightened too firmly.
Nominal
value
Check the X2 pressure according to the Yes Go to next step. SERVICE
No or too low MANUAL
1 instructions and specifications in the Re-adjust and verify
X pressure
SERVICE MANUAL and PM-CLINIC sheets. No that the ladder is PM-CLINIC
Is the X2 pressure adjustment correct? operated orderly. 45bar
Check the SRV pressure in the ladder circuit Yes Go to next step. SERVICE
Too low SRV pressure according to the instructions and specifications
2 MANUAL
or the valve is defective in the SERVICE MANUAL and PM-CLINIC Re-adjust and verify
PM-CLINIC
sheets. No that the ladder is
operated orderly. 70bar
Is the SRV pressure adjustment correct?
Valve 57Q623a Disassemble the solenoid valve 57Q623a/b Yes Go to next step.
or 57K623b is 3 and check the inner part of the spool for proper
mechanically stuck condition. Replace valve
No
57Q623a/b.
Is the inner part of the spool in good condition?
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, and measure the temperature
an internal leakage 4 difference between the cylinder rod and
(piston seal defective) the cylinder bottom side with an infrared
thermometer gun. No Go to next step.
Is the temperature difference in the piston area
higher than 10°C?
TS 08199-xD-GB-2 PC4000-6 8 - 47
SHY014 - Ladder does not move, or slow movement

[2/2]
Nominal
value
Inspect:
Is the standard ladder
frame used (standard
weight & size)?
The ladder bearing Check the ladder bearing for proper condition Yes Is the ladder or the
is defective or it is 5 and for the hand-tight tightening torque. ladder support
tightened too firmly Also refer to the ASSEMBLY MANUAL. defective or damaged ASSEMBLY
by an accident? MANUAL
Are the bearings in good condition and are
they tightened correctly? Replace or repair as
necessary.
bearings as necessary
No
and/or correct the
tightening torque.
Final check 6
8 - 48 PC4000-6 TS 08199-xD-GB-2
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.

Related information - The refilling arm pressure supply is charged by X2 pressure.
- The refilling arm circuit has no SRV.
The refilling arm does not move, or its movement is too slow.
on the machine
- Valve 57Q624a/b 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
value
Check the X2 pressure according to the Yes Go to next step. SERVICE
No or too low MANUAL
1 instructions and specifications in the Re-adjust and verify
X2 pressure
SERVICE MANUAL and PM-CLINIC sheets. No that the refilling arm PM-CLINIC
Is the X2 pressure adjustment correct? is operated orderly. 45 bar
Valve 57K624a/b is Disassemble the solenoid valve 57Q624a/b Yes Go to next step.
2
mechanically stuck and check the inner part of the spool for proper
condition. Replace valve
No
57Q624a/b.
Is the inner part of the spool in good condition?
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 temperature difference between the cylinder
internal leakage
(piston seal defective) rod and the cylinder bottom side with an
infrared thermometer gun. No Go to next step.
Is the temperature difference in the piston area
higher than 10°C?
TS 08199-xD-GB-2 PC4000-6 8 - 49
SHY015 - Refilling arm does not move, or slow movement

[2/2]
Nominal
value
Inspect:
Is the standard refilling
arm used (standard
weight & size)?
The refilling arm
connection Check the refilling arm for proper function. Yes Is the refilling arm or
4 its support defective
(pin and bushing) Disconnect the hydraulic cylinder and check SERVICE
is defective or damaged by an
the free movement of the refilling arm. MANUAL
accident?
Is the refilling arm movement ok?
Replace or repair
as necessary.
No refilling arm or the pin/
bushing as necessary.
Final check 5
8 - 50 PC4000-6 TS 08199-xD-GB-2
SHY016 - The hydraulic driven grease pump does not move

[1/2]
Trouble code
Trouble The hydraulic driven grease pump does not move
SHY016
Contents of trouble The hydraulic driven grease pump does not start or move correctly.

- 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 pump is reduced.
- Also refer to the information in the SERVICE MANUAL, section "Lubrication Systems".
Problem that appears - The grease system is inoperative because the pump does not work.
on the machine - Any relevant trouble message may be displayed on VHMS monitor.
- 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 (62Q507a) causes a mechanical jam (grease pump overload).
Nominal
value
Keep the engine running at high idle. Yes Go to next step.
No or too low Check the X4 pressure according to the SERVICE
1 Readjust and verify
X4 pressure instructions and specifications in the MANUAL
SERVICE MANUAL and PM-CLINIC sheets. No that the grease pump PM-CLINIC
operation is orderly.
Is the X4 pressure adjustment correct?
No or insufficient Check the pressure of the grease pump relief Yes Go to next step.
performance of the valve according to the instructions and SERVICE
2
relief valve on the specifications in the SERVICE MANUAL. Readjust and verify MANUAL
grease pump No that the grease pump
Is the pressure adjustment of the grease pump 45bar
relief valve correct? operation is orderly.

No or insufficient
Check the volume adjustment of the grease Yes Go to next step. SERVICE
performance of the
pump volume reducing valve according to MANUAL
"Q" volume reducing 3
the instructions and specifications in the Readjust and verify
valve on the grease 16-19 dou-
SERVICE MANUAL. No that the grease pump
pump ble-strokes
operation is orderly.
Is the volume adjustment correct? per minute
Check the adjustment and operation of the Yes Go to next step.
Internal leakage or
grease pump according to the instructions and
damage at the 4 SERVICE
specifications in the SERVICE MANUAL. Repair or replace
grease pump MANUAL
No the grease pump
Is the grease pump adjustment and operation
as necessary.
correct?
Keep the engine running at high idle.
Yes Go to next step. SERVICE
Wrong grease
Check the grease pressure adjustment MANUAL
pressure adjustment
5 according to the instructions and specifications Grease
(grease pressure
in the SERVICE MANUAL. Readjust or replace
too high) No pressure
the end of line switch.
Is the grease pressure correct? max.
180 bar
TS 08199-xD-GB-2 PC4000-6 8 - 51
SHY016 - The hydraulic driven grease pump does not move

[2/2]
Nominal
value
The vent valve causes Engine running at high idle.
a mechanical jam Test the vent valve operation according to Repair or replace the vent valve
6 SERVICE
(grease pump the instructions and specifications in the and test and adjust the grease
overload) MANUAL
SERVICE MANUAL. system if necessary.
Final check 7
8 - 52 PC4000-6 TS 08199-xD-GB-2
SHY017 - Trouble pump bearing lubrication

[1/1]
Trouble code
Trouble Trouble pump bearing lubrication
SHY017
Contents of trouble There is a malfunction in the external lubrication system for the pump bearing.
- The pump bearing lubrication pressure supply is charged by X4 pressure.

