Troubleshooting Manual

TS 15110-xD-GB-0
Troubleshooting Manual
HYDRAULIC
MINING PC5500-6
SHOVEL
SERIAL NUMBER 15110 (15100) - 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 Service Manuals written in other

languages. If a foreign language manual 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.
PC5500-6
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 ELECTROMAGNETIC COMPATIBILITY (EMC) ................................................................. 1-13
1.4.10 PRECAUTIONS AT JOBSITE ............................................................................................. 1-14
1.4.10.1 VISIBILITY FROM OPERATOR’S SEAT ............................................................. 1-15
1.4.10.2 CAMERA SYSTEM WITH MONITORS ............................................................... 1-15
1.4.10.3 ENSURE GOOD VISIBILITY ............................................................................... 1-15
1.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS ........................................... 1-15
1.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS ................................... 1-16
1.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES .......................................... 1-16
TS 15110-xD-GB-0 PC5500-6 TOC - 1

1.4.10.7 WORKING ON LOOSE GROUND ....................................................................... 1-17
1.4.10.8 GAS, DUST, STEAM AND SMOKE ..................................................................... 1-17
1.4.10.9 VENTILATION OF ENCLOSED AREAS.............................................................. 1-18
1.4.11 STARTING MOTOR............................................................................................................. 1-19
1.4.11.1 WARNING TAG.................................................................................................... 1-19
1.4.11.2 CHECKS BEFORE STARTING MOTOR ............................................................. 1-19
1.4.11.3 PRECAUTION WHEN STARTING MOTOR ........................................................ 1-19
1.4.11.4 PRECAUTION IN COLD AREAS ......................................................................... 1-20
1.4.12 OPERATION ........................................................................................................................ 1-20
1.4.12.1 CHECKS BEFORE OPERATION ........................................................................ 1-20
1.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE ............... 1-21
1.4.12.3 PRECAUTIONS WHEN TRAVELLING ................................................................ 1-22
1.4.12.4 TRAVELLING ON SLOPES ................................................................................. 1-23
1.4.12.5 OPERATIONS ON SLOPES ................................................................................ 1-24
1.4.12.6 PROHIBITED OPERATIONS............................................................................... 1-24
1.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES....................... 1-25
1.4.12.8 PARKING THE MACHINE ................................................................................... 1-25
1.4.12.9 TRANSPORTATION ............................................................................................ 1-25
1.5 PRECAUTION FOR MAINTENANCE .............................................................................................. 1-26
1.5.1 GENERAL PRECAUTIONS ................................................................................................. 1-26
1.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL -
BASIC RESPONSIBILITIES................................................................................. 1-27
1.5.1.2 STOP MOTOR FOR MAINTENANCE ................................................................. 1-28
1.5.1.3 WARNING TAG.................................................................................................... 1-29
1.5.1.4 KEEP WORKPLACE CLEAN AND TIDY ............................................................. 1-30
1.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS ..................................... 1-30
1.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING.. 1-31
1.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS ............................... 1-31
1.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 1-32
1.5.1.9 NOISE .................................................................................................................. 1-32
1.5.1.10 WHEN USING A HAMMER.................................................................................. 1-32
1.5.1.11 PROPER TOOLS ................................................................................................. 1-33
1.5.1.12 ACCUMULATOR.................................................................................................. 1-33
1.5.1.13 PERSONNEL ....................................................................................................... 1-33
1.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE................................................ 1-34
1.5.2.1 PRECAUTION WHEN WELDING ........................................................................ 1-34
1.5.2.2 BATTERY HANDLING ......................................................................................... 1-34
1.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID............................................................... 1-35
1.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE ................................................ 1-35
1.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES .......................................... 1-36
1.5.3.3 REPLACEMENT OF HOSE LINES...................................................................... 1-36
1.5.3.4 INSPECTION OF HOSE LINES........................................................................... 1-36
1.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................. 1-37
1.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE............................................................... 1-37
1.5.3.7 AIR CONDITIONING MAINTENANCE................................................................. 1-37
1.5.3.8 COMPRESSED AIR............................................................................................. 1-38
1.5.3.9 WASTE MATERIALS ........................................................................................... 1-38
TOC - 2 PC5500-6 TS 15110-xD-GB-0