Related information
- Also refer to the PARTS & SERVICE NEWS AH05510 (latest version).
Due to no or insufficient pump bearing lubrication the lifetime of the main pump will be decreased.
on the machine
Possible causes
- Wrong adjustment of the main pump bearing throttle valve.
Nominal
value
Re-adjust and verify
Check the X4 pressure adjustment according SERVICE
No or too low that the pump bearing MANUAL
1 to the instructions and specifications in the Yes
X4 pressure lubrication operation
SERVICE MANUAL and PM-CLINIC sheets. PM-CLINIC
is orderly.
Is the X4 pressure adjustment correct? 60bar
No Go to next step.
Wrong adjustment PARTS &

Verify that the pump bearing SERVICE
of the main pump 2 Follow the instructions in the
bearing throttle valve lubrication is working orderly. NEWS
PARTS & SERVICE NEWS AH05510
AH05510
(latest version). Go to final step 3. (latest
version)

Final check 3
TS 08199-xD-GB-2 PC4000-6 8 - 53
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 (FSA) the track chain(s) make 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 (BHA) the track chain(s) make a self-movement in forward direc-
tion. That means the reverse loading force will be eliminated by a self-forwarding movement of
the track system.
Insufficient digging or loading performance.
on the machine
Possible causes Internal leakage at the rotary joint.
Nominal
value
Test and adjust the SRV pressure according to the instructions and
specifications in the SERVICE MANUAL and PM-CLINIC sheets.
→ Measure the SRV pressure at the travel system with connected
travel main lines (310±5 bar).
Perform the following work steps: SERVICE
Internal leakage MANUAL
1 1. Test the travel system during loading.
at the rotary joint PM-CLINIC
2. Measure the SRV pressure at the travel system with plugged (closed)
SRV press
travel main lines before the rotary joint inlet (310±5 bar).
310±5bar
3. If the pressure is ok replace or re-seal the rotary joint.
4. Test and adjust the MRVs of the travel system on the main blocks II & IV.
After adjustment/repair/replacement verify that chain movement is no longer
abnormal.
Final check 2
8 - 54 PC4000-6 TS 08199-xD-GB-2
SHY019 - Swing parking brake without function

[1/1]
Trouble code
Trouble Swing parking brake without function
SHY019
- The swing parking brake is inoperative (the superstructure moves) although the swing parking
brake switch 20S029 is switched to position "1" (brake closed).
Contents of trouble
- The X2 pressure circuit is already tested and ok (X2 pressure (45 bar) at valve 57Q505).
- The electrical circuit is already tested and ok.
- The swing parking brake is a disc brake mounted on the top of each swing gearbox.
- The "Siebenhaar" swing gearbox has an external swing brake housing with a separate oil filling.
- The "L&S" swing gearbox has an integrated swing brake system which is lubricated by the
Related information gearbox oil.
- According to the safety regulations both swing parking brakes are working as a "Spring Loaded
System". That means the pilot pressure opens the swing parking brakes. Without pilot pressure
the springs close the swing parking brakes.
The swing parking brake is inoperative.
on the machine
- The pilot pressure in the swing parking brake circuit is not released.
Possible causes
- The brake discs are burnt and/or the piston seals are defective.
Nominal
value
The pilot pressure
The solenoid valve 57Q505 is mechanically Replace the solenoid
in the swing parking Yes 0 bar
1 stuck. The pilot pressure in the swing parking valve 57Q505.
brake circuit is not
brake line is not released to the hydraulic oil
released
tank. No Go to next step.
Is the piston of the solenoid valve stuck?
Check for leaks or