1.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS ....... 1-39
1.6.1 INSPECTION OF THE HYDRAULIC SYSTEM ................................................................... 1-39
1.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 1-39
1.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...................................... 1-39
1.7 SPECIAL SAFETY EQUIPMENT..................................................................................................... 1-40
1.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB ................ 1-41
1.7.2 OBJECT HANDLING ........................................................................................................... 1-41
1.7.3 LIGHTING ............................................................................................................................ 1-41
1.7.4 WARNING BEACON ........................................................................................................... 1-41
1.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ........... 1-41
1.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361
(EUROPEAN STANDARD) .................................................................................. 1-41
1.7.5.2 INSTRUCTIONS FOR USE ................................................................................. 1-43
1.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL ......................... 1-45
1.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND
HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), .................................... 1-45
1.7.5.5 INSTRUCTIONS FOR USE ................................................................................. 1-47
2 INTRODUCTION & GENERAL INFORMATION FOR

TROUBLESHOOTING ............................................................................... 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 TROUBLE-SHOOTING.............................................................. 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 ........................ 2-18
2.11 GENERAL WORKING PROCEDURES ........................................................................................... 2-20
2.11.1 AIR BLEEDING OF VARIOUS YYDRAULIC PARTS .......................................................... 2-20
2.11.2 AIR BLEEDING FROM THE HYDRAULIC PUMPS ............................................................ 2-20
2.11.3 AIR BLEEDING FROM THE HYDRAULIC CYLINDERS..................................................... 2-20
2.12 CYLINDER BYPASS TEST ............................................................................................................. 2-21
TS 15110-xD-GB-0 PC5500-6 TOC - 3

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
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 MACHINE HOUSE................................................................................................................. 3-4
3.1.3 LOCATION OF THE ELECTRICAL PARTS ON THE ENGINES........................................... 3-6
3.1.4 LOCATION OF ENGINE REMOTE OIL TANK SENSORS.................................................... 3-8
3.1.5 SUCTION OIL MANIFOLD WITH STRAINERS................................................................... 3-10
3.1.6 CONTROL AND FILTER PANELS – LOCATION OF COMPONENTS ............................... 3-12
3.1.7 LOCATION OF THE REMOTE CONTROL VALVES........................................................... 3-16
3.1.8 HYDRAULIC OIL TANK - LOCATION OF ELECTRICAL COMPONENTS ......................... 3-18
3.1.9 CLS1/2 & SLS LUBRICATION STATION AND THE LUBRICATION CYCLE
COMPONENTS ................................................................................................................... 3-20
3.1.10 ELECTRICAL COMPONENTS IN THE CAB BASE ............................................................ 3-22
3.1.11 EMERGENCY SHUTDOWN SWITCHES & SAFETY SWITCH FOR MAINTENANCE ...... 3-26
3.1.12 HYDRAULICALLY OPERATED ACCESS LADDER ........................................................... 3-28
3.1.13 SERVICE ARM .................................................................................................................... 3-30
3.2 CONNECTOR TYPES OVERVIEW.................................................................................................. 3-32
4 STANDARD VALUE TABLE FOR ELECTRICAL COMPONENTS............ 4-1
5 REFERENCES FOR TROUBLESHOOTING (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
TOC - 4 PC5500-6 TS 15110-xD-GB-0

5.3 TROUBLESHOOTING FOR RELAY MONITORED NODE OUTPUTS ............................................. 5-7
5.3.1 RELAY CHECK...................................................................................................................... 5-7
5.3.2 OUTPUT CHECK................................................................................................................. 5-12
6 TABLES FOR TESTING AND TROUBLESHOOTING .............................. 6-1