Perform the following steps: mixed-up connections 45bar
Yes in the pilot supply lines kept up for
– Disconnect the pilot pressure supply for the swing parking 15 minutes
hoses for the swing parking brakes from brake system.
the swing gearboxes.
– Install a manual hydraulic pump with
Refer to the
The brake discs are 60 bar manometer in order to test the
instructions in the
burnt and the piston 2 swing parking brake piston seals
SERVICE MANUAL.
seals are defective (perform the test for both swing gear-
boxes). - Repair or replace
the swing parking
– Use a manual pump and increase the
brake(s).
pressure up to 45 bar. SERVICE
No REMARKS:
– The built-up pressure must be kept up MANUAL
Bleed the air from
for 15 minutes.
the swing parking
Can you build-up 45 bar and is the pressure brake(s).
kept up for 15 minutes without further action?
- Then check the swing
parking brakes for
proper operation.
Final check 3
TS 08199-xD-GB-2 PC4000-6 8 - 55
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 (X2 pressure (45 bar) at solenoid valve 57Q516).
- The electrical circuit is already tested and ok.
- The travel parking brake is a disc brake, mounted between the travel motors and the
travel gearboxes.
Related information - According to the safety regulations both travel parking brakes are working as a "Spring Loaded
System". That means the pilot pressure opens the travel parking brakes. Without pilot pressure
the springs close the travel parking brakes.
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 pressure adjustment is too low, or pressure reducing valve no. 47 is defective.
- The brake discs are burnt and/or the piston seals are defective.
Nominal
value
The pilot pressure in The solenoid valve 57Q516 is mechanically Replace the solenoid
Yes 0bar
the travel parking brake 1 stuck. The pilot pressure in the travel parking valve 57Q516.
circuit is not released brake line is not released to the hydraulic oil
tank. No Go to next step.
Is the piston of the solenoid valve stuck?
The pressure Check and adjust the pressure at valve no. 47 SERVICE
according to the instructions and specifications MANUAL
adjustment is too low Yes Go to next step.
2 in the SERVICE MANUAL and PM-CLINIC PM-CLINIC
or valve no. 47 is
defective sheets. 35bar
Is it possible to adjust the pressure as
No Replace valve no. 47.
specified?
Main key switch 20S001 OFF
Check for leaks or
Perform the following steps: mixed-up connections 45bar,
– Disconnect the pilot pressure supply Yes in the pilot supply lines kept up for
hoses from the travel parking brake for the travel parking 15 minutes
housings. brake system.
– Install a manual hydraulic pump with Refer to the
The brake discs are 60 bar manometer in order to test the instructions in the
burnt and/or the piston 3 travel parking brake piston seals SERVICE MANUAL.
seals are defective (perform the test for both travel brake - Repair or replace the
housings). travel parking brakes.
– Using the manual pump increase the REMARKS: SERVICE
No
pressure up to 45 bar. Bleed the air from MANUAL
– The built-up pressure must be kept up for the swing parking
15 minutes. brake(s).
Can you build-up 45 bar and is the pressure - Then check the travel
kept up for 15 minutes without further action? parking brakes for
proper operation.
Final check 4
8 - 56 PC4000-6 TS 08199-xD-GB-2
Troubleshooting by Symptoms Symptoms of the Mechanical System
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 At first judge whether the noise is an internal noise or an external noise.
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
value
Yes Go to final step 2.
Refer to the following
judgment table and
Check all related parts and components for locate the problem.
External noise
(the abnormal noise is proper function. When the cause for the
1 noise is determined,
not coming from inside Check suspicious screw connections and
the engine) mountings for proper tightening condition. perform the
No
appropriate repair
Could you locate and rectify the cause for the procedures as
abnormal noise? necessary.
After the repair is
completed, go to
final step 2.
Final check 2
TS 08199-xD-GB-2 PC4000-6 8 - 57
Symptoms of the Mechanical System Troubleshooting by Symptoms
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

Deformed fan or defective fan hub
Improper gear train backlash

Legend
Clogged, seized injector

Missing, seized bushing
Defective fuel pump


Questions
Gradually occurred Ο Ο
Condition of abnormal noise
Suddenly occurred Ο Ο Ο
Non-specified fuel is being used Ο Ο
Black ◙ Ο Ο
Metal particles are found in the oil filter ◙ ◙
Check items

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 ◙

When rotating the turbocharger by hand, it is too rough-running ●
Troubleshooting
Remove the gear cover and inspect directly ● ●

Fan is deformed or the fan hub is defective ●
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
8 - 58 PC4000-6 TS 08199-xD-GB-2
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 concerning the
correct oil specifications and oil qualities.
Problem that appears - Abnormal noise.
- 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
- No or not enough external lubrication (X4 pressure) at the pump bearings (refer to the latest
version of PARTS & SERVICE NEWS AH05510, latest version)
Possible causes
- The internal throttle lubrication valve in the main pump housing is not opened enough
or it is closed.
- Main pump defective (internal mechanical damage)
- Air entering the hydraulic system or air bubbles inside the hydraulic suction lines
Nominal
value
Between
Yes Go to next step. MIN &
Check the oil level in the PTO housing using
No oil or the oil level MAX
1 the dipstick. For details refer to the
is too low in the PTO Refill specified oil up
OPERATION & MAINTENANCE MANUAL.
to the specified level
Is the oil level correct between the MIN and
No and recheck if the
MAX marks?
abnormal noise
disappeared.
Yes Go to next step. Oil specifi-
Check the oil level and the oil quality in the cation and
pump bearing housing of the PTO gearbox. refill level
No oil or the oil level reference:
For details refer to the OPERATION & Refill specified oil up
is too low in the pump 2
MAINTENANCE MANUAL and to the to the specified level - O/MM
bearing housing
PARTS & SERVICE NEWS AH07515 No and recheck if the - P&S
(latest version). abnormal noise NEWS
Is the oil level correct and does the oil quality disappeared. AH07515
meet the specification? (latest
version)
Yes Go to next step. 60bar
Check the X4 pressure (60 bar) at the valve SERVICE
No or not enough and filter plate.
external lubrication MANUAL
3 For details refer to the SERVICE MANUAL and
(X4 pressure) at the Adjust the specified P&S
pump bearings to the PARTS & SERVICE NEWS AH05510 No NEWS
(latest version). X4 pressure.
AH05510
Does the X4 pressure meet the specification? (latest
version)
TS 08199-xD-GB-2 PC4000-6 8 - 59
SME002 - Abnormal noise around the PTO / hydraulic pumps

[2/2]
Nominal
value
Check the basic adjustment of the throttle Throttle
lubrication valve. Yes Go to next step. valve:
fully open
For details refer to the PARTS & SERVICE
NEWS AH05510 (latest version). Check the X4 pressure
The internal throttle at this port and adjust
lubrication valve in the Is the throttle lubrication valve fully open and No 60bar
the throttle valve to
main pump housing 4 is X4 pressure present? fully open position.
is not opened enough
or it is closed REMARKS: If the pump was operated after pump replacement, with the
throttle valve closed or not fully open, the pump bearing was
not enough lubricated!
In this case, replace the complete main pump again and make
sure that the throttle valve is set to "fully open" before operating
the pump.
New pumps are always delivered with closed throttle valves.