6.1 TEST VALUE TABLE FOR TEMPERATURE SENSORS (PT100) CENTIGRADE - VOLT ......... 6-2
6.2 TEST VALUE TABLE FOR TEMPERATURE SENSORS (PT100) CENTIGRADE - OHM .......... 6-3
6.3 TABLE OF TROUBLE CODES (G-CODES) ..................................................................................... 6-4
6.4 TABLE OF INSTRUCTION MESSAGES......................................................................................... 6-11
6.5 TABLE OF BINARY CODES ........................................................................................................... 6-14
6.5.1 TABLE OF ADD-ON BINARY CODES FOR G00308 .......................................................... 6-16
6.6 BINARY OUTPUT SIGNALS ON THE KOMTRAX PLUS MONITOR ............................................. 6-17
6.7 TABLES OF SYMPTOM CODES .................................................................................................... 6-20
6.7.1 SYMPTOMS OF THE ENGINES AND RELATED ELECTRICAL SYSTEMS...................... 6-20
6.7.2 SYMPTOMS OF THE HYDRAULIC SYSTEM..................................................................... 6-20
6.7.3 SYMPTOMS OF THE MECHANICAL SYSTEM .................................................................. 6-21
6.7.4 SYMPTOMS OF ADDITIONAL SYSTEMS.......................................................................... 6-21
6.8 POWER SUPPLY............................................................................................................................. 6-22
6.9 CABLE COLOUR IDENTIFICATION ............................................................................................... 6-22
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 KOMTRAX Plus monitor........................ 7-5
Wiring diagram (40B031) for trouble code G00001 (Trouble Shut-Off (gate) valve) ..................... 7-6
G00002 - Test speed 1800 1/min engine 1 ........................................................................................... 7-7

Wiring diagram (11S041-1 & 11S041-2) for trouble codes G00002 & G00006............................. 7-8
G00003 - Trouble pump controller ....................................................................................................... 7-9
G00005 - Low hydraulic oil level......................................................................................................... 7-15

Wiring diagram, oil level label, and defined position of the attachment (G00005)....................... 7-17
G00006 - Test speed 1800 1/min engine 2 ......................................................................................... 7-18
G00007 - Trouble hydraulic oil level................................................................................................... 7-18

Wiring diagram (40B004) and the defined position of the attachment (G00007)......................... 7-19
G00012 - Central lubrication system grease level too low............................................................... 7-20
G00013 - Slew ring gear lubr. system grease level too low ............................................................. 7-20
Troubleshooting for sonar type grease level sensors .................................................................. 7-20
Troubleshooting for binary type grease level sensors ................................................................. 7-24
Wiring diagram (sonar type sensors) for trouble codesG00012 / G00013 / G00202................... 7-27
Wiring diagram (sonar sensor junction box) for trouble codes G00012 / G00013 / G00202 ....... 7-28
TS 15110-xD-GB-0 PC5500-6 TOC - 5

Wiring diagram (binary type sensors) for trouble codesG00012 / G00013 / G00202 .................. 7-29
Wiring diagram (binary sensor junction box) for trouble codes G00012 / G00013 / G00202 ...... 7-30
G00020 - Trouble Shut-Off (gate) valve (Start blocked) ................................................................... 7-31

View onto the gap of proximity switch 40B031 (G00020) ............................................................ 7-33
Wiring diagram (40B031) for trouble code G00020 (Main gate valve closed) ............................. 7-34
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR ................. 7-35
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor ...................... 7-35
G00031 - Set engine to low idle .......................................................................................................... 7-36

Wiring diagram (20S030) for trouble code G00031 ..................................................................... 7-37
Input signal of the engine speed switch 20S030 on the REAL TIME MONITOR ........................ 7-37
G00032 - Trouble starter...................................................................................................................... 7-38

Wiring diagram (Cold Start Signal Engine 1 & 2) for trouble code G00032 ................................. 7-39
Wiring diagram ("Engine running" signals) for trouble code G00032........................................... 7-40
G00033 - Trouble KOMTRAX Plus controller .................................................................................... 7-41
G00034 - Trouble KOMTRAX Plus display......................................................................................... 7-42
G00035 - Trouble totally loss gear oil (PTO 1) .................................................................................. 7-43
G00036 - Trouble totally loss gear oil (PTO 2) .................................................................................. 7-43

View onto the location of sensor 57B175-1/-2 at the PTO1/2 (G00035) ..................................... 7-45
Input signal (analog) of the gear oil sensors 57B175-1/-2 on the REAL TIME MONITOR .......... 7-46
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor ...................... 7-46
Wiring diagram (57B175-1/-2) for trouble codes G00035 & G00036........................................... 7-47
G00037 - Trouble monitoring, engine 2 speed too low .................................................................... 7-48
G00038 - Trouble monitoring, engine 2 speed too high ................................................................... 7-48
G00039 - Actuate engine speed selector switch ............................................................................... 7-48
G00043 - Trouble output short-circuit................................................................................................ 7-49
G00048 - Trouble emergency safety circuit....................................................................................... 7-50