Move the attachment in working condition.
Double-check the
suspicious main pump
Check for abnormal noise coming from around for excessive noise
Main pump defective or directly from the main pumps. Yes generation.
(internal mechanical 5 Use a vibration analyzer, take measurements If it is confirmed,
damage) at all 4 main pumps and compare the replace the noisy
measurement results. main pump.
Does any main pump show excessive noise All main pumps
generation? generate too much
No noise simultaneously.
Got to next step.
Move the attachment in working condition.
If you located air
bubbles in the
hydraulic system There is no
refer to the latest air in the
Check the sight glass at the hydraulic tank version of PARTS & hydraulic
for air bubbles. Yes SERVICE NEWS oil tank
Air entering the Also check the suction lines and clamps of - AH01513 & and in the
hydraulic system or sealed connections for air leakage. - AH00504 & suction
6 - 21.531 lines.
air bubbles inside the NOTE! Suction lines always must be
hydraulic suction lines for bleeding the
mounted with silicon applied
hydraulic cylinders.
to the pipes and they must
be fixed with double-clamps. Check the lifetime of
the PTO and the main
Could you locate air in the hydraulic tank or air
pumps.
bubbles in the suction lines?
No The abnormal noise
may be caused by
normal wear due to
component aging.
Final check 7
8 - 60 PC4000-6 TS 08199-xD-GB-2
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 function and proper tightening.
- Measure the alignment/incline of the engine (& PTO) mountings (horizontal & vertical).
Related information
- For detailed information regarding Diesel engine suspension refer to the latest version of
Problem that appears - Abnormal vibration and the risk that a breakdown may occur.
- Defective parts → mounting supports of engine and PTO.
- Improper alignment → mixed mounting of old (worn and/or defective) and new mounting supports.
Possible causes - Abnormal combustion.
- Defective front damper.
- Defective rear damper (coupling to PTO).
Nominal
value
- Defective parts Yes Go to final step 2.
→ mounting supports of engine and PTO.
- Improper alignment Refer to the following
→ mixed mounting of old (worn and/or judgment table and
defective) and new mounting supports. locate the problem.
Abnormal or excessive
vibration coming from - Abnormal combustion. When the cause for
1 the noise is deter-
the engine or related - Defective front damper.
parts - Defective rear damper (coupling to PTO). mined perform the
No
appropriate repair
Check all related parts and components of the
procedures as
above items for proper function and condition.
necessary.
Check suspicious screw connections and
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?
Final check 2
TS 08199-xD-GB-2 PC4000-6 8 - 61
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


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
8 - 62 PC4000-6 TS 08199-xD-GB-2
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
QSK60 Engine (SDA 12V 160 Komatsu Engine).
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.
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
value
Front double-mass Replace the damper.
Check the front double-mass vibration damper Cummins
vibration damper 1 Also check the rear
according to the specifications given in the Yes specifica-
defective coupling for wear
Cummins Service Manual. tion
(step 2).
Is the damper defective?
No Go to next step.
Replace the coupling.
Also check the front
SERVICE
Yes double-mass vibration
Rear coupling MANUAL
2 Check the rear coupling for wear and proper damper on the
defective function. crankshaft (step 1).
Is the coupling defective? Inform the Cummins
Service and measure
No
the blow-by pressure
of the engine.
Final check 3
TS 08199-xD-GB-2 PC4000-6 8 - 63
SME005 - There is a big shock when stopping swing

[1/1]
Trouble code
Trouble There is a big shock when stopping swing
SME005
A big shock occurs when stopping the swing movement with the swing foot brake or by the
Contents of trouble
counter swing function.
Related information A big shock occurs when the superstructure changes its swing direction.

Excessive wear and in consequence further damage may occur.
on the machine
- Wear in vertical & horizontal direction at the boom foot bushings and pins.
Possible causes
- Excessive wear of the swing circle (causing heavy backlash).
Nominal
value
Replace pins
and bushings at Boom foot
the connection bushings &
between boom pins, max.
and superstructure. clearance
2.5mm
Wear in vertical & After replacement
horizontal direction Move the attachment smoothly and check for measure the axial
1 Yes Axial play
at the boom foot excessive wear at the boom foot bushings. clearance at the con-
bushings and pins Is the movement too large? nection between boom between
and superstructure. boom and
super-
If the axial play is still structure,
out of range repair with max.
the welding and lathe clearance
tool. 2.5mm
No Go to next step.
P&S
NEWS
Replace the swing
Yes AH02513
circle.
(latest
version)
Move the attachment smoothly and check for
Check the teeth
Excessive wear of the excessive wear and movement of the swing
around the swing
swing circle (causing 2 circle and backlash.
circle.
heavy backlash) Also refer to the latest version of
PARTS & SERVICE NEWS AH02513. Also check the grease
dummy wheel for the
Is the wear out of range? No
swing circle teeth
(tightening).
Go to SME006 and
refer to its trouble-
shooting procedures.
Final check 3
8 - 64 PC4000-6 TS 08199-xD-GB-2
SME006 - There is a big abnormal noise when moving/stopping swing

[1/2]
Trouble code
Trouble There is a big abnormal noise when moving/stopping swing
SME006
- A big abnormal noise occurs when moving/stopping swing.
Contents of trouble
- The abnormal noise may also exist permanently during the swing movement.
- First check all oil levels at the swing gearboxes.
- Verify the oil level and the used oil viscosity in the swing gearboxes (CLP 220 only).
Related information - Verify the oil level and the used oil viscosity in the swing parking brake housing (SAE 30 only).
- Verify the oil level and the used oil viscosity in the motor adapter housing (SAE 30 only).
- Also refer to the OPERATION & MAINTENANCE MANUAL and to the SERVICE MANUAL.
Abnormal noise and in consequence any damage may occur.
on the machine
- Swing gearbox - internal damage.
- Faulty bottom bearing of the swing gearbox pinion (external grease lubrication).
Possible causes - Swing parking brake - internal damage (discs are welded with each other).
- Damaged mechanical connection between the swing hydraulic motor and the swing gearbox
(motor adapter housing, excessive wear at the connection).
Nominal
value
Smooth swing movement of the superstructure.
Check for proper tightening of the swing SERVICE
Swing gearbox gearboxes, and retighten if necessary. Replace the defective MANUAL
1 Yes
internal damage swing gearbox. Tightening
During swing movement, check and listen
chart
for noise at the gearboxes.
Can you identify any abnormal noise coming No Go to next step.
from any swing gearbox?
During swing movement check the movement SERVICE
of the swing gearbox pinion. MANUAL
Faulty bottom bearing Replace the defective Component
During swing movement also check and listen Yes
of the swing gearbox swing gearbox. structure
for noise at the lower side of the respective and grease
pinion 2 swing gearbox. system
(external grease
lubrication) Check the grease supply and grease amount
(injector adjustment) at the pinion bearing.
Can you identify any abnormal noise or No Go to next step.
abnormal movement of the swing gearbox
pinion?
TS 08199-xD-GB-2 PC4000-6 8 - 65
SME006 - There is a big abnormal noise when moving/stopping swing

[2/2]
Nominal
value
Although the swing
parking brake is closed
the superstructure
moves and causes
noise or shock during
Check the swing parking brake for proper stopping or starting the
condition swing movement.
Swing parking brake
internal damage (parking brake switch in position "1" = brake Inspect and replace
3 closed). the defective swing SERVICE
(discs are welded Yes
parking brakes as MANUAL
together) Carefully move the control lever to start swing
movement. necessary.
Can you identify any abnormal noise or Also check for

abnormal swing movement? contamination of the
gearbox oil.
Drain contaminated
oil and refill fresh
specified gearbox oil.
No Go to next step.
Disconnect the
hydraulic swing motor
from the swing gear-
box and check the
Check the swing movement for proper connection between SERVICE
Damaged mechanical Yes both components.
condition → MANUAL
connection between If the connection is
- starting swing
the swing hydraulic damaged, replace the
- stopping swing
motor and the swing swing gearbox and the
4 - counter swing
gearbox hydraulic motor.
- foot brake actuation
(motor adapter
- fast swing speed Check the hydraulic
housing, excessive
- low swing speed) swing adjustment
wear at the connection)
Can you identify any abnormal noise, (two stage valve).
SERVICE
abnormal swing movement, Refer to the SERVICE
MANUAL
or abnormal vibration? No MANUAL and the
& PM-
PM-CLINIC sheets.
CLINIC
Also see the trouble-
shooting charts of
SHY008-010.
Final check 5
8 - 66 PC4000-6 TS 08199-xD-GB-2
SME007 - Fan hub bearing noise is abnormal

[1/1]
Trouble code
Trouble Fan hub bearing noise is abnormal
SME007
- Abnormal noise occurs when the hydraulic oil cooler/radiator fans are starting or stopping.
Contents of trouble
- The abnormal noise may also exist permanently when the fan is running continuously.
- First check all oil levels at the fan hubs.
- Verify the oil level and the used oil viscosity in the fan hubs (CLP 220 only).
Related information - Make sure that the vent valves on top of the fan hubs are clean.
- Check for horizontal & vertical movement of the fan hub bearing.
Abnormal noise and in consequence any cooler damage may occur.
on the machine
- Fan hub bearing worn out.
- A wrong oil viscosity is used (bearing sound during rotating)
Possible causes
→ Short lifetime of the fan hub bearings.
- Fan blades are loose or broken.
Nominal
value
Check the fan hub bearings for wear. No hori-
Fan hub bearing Replace the worn or zontal &
1 Move the fan manually and check Yes
worn out damaged fan hub(s). axial fan
for horizontal & axial movement.
movement
Can you identify any horizontal & axial
fan movement? No Go to next step.
Replace the worn &
noisy fan hub(s) and No hori-
A wrong oil viscosity is Manually check the fan hub bearings for wear refer to the O/MM in zontal &
used (bearing sound and rotating sound. order to verify the axial fan
during rotating). 2
Move the fan manually and check Yes correct oil viscosity. move-
Short lifetime of the fan ment, no
for horizontal & axial movement. Only CLP 220 is
hub bearings. rotating
Can you identify any horizontal & axial approved:
Replacement interval sound
fan movement?
3000 hrs.
No Go to next step.
Check the lifetime of
the concerned fan(s). No hori-
zontal &
Yes If the lifetime exceeds axial fan
Fan blades are loose Manually check the fan blades 10,000 hrs, replace all
3 movement
or broken for proper connection. fans.
Turn the fan manually and check each blade. Check the hydraulic
Is any fan blade loose? cooler fan drive for
overspeed. RPM max
No
1250±50
Adjust the specified
speed if necessary.
Final check 4
TS 08199-xD-GB-2 PC4000-6 8 - 67
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 when the shovel is travelling continuously.
- 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.
Abnormal noise and in consequence any capital damage may occur.
on the machine
- Gearbox broken (housing or 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).
Nominal
value
Refer to the SERVICE
MANUAL & PM-
CLINIC sheets and
Gearbox broken carry out the basic SERVICE
Take the track off the ground - during rotation adjustment of the MANUAL
(housing or internal
1 check each side for abnormal noise or shocks. Yes travel system.
parts defective) PM-
Short-term failure. Can you identify any abnormal noise or shock If the noise continues CLINIC
during track rotation? after the basic adjust-
ment, replace the con-
cerning travel gearbox.
No Go to step 3.
Refer to the SERVICE
MANUAL & PM-
CLINIC sheets and
A wrong oil viscosity is
carry out the basic SERVICE
used (any planetary Take the track off the ground - during rotation adjustment of the MANUAL
gear teeth and/or 2 check each side for abnormal noise or shocks. Yes travel system. PM-
bearing defective).
Can you identify any abnormal noise or shock If the noise continues CLINIC
Long-term failure. during track rotation? after the basic adjust-
ment, replace the con-
cerning travel gearbox.
No Go to next step.
8 - 68 PC4000-6 TS 08199-xD-GB-2
SME008 - Abnormal noise coming from a travel gearbox