Wiring diagram (11K044a) for trouble code G00048 ................................................................... 7-51
G00053 - Reset emergency safety circuit .......................................................................................... 7-52
G00054 - Monitoring idle position cut off .......................................................................................... 7-53

Wiring diagram (11K032) for trouble code G00054 ..................................................................... 7-54
Input signal (analog) of relay 11K032 on the REAL TIME MONITOR (G00054) ......................... 7-55
Exemplary view onto the KOMTRAX Plus Failure History (G00054) .......................................... 7-55
G00060 - Fire in the power house....................................................................................................... 7-56

Wiring diagram (fire alarm) for trouble code G00060 .................................................................. 7-58
Wiring diagram (10B350 in the safety circuit) for G00060 ........................................................... 7-59
TOC - 6 PC5500-6 TS 15110-xD-GB-0

G00061 - Trouble monitoring, engine 1 speed too low .................................................................... 7-60
Input signal (analog) of 51K003b-1 & 51K003b-2 on the REAL TIME MONITOR....................... 7-62
Wrong signal of the engine 2 speed converter on the REAL TIME MONITOR ........................... 7-62
Wiring diagram (engine speed) for trouble codes G00061 & G00037......................................... 7-63
G00062 - Trouble monitoring, engine 1 speed too high................................................................... 7-64

Wiring diagram (engine speed) for trouble codes G00062 & G00038......................................... 7-65
G00063 - Trouble monitoring hydraulic oil temp .............................................................................. 7-66

Wiring diagram (59B015) for trouble code G00063 ..................................................................... 7-67
G00064 - Trouble monitoring hydraulic oil level............................................................................... 7-68

Wiring diagram (40B004) for trouble code G00064 ..................................................................... 7-70
G00065 - Very low hydraulic oil level ................................................................................................. 7-71

View onto the hydraulic oil level label .......................................................................................... 7-71
G00066 - Trouble hydraulic oil temperature...................................................................................... 7-72

Hydraulic oil temperature table .................................................................................................... 7-73
Wiring diagram (57K506a-1/57K506b-1 & 57K506a-2/57K506b-2) and location for G00066 ..... 7-74
G00067 - Trouble battery voltage too high ........................................................................................ 7-75

Wiring diagram (11T080) and component location for G00067................................................... 7-76
Input signal of 11T080 on the REAL TIME MONITOR for G00067 ............................................. 7-77
G00068 - Trouble gear lubrication (PTO 2) ........................................................................................ 7-78
G00069 - Trouble monitoring oil temperature gear (PTO 1)............................................................. 7-79

Input of 57B049-1 on the REAL TIME MONITOR (G00069) ....................................................... 7-80
Gear oil temperature (PTO 1 & PTO 2) on the Main Gauge Screen ........................................... 7-80
Wiring diagram (57B049-1 & 57B049-2) and component location (G00069 & G00083) ............. 7-81
G00070 - Trouble oil temperature gear (PTO 1) ................................................................................ 7-82

PTO gear oil settings (oil type and viscosity)............................................................................... 7-84
Location of the PTO gear oil level dipstick & temperature sensors 57B049-1/57B049-2 ............ 7-85
G00071 - Trouble gear lubrication (PTO 1) ........................................................................................ 7-86

Wiring diagram (57B017-1 & 57B017-2) for trouble codes G00071 & G00068........................... 7-87
G00081 - Trouble lubrication system ................................................................................................. 7-88

Wiring diagram (11K050) for trouble code G00081 ..................................................................... 7-89
Operation cycles of the lubrication systems ................................................................................ 7-90
G00083 - Trouble monitoring oil temperature gear (PTO 2)............................................................. 7-91
G00084 - Trouble oil temperature gear (PTO 2) ................................................................................ 7-91
G00086 - SHUTDOWN.......................................................................................................................... 7-91
G00087 - Stop all movements for low idle ......................................................................................... 7-92
TS 15110-xD-GB-0 PC5500-6 TOC - 7

G00090 - Trouble power supply.......................................................................................................... 7-93
Wiring diagram (stabilized power supply) for G00090 & G00099 ................................................ 7-94
G00091 - Pilot control cut out ............................................................................................................. 7-95

View onto the lock lever and the cover of 20S105 (G00091) ...................................................... 7-96
G00092 - Emergency shut-down at access ladder ........................................................................... 7-97
G00093 - Emergency shut-down at valve block ................................................................................ 7-97
G00094 - Emergency shut-down at hydraulic control panel............................................................ 7-97
G00095 - Emergency shut-down in cabin.......................................................................................... 7-97

Wiring diagram (emergency switches) for G00092~G00095 & G00097...................................... 7-99
G00096 - Pilot control cut out ........................................................................................................... 7-100

Wiring diagram (20S094) for trouble code G00096 ................................................................... 7-101
G00097 - Emergency shut-down at counterweight......................................................................... 7-102
G00099 - Trouble power supply........................................................................................................ 7-102
G00100 - Maintenance Safety Switch............................................................................................... 7-102

G00103 - Faulty switch 20M004 ........................................................................................................ 7-104

Wiring diagram 1 (windscreen wiper) for trouble code G00103................................................. 7-106
Wiring diagram 2 (windscreen wiper) for trouble code G00103................................................. 7-107
G00104 - Trouble battery current ..................................................................................................... 7-108

Wiring diagram (battery current) for trouble code G00104 ........................................................ 7-110
G00105 - Trouble battery charging current too low........................................................................ 7-111

Wiring diagram (11T080) for trouble code G00105 ................................................................... 7-112
G00107 - Trouble slew parking brake control 56K250a.................................................................. 7-113

View onto the CoDeSys HMI Visualization screen for trouble code G00107 ............................ 7-115
Wiring diagram (56K250a & 56K250b) for trouble code G00107 .............................................. 7-116
G00108 - Trouble slew parking brake control Output to 56K250a ................................................ 7-117
View onto the CoDeSys HMI Visualization screen for trouble code G00108 ............................ 7-119
Wiring diagram (56K250a & 56K250b) for trouble code G00108 .............................................. 7-120
G00109 - Trouble slew parking brake control 56K250b ................................................................. 7-121
G00110 - Trouble slew parking brake control Output to 56K250b ................................................ 7-121
G00111 - Trouble travel parking brake control 56K251a ................................................................ 7-121

56K251a & 56K251b (relay check) on the REAL TIME MONITOR (G00111 & G00113).......... 7-121
G00112 - Trouble travel parking brake control Output to 56K251a............................................... 7-122

56K251a & 56K251b (output check) on the REAL TIME MONITOR (G00112 & G00114) ....... 7-122
TOC - 8 PC5500-6 TS 15110-xD-GB-0

G00113 - Trouble travel parking brake control 56K251b................................................................ 7-123
G00114 - Trouble travel parking brake control Output to 56K251b .............................................. 7-123
G00115 - Trouble slew hydraulic brake control 56K252a............................................................... 7-123

G00116 - Trouble slew hydraulic brake control Output to 56K252a ............................................. 7-124
G00117 - Trouble slew hydraulic brake control 56K252b .............................................................. 7-125
G00118 - Trouble slew hydraulic brake control Output to 56K252b ............................................. 7-125
G00139 - Trouble monitoring X1-2 pressure ................................................................................... 7-125
G00140 - Trouble monitoring X1-1 pressure ................................................................................... 7-125

Wiring diagram (57B085-1 & 57B085-2) for trouble codes G00140 & G00139......................... 7-127
G00141 - Trouble monitoring X2 pressure ...................................................................................... 7-128

Wiring diagram (57B086) for trouble code G00141 ................................................................... 7-130
G00142 - Trouble monitoring pump support pressure X4-1 .......................................................... 7-131

Input signal of 57B097-1 & 57B097-2 on the REAL TIME MONITOR for G00142 & G00196... 7-133
Wiring Diagram (57B097-1 & 57B097-2) for G00142 & G00196............................................... 7-134
G00147 - Trouble monitoring gear lubrication (PTO 1) .................................................................. 7-135