[2/2]
Nominal
value
Replace the concern-
ing travel motor and
Yes replace the planetary
gear pinion at the
Hydraulic travel motor Disconnect the concerning travel motor from gearbox.
connection defective the adapter housing and check the connection
3 Check the travel
(no oil in the motor at the motor and inside the motor adapter
housing for any damage. motor(s) for internal
adapter housing)
and external leakage
Can you identify any damage (because of and replace if
missing oil)? No necessary.
Also refer to the
troubleshooting chart
of SHY006.
Final check 4
TS 08199-xD-GB-2 PC4000-6 8 - 69
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 (CLS) at the pins and the bushings of the
work equipment.
- First check the grease level at the CLS grease barrel.
- Verify that the barrel contains grease of the specified quality and viscosity.
Related information - Verify that all injectors are in good condition and properly adjusted.
- Verify that the setting of the pause time (VHMS monitor) is correct.
Abnormal noise and in consequence any capital damage of the pins and bushings may occur.
on the machine
- A wrong grease quality is used.
- Contaminated grease is used.
Possible causes
- Daily fault messages of the CLS system occur - download the history data via VHMS and verify
the system status.
Nominal
value
SERVICE
MANUAL
PM-
CLINIC
Yes Go to next step. P&S
NEWS
AH02539
(latest
Recheck the grease quality and specification
version)
under consideration of the KMG recommenda-
A wrong grease quality tions in the OPERATION & MAINTENANCE Replace wrong grease
1
is used MANUAL and in the latest version of the by specified grease
PARTS & SERVICE NEWS AH02539. and replace the
defective pins and
Does the used grease correspond to the KMG
bushings on the
recommendations?
attachment side.
No Check all grease
injectors for proper
function.
Pre-lubricate all pins
and bushings through
the injectors until the
new grease flows out.
8 - 70 PC4000-6 TS 08199-xD-GB-2
SME009 - Abnormal noise coming from the work equipment (lack of grease)
[2/2]
Nominal
value
Replace the contami-
nated grease by
specified grease.
Clean or replace the
Contaminated grease The injectors are worn out due to barrel as necessary.
is used contaminated grease in the barrel. Replace the defective
(grease barrel refilling 2 No or not enough grease causes early wear pins and bushings on
Yes
without refilling the and noise at the pins and bushings of the the attachment side.
filter) attachment. Check all grease injec-
Are pins and bushings worn out due to lacking tors for proper function.
grease and defective injectors? Pre-lubricate all pins
and bushings through
the injectors until the
new grease flows out.
No Go to next step.
Main key switch OFF & mainte-
nance safety switch locked.
Repair or replace any defective
parts of the CLS system as
Daily fault messages of necessary.
the CLS system occur Download the history data via VHMS
and verify the system status. Replace the defective pins and
Download the history 3 bushings on the attachment
data via VHMS and Do the history data show a lot of side (standardization of
verify the system status "bucket cut-off" messages due to overriding importance).
missing grease?
Check all grease injectors for
proper function.
Pre-lubricate all pins and
bushings through the injectors
until the new grease flows out.
Final check 4
TS 08199-xD-GB-2 PC4000-6 8 - 71
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 pin and bushings for wear.

- Verify that the specified oil quality and viscosity is used inside the idler
Related information (CLP 220 / HD 220 for arctic temperatures).
- Verify that the track tensioning system is working properly.
Problem that appears Abnormal idler movement and in consequence any capital damage of pins, bushings, or supports
on the machine may occur.
- Leak at the life time seals (pin & bushing worn out).
Possible causes
- Idler supports are below the wear limit.
Nominal
value
Leak at the life time Open the track chain and remove the idler. Replace the complete
seals (pin & bushing 1 Disconnect the supports of the idler and check Yes idler including new
worn out) the lifetime seals and the wear of pin and supports.
bushings.
No Go to next step.
Are pin and bushings worn out?
If excessive wear is found,
Idler supports are replace the idler supports.
2
below the wear limit Check for excessive wear between the idler Also check the lifetime of the
supports and the track frame. idler, and if the lifetime is
exceeded, replace worn
components as necessary.
Final check 3
8 - 72 PC4000-6 TS 08199-xD-GB-2
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).
Related information
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.
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
value
Replace or repair as
necessary.
Recommendation
(Diesel only)
For the removal of
the input drive shaft
it is beneficial to
The bearing of the Remove the coupling. remove the complete Movement
drive shaft is defective
1 Check the input shaft bearing of the PTO gearbox and to max. 2mm
(too much movement), Yes
PTO gearbox. remanufacture the horizontal
check the PTO lifetime
removed one & vertical
Is abnormal bearing movement (horizontal &
according to the
vertical) detectable?
Reman Guideline
later.
The removal of the
drive shaft in place is
not possible!
No Go to next step.
TS 08199-xD-GB-2 PC4000-6 8 - 73
SME011 - Leak at the PTO shaft seal

[2/2]
Nominal
value
Check the PTO lifetime
Clean up the PTO drive shaft area and check and replace the PTO
for any leakage. if necessary.
Yes
The shaft seal is burnt Remanufacture the old
In some areas the oil viscosity recommend by
due to use of a wrong 2 PTO according the Oil specifi-
KMG is not available.
oil viscosity Reman Guideline. cation:
If a wrong oil viscosity was used, the seal ring
Replace / reseal - CLP 150
on the drive shaft may be burnt, causing a
leakage. remanufacture the
No PTO, and from now on
Was oil type CLP 150 used on your shovel? use the correct oil
specification CLP 150.
Replace the coupling
Yes and observe the
correct alignment.
Due to a long term
PTO overheating
Coupling mounting Remove the coupling. (permanently over
or coupling defective 3 95C°) the seal ring on
Check the coupling lifetime and SERVICE
(misalignment) the input shaft may be
check the coupling for any defect MANUAL
hardened and brittle.
Is any problem present? No
Check the PTO cooling
system - verify that the
PTO temperature does
not exceed 75C°
during normal
operation.
Final check 4
8 - 74 PC4000-6 TS 08199-xD-GB-2
Troubleshooting by Symptoms Symptoms of Additional Systems
8.4 SYMPTOMS OF ADDITIONAL SYSTEMS
SAD001 - Air conditioner does not work