Wiring diagram (57B017-1 & 57B017-2) for trouble codes G00147 & G00150......................... 7-138
G00148 - Trouble monitoring fuel level............................................................................................ 7-139

Wiring diagram (31B063) for G00148........................................................................................ 7-141
G00150 - Trouble monitoring gear lubrication (PTO 2) .................................................................. 7-142
G00151 - Trouble monitoring gear (PTO) oil filter 1........................................................................ 7-142

Wiring diagram (57B027-1/-2) and component location for G00151 & G00193 ........................ 7-145
G00154 - Trouble monitoring return oil filter................................................................................... 7-146

G00155 - Trouble monitoring leak oil filter ...................................................................................... 7-149

G00159 - Trouble monitoring breather filter.................................................................................... 7-152

G00160 - Trouble monitoring engine air cleaner 1 ......................................................................... 7-155

Wiring diagram (52B018-1/-2 & 52B019-1/-2) for trouble codes G00160 & G00197 ................ 7-157
G00161 - Trouble monitoring battery voltage ................................................................................. 7-158

TS 15110-xD-GB-0 PC5500-6 TOC - 9

G00162 - Trouble monitoring charging-/discharging current ........................................................ 7-161
Wiring diagram (battery charging current) for trouble code G00162 ......................................... 7-163
G00164 - Trouble air cleaner 1 .......................................................................................................... 7-164

View onto the engine air cleaners (G00164 & G00198) ............................................................ 7-165
G00165 - Trouble breather filter hydraulic oil tank ......................................................................... 7-166

Sight glass, hydraulic oil temperature information, and defined positions (G00165) ................. 7-167
G00166 - Trouble oil filter gear (PTO 1) ........................................................................................... 7-168

View onto the pressure sensors 57B027-1 & 57B027-2 (G00166/G00191) .............................. 7-169
G00169 - Trouble return oil filter hydraulic oil tank ........................................................................ 7-170
G00170 - Trouble leak oil filter hydraulic oil tank ........................................................................... 7-171
G00176 - Trouble battery voltage too low........................................................................................ 7-172

Wiring diagram (batteries) for trouble code G00176.................................................................. 7-174
G00177 - Trouble battery charging circuit ....................................................................................... 7-175

Wiring diagram (measuring points 1-4) for trouble code G00177 .............................................. 7-176
G00178 - Trouble battery charging current too high ...................................................................... 7-177

G00179 - Trouble control pressure X1-1 .......................................................................................... 7-179

The adjustment of the X1-pressure with two different methods (G00179 & G00182) ............... 7-180
G00180 - Trouble pilot pressure X2 too low .................................................................................... 7-181

Rear control & filter panel with X2 pressure sensor 57B086 & M3 ............................................ 7-182
G00181 - Trouble pilot pressure X2 too high .................................................................................. 7-183

Rear control & filter panel with X2 pressure sensor 57B086 & M3 ............................................ 7-184
G00182 - Trouble control pressure X1-2 .......................................................................................... 7-185
G00183 - Trouble pump support pressure X4-1 .............................................................................. 7-185

Wiring Diagram (57B097-1 & 57B097-2) for G00183 & G00195 ............................................... 7-186
Input signals of 57K602-1 & 57K602-2 on the REAL TIME MONITOR for G00183 & G00195 . 7-186
Wiring Diagram (57K602-1 & 57K602-2) for G00183 & G00195 ............................................... 7-187
Locations 57B097-1 / 57B097-2 & 57K602-1 / 57K602-2 for G00183 & G00195 ..................... 7-188
G00184 - Central lubrication system empty .................................................................................... 7-189

Grease level (CLS 1 & SLS & CLS 2) on the REAL TIME MONITOR....................................... 7-191
G00185 - Trouble central lubrication system .................................................................................. 7-192

Allocation of vent valves and end-of-line switches .................................................................... 7-193
Action chart for lube cycles ........................................................................................................ 7-194
View onto the vent valve (62Q507a - 62Q509a - 62Q642a)...................................................... 7-195
Wiring diagram (60B043/62B046/80B043) for trouble codes G00185/G00188/G00203 ........... 7-196
TOC - 10 PC5500-6 TS 15110-xD-GB-0

G00186 - Trouble central lubrication system .................................................................................. 7-197
Action chart for lube cycles........................................................................................................ 7-198
View onto the vent valve (62Q507a - 62Q509a - 62Q642a)...................................................... 7-199
G00187 - Slew ring gear lubrication system empty ........................................................................ 7-200
G00188 - Trouble slew ring gear lubrication system...................................................................... 7-200
G00189 - Trouble slew ring gear lubrication system...................................................................... 7-200
G00191 - Trouble oil filter gear (PTO 2) ........................................................................................... 7-200
G00193 - Trouble monitoring gear (PTO) oil filter 2........................................................................ 7-200
G00195 - Trouble pump support pressure X4-2.............................................................................. 7-200
G00196 - Trouble monitoring pump support pressure X4-2 .......................................................... 7-200
G00197 - Trouble monitoring engine air cleaner 2 ......................................................................... 7-200
G00198 - Trouble air cleaner 2.......................................................................................................... 7-200
G00201 - Attachment lubrication system empty............................................................................. 7-200
G00202 - Attachment lubrication system grease level too low ..................................................... 7-200
G00203 - Trouble attachment lubrication system........................................................................... 7-200
G00204 - Trouble attachment lubrication system........................................................................... 7-201
G00207 - Engine remote oil tank 1 empty........................................................................................ 7-201
G00208 - Engine remote oil tank 2 empty........................................................................................ 7-201
G00216 - Trouble software not compatible ..................................................................................... 7-202
G00218 - Switch off all motors for running transfer pump ............................................................ 7-204
G00220 - Trouble transfer pump motor overheated ....................................................................... 7-205

Wiring diagram (transfer pump) for trouble code G00220 ......................................................... 7-206
G00221 - Trouble slew direction module defect ............................................................................. 7-207

Slew direction module 11B142 for trouble code G00221 .......................................................... 7-208
G00223 - Trouble starter control 51K001a-1.................................................................................... 7-209

51K001a-1/-2 & 51K001b-1/-2 (relay check) on the REAL TIME MONITOR ............................ 7-209
G00224 - Trouble starter control Output to 51K001a-1 .................................................................. 7-210

51K001a-1/-2 & 51K001b-1/-2 (output check) on the REAL TIME MONITOR .......................... 7-210
G00225 - Trouble starter control 51K001b-1 ................................................................................... 7-211
G00226 - Trouble starter control Output to 51K001b-1 .................................................................. 7-211
G00227 - Trouble starter control 51K001a-2.................................................................................... 7-211
G00228 - Trouble starter control Output to 51K001a-2 .................................................................. 7-211
TS 15110-xD-GB-0 PC5500-6 TOC - 11

G00229 - Trouble starter control 51K001b-2 ................................................................................... 7-211
G00230 - Trouble starter control Output to 51K001b-2 .................................................................. 7-211
G00231 - Trouble pilot control lever 20S019 ................................................................................... 7-212
G00232 - Trouble pilot control lever 20S020 ................................................................................... 7-212

G00233 - Trouble pilot control 11Q045 ............................................................................................ 7-215

Wiring diagram (11Q045) for trouble code G00233................................................................... 7-216
G00234 - Trouble pilot control 11K111a .......................................................................................... 7-217

G00235 - Trouble pilot control Output to 11K111a ......................................................................... 7-218

G00236 - Trouble pilot control 11K111b .......................................................................................... 7-219
G00237 - Trouble pilot control Output to 11K111b. ........................................................................ 7-219
G00238 - Trouble supply by key switch 11Q044 ............................................................................. 7-220

Input signal of 11Q044 on the REAL TIME MONITOR (G00238) ............................................. 7-220
G00240 - Trouble hydraulic oil temperature .................................................................................... 7-222
G00242 - Engine 1 already running .................................................................................................. 7-223
G00243 - Fill up fuel tank................................................................................................................... 7-224
G00245 - Engine shutdown from ground......................................................................................... 7-225

Input signal of 54S007/51 & 54S008/52 on the REAL TIME MONITOR (G00245) ................... 7-226
G00246 - Hydraulic oil temperature.................................................................................................. 7-227
G00248 - Engine 2 already running .................................................................................................. 7-227
G00252 - Emergency shut-down at access ladder ......................................................................... 7-228
G00253 - Emergency shut-down at valve block .............................................................................. 7-228
G00254 - Emergency shut-down at hydraulic control panel.......................................................... 7-228
G00255 - Emergency shut-down in cabin........................................................................................ 7-228