[1/2]
Trouble code
Trouble Air conditioner 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 the latest version of
Related information
Problem that appears - A/C does not work and excessive heat in the operator's cab is possible.
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 - Any electrical problem causes a disconnection or short circuit in the wiring or any component of
the A/C system.
Nominal
value
A/C switched ON.
Wrong or no
maintenance of 1 P&S
Check the maintenance history. Using the A/C test
the A/C system NEWS
tools, perform the
Was the maintenance done as scheduled? No AH05537
standard checking
(latest
procedure.
version)
A/C switched ON.
WARNING
If air conditioner refrigerant gets into your eyes, it - Check the A/C
may cause blindness. If it touches your skin, it may system together with
cause frostbite. Never touch refrigerant. an A/C specialist and
- Refer to the A/C P&S
Any electrical problem In compliance with the regulations: manual and follow NEWS
causes a disconnection When working at the A/C circuit or when handling the given procedures. AH05537
or short circuit in the refrigerant R134a always observe the safety hints - Refer to the Wiring (latest
2 version)
wiring or in any given in the A/C manual and in the data sheet of Diagram and check
component of the the refrigerant manufacturer. the main fuse box
A/C system A/C
Work on the air conditioning system may only be and the relays in the
Manual
carried out by persons having special knowledge A/C unit.
and experience in these systems. - Check the wiring for Wiring
Always wear Safety Glasses and Safety Gloves when disconnection or Diagrams
working on the A/C circuit. short circuit.
1. Using the A/C test tools perform a standard check Locate the problem
of the A/C system. and repair as
2. Check for trouble codes displayed at the A/C necessary.
control unit (for details refer to the A/C manual).
3. Check for electrical problems.
Could you identify any problem?
Final check 3
TS 08199-xD-GB-2 PC4000-6 8 - 75
Symptoms of Additional Systems Troubleshooting by Symptoms
View onto the A/C unit (SAD001)

[2/2]
Fig. 8-4 View onto the A/C unit (SAD001)
Legend for Fig. 8-4
(1) Relays
(2) Fuse box
(3) A/C control unit
8 - 76 PC4000-6 TS 08199-xD-GB-2
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 version of
Related information
- For repair hints concerning the clutch pulley also refer to the latest version of
PARTS & SERVICE NEWS AH05542 & AH06516 & AH06531.
- A/C does not work and excessive heat in the operator's cab is possible.
- 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).
Possible causes - A wrong refilling procedure has been performed.
- Wrong installation or alignment of the A/C compressor support.
Nominal
value
A/C switched ON.
Wrong or no
maintenance of 1 P&S
the A/C system NEWS
tools, perform the
standard checking
(latest
procedure.
version)
A wrong refilling Engine running at high idle.
procedure has A/C switched ON.
been performed P&S
WARNING NEWS
Yes Go to next step. AH05537
In compliance with AIR CONDITIONING REFRIGERANT IS (latest
the regulations: HARMFUL! version)
If air conditioner refrigerant gets into your
When working at the eyes, it may cause blindness. If it touches
A/C circuit or when your skin, it may cause frostbite. Never Repair and replace defective parts
handling refrigerant touch refrigerant. as necessary.
R134a always observe
the safety hints given in Details for repair or replacement
the A/C manual and in
the data sheet of the 1. Using the A/C test tools perform a 1. Is the specified amount of the
2 standard check of the A/C system. specified compressor oil filled
refrigerant manufac-
turer. 2. Follow the appropriate filling procedure in?
and consider the filling capacity in the
Work on the air cooling circuit. Make sure that the No compressor oil or the wrong
conditioning system pressure safety valve at the compressor No amount of it causes early
may only be carried out is open before filling the A/C circuit. defects of the A/C compressor.
by persons having 3. Is the specified amount of the specified 2. Is the specified amount of
special knowledge compressor oil filled in? refrigerant R134a filled in?
and experience in 4. Is the specified amount of refrigerant
these systems. R134a filled in? Too much R134a (only refilled
over the system pressure)
Always wear Safety 5. Has the system been evacuated and is it causes an early defect of the
Glasses and Safety free of moisture?
A/C compressor shaft seal or
Gloves when working 6. Is the A/C system dry and clean? a burnt clutch.
on the A/C circuit.
TS 08199-xD-GB-2 PC4000-6 8 - 77
SAD002 - Air conditioner compressor clutch is burnt

[2/2]
Nominal
value
– 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
– Check the drive belts for wear and correct Yes Manual and follow the NEWS
alignment of the A/C 3
tension. maintenance hints. AH05537
compressor support
– Check for the correct V-belt running (latest
direction between the pulleys. version)
Adjust, repair, or
Are the above items ok? No
replace as necessary.
Final check 4
View onto the A/C compressor and its mounting (SAD002)
Fig. 8-5 View onto the A/C compressor and its mounting (SAD002)
Legend for Fig. 8-5
(1) A/C compressor (3) Mounting bracket
(2) Belt running direction (4) Mounting bolt
8 - 78 PC4000-6 TS 08199-xD-GB-2
SAD003 - Air conditioning system defective (pipes and hoses full of

moisture)
[1/1]
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 version of
Related information
- For repair hints concerning the clutch pulley also refer to the latest version of
PARTS & SERVICE NEWS AH05542 & AH06516 & AH06531.
- A/C does not work and excessive heat in the operator's cab is possible.
- 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).
Possible causes - Maintenance or repair is impossible because of too much moisture in the pipes and hoses of the
A/C system.
Nominal
value
A/C switched ON.
Wrong or no
maintenance of the 1 P&S
A/C system NEWS
tools, perform the
standard checking
(latest
procedure.
version)
WARNING
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 A/C
Maintenance or repair refrigerant manufacturer. Manual
is impossible because Work on the air conditioning system may only be carried out by persons having P&S
of too much moisture in 2 special knowledge and experience in this system. NEWS
the pipes and hoses of Always wear Safety Glasses and Safety Gloves when working on the A/C circuit. AH05537
the A/C system (latest
– Disassemble the A/C system and check all parts for moisture. version)
If hoses and pipes are full of moisture, this is an indication that no
or not enough maintenance of the A/C system has been done.
– Replace any defective or contaminated parts.
Assemble and evacuate the system.
– Refill the specified amount of the specified compressor oil and
the specified volume of the R134a refrigerant.
– 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.
Final check 3
TS 08199-xD-GB-2 PC4000-6 8 - 79
SAD004 - Travel alarm does not sound

[1/2]
Trouble code
Trouble Travel alarm does not sound
SAD004
Contents of trouble The travel alarm does not sound when the travel pedals are operated.
Related information The travel alarm does not sound when the travel pedals are operated in both directions.

No warning sound during traveling.
on the machine
- The signal beeper 60P140 is defective.
Possible causes
- No signals coming from the pedals 20S021a & 20S021b, or any wiring problem occurred.
Nominal
value
Activate the travel pedals.
– Check if battery voltage and ground Vmin 22V
Replace the signal
is present at connector 51X252, Yes
beeper 60P140. Vmax 24V
terminals 30, 31.
The signal beeper – Main key switch 20S001 in OFF position.
1
60P140 is defective – Disconnect connector 51X252 and insert
the T-cable.
No Go to next step.
– Measure the voltage.
– Measure ground at 51X252 terminal 31.
Is specified battery voltage present?
No signals coming Activate the travel pedals.
from the pedals Refer to the Wiring Diagram.
20S021a & 20S021b, 2 Locate the problem Vmin 22V
– Check the signal wiring of the travel pedals.
or any wiring problem and repair or replace
occurred – Check the wiring leading to the signal beeper as necessary. Vmax 24V
60P140.
Final check 3
8 - 80 PC4000-6 TS 08199-xD-GB-2
Wiring Diagram (60P140) for trouble code SAD004

[2/2]
Fig. 8-6 Wiring Diagram (60P140) for trouble code SAD004
TS 08199-xD-GB-2 PC4000-6 8 - 81
8 - 82 PC4000-6 TS 08199-xD-GB-2

TS 08199-xD-GB-2

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Unsafe use of this machine may cause serious

Komatsu has Troubleshooting Manuals written

1 SAFETY ..................................................................................................... 1-1

TS 08199-upD-GB-2 PC4000-6 TOC - 1

TOC - 2 PC4000-6 TS 08199-upD-GB-2

2 INTRODUCTION & GENERAL INFORMATION FOR TROUBLESHOOT. 2-1

TS 08199-upD-GB-2 PC4000-6 TOC - 3

3 MOUNTING LOCATIONS AND CONNECTOR TYPES ............................ 3-1

4 STANDARD VALUE TABLE FOR ELECTRICAL COMPONENTS............ 4-1

TOC - 4 PC4000-6 TS 08199-upD-GB-2

6 TABLES FOR TESTING AND TROUBLESHOOTING .............................. 6-1

7 TROUBLESHOOTING BY TROUBLE CODE............................................ 7-1

G00002 - Test speed 1800 1/min engine 1 ........................................................................................... 7-7

G00003 - Trouble pump controller ....................................................................................................... 7-9

G00005 - Low hydraulic oil level......................................................................................................... 7-13

G00007 - Trouble hydraulic oil level................................................................................................... 7-16

G00012 - Central lubrication system grease level too low............................................................... 7-18

G00020 - Trouble Shut-Off (gate) valve (Start blocked) ................................................................... 7-24

TS 08199-upD-GB-2 PC4000-6 TOC - 5

G00032 - Trouble starter...................................................................................................................... 7-31

G00033 - Trouble VHMS-Controller .................................................................................................... 7-34

G00034 - Trouble VHMS-Display ........................................................................................................ 7-35

G00035 - Trouble totally loss gear oil (PTO 1) .................................................................................. 7-36

G00039 - Actuate engine speed selector switch ............................................................................... 7-41

G00043 - Trouble output short-circuit................................................................................................ 7-42

G00048 - Trouble emergency safety circuit....................................................................................... 7-43

G00053 - Reset emergency safety circuit .......................................................................................... 7-44

G00054 - Monitoring idle position cut off .......................................................................................... 7-45

G00060 - Fire in the power house....................................................................................................... 7-48

G00061 - Trouble monitoring, engine 1 speed too low .................................................................... 7-52

G00062 - Trouble monitoring, engine 1 speed too high ................................................................... 7-55

G00063 - Trouble monitoring hydraulic oil temp .............................................................................. 7-57

G00064 - Trouble monitoring hydraulic oil level ............................................................................... 7-59

G00065 - Very low hydraulic oil level ................................................................................................. 7-62

TOC - 6 PC4000-6 TS 08199-upD-GB-2

G00067 - Trouble battery voltage too high ........................................................................................ 7-66

G00069 - Trouble monitoring oil temperature gear (PTO 1)............................................................. 7-68

G00070 - Trouble oil temperature gear (PTO 1) ................................................................................ 7-71

G00071 - Trouble gear lubrication (PTO 1) ........................................................................................ 7-74

G00081 - Trouble lubrication system ................................................................................................. 7-76

G00086 - SHUTDOWN.......................................................................................................................... 7-81

G00087 - Stop all movements for low idle ......................................................................................... 7-82

G00090 - Trouble power supply.......................................................................................................... 7-83

G00099 - Trouble power supply.......................................................................................................... 7-83

G00091 - Pilot control cut out ............................................................................................................. 7-85

G00092 - Emergency shut-down at access ladder ........................................................................... 7-87

G00093 - Emergency shut-down at valve block................................................................................ 7-87

G00094 - Emergency shut-down at hydraulic control panel............................................................ 7-87

G00095 - Emergency shut-down in cabin.......................................................................................... 7-87

G00096 - Pilot control cut out ............................................................................................................. 7-89

G00100 - Maintenance Safety Switch................................................................................................. 7-91

G00102 - Switch off wiper [S/N 08199 only]....................................................................................... 7-93

TS 08199-upD-GB-2 PC4000-6 TOC - 7

G00104 - Trouble battery current ....................................................................................................... 7-98

G00105 - Trouble battery charging current too low........................................................................ 7-101

G00107 - Trouble slew parking brake control 56K250a.................................................................. 7-103

G00109 - Trouble slew parking brake control 56K250b ................................................................. 7-103

G00111 - Trouble travel parking brake control 56K251a ................................................................ 7-111

G00113 - Trouble travel parking brake control 56K251b................................................................ 7-111