Wiring diagram (emergency switches) for trouble codes G00252~G00255 & G00258 ............. 7-230
G00256 - Operator warning system.................................................................................................. 7-231
G00257 - Hydraulic oil temperature.................................................................................................. 7-232
G00258 - Emergency shut-down at counterweight......................................................................... 7-233
TOC - 12 PC5500-6 TS 15110-xD-GB-0

G00261 - Maintenance Safety Switch............................................................................................... 7-233
G00262 - Trouble screen at hydr. cooler entry clogged................................................................. 7-235

40B166 and 40B165 on the REAL TIME MONITOR (05 Hydraulic).......................................... 7-235
Location of 40B166 and 40B165 at the hydraulic oil tank (G00262) ......................................... 7-236
Wiring diagram (40B166 & 40B165) for trouble code G00262 .................................................. 7-237
G00308 - Trouble CAN-Bus or CAN-Hardware ................................................................................ 7-238
G00309 - Trouble ladder up 56K253a ............................................................................................... 7-242

G00310 - Trouble ladder up Output to 56K253a.............................................................................. 7-243

G00311 - Trouble ladder up redundant 56K253b ............................................................................ 7-244
G00312 - Trouble ladder up redundant Output to 56K253b ........................................................... 7-244
G00313 - Trouble ladder down 56K254a .......................................................................................... 7-244

G00314 - Trouble ladder down Output to 56K254a......................................................................... 7-245

G00315 - Trouble ladder down redundant 56K254b ....................................................................... 7-246
G00316 - Trouble ladder down redundant Output to 56K254b ...................................................... 7-246
G00317 - Trouble service arm up 56K255a...................................................................................... 7-246

G00318 - Trouble service arm up Output to 56K255a..................................................................... 7-247

G00319 - Trouble service arm up redundant 56K255b ................................................................... 7-248
G00320 - Trouble service arm up redundant Output to 56K255b.................................................. 7-248
G00321 - Trouble service arm down 56K256a................................................................................. 7-248

G00322 - Trouble service arm down Output to 56K256a................................................................ 7-249

G00323 - Trouble service arm down redundant 56K256b .............................................................. 7-250
G00324 - Trouble service arm down redundant Output to 56K256b............................................. 7-250
G00325 - Trouble service arm Input ................................................................................................. 7-251
G00326 - Trouble ladder Input .......................................................................................................... 7-251
TS 15110-xD-GB-0 PC5500-6 TOC - 13

G00327 - Trouble parking brake Input ............................................................................................. 7-251
G00328 - Trouble start Input ............................................................................................................. 7-251
G00330 - Trouble pilot control 11Q111 ............................................................................................ 7-254

Wiring diagram (11Q111/11K126) for trouble code G00330 ..................................................... 7-256
G00331 - Automatic after_running engine 1.................................................................................... 7-257
G00332 - Automatic after_running engine 2.................................................................................... 7-257
G00333 - Trouble battery charger relay ........................................................................................... 7-258

G00336 - Trouble monitoring slew speed ........................................................................................ 7-260

Slew speed module 11B143 for trouble code G00336 .............................................................. 7-261
G00349 - Engine 2 running................................................................................................................ 7-262
G00350 - Engine 2 standstill ............................................................................................................. 7-262
G00351 - Engine 1 running................................................................................................................ 7-262
G00352 - Engine 1 standstill ............................................................................................................. 7-262
G00417 - Communication failure PLC [MTC] <=> KOMTRAX Plus controller .............................. 7-263
G00420 - Connector sel error............................................................................................................ 7-265
G00421 - Farm sys error.................................................................................................................... 7-266
G00422 - Can-net sys (J1939) ........................................................................................................... 7-267
G00423 - Application sys error ......................................................................................................... 7-268
G00425 - Settings impossible to take over into the PLC [MTC] .................................................... 7-269
Wiring diagram overview for G00425:
KOMTRAX Plus monitor → KOMTRAX Plus controller → MTC ............................................... 7-270
G00491 - Communication failure MH800 <=> KOMTRAX Plus controller..................................... 7-271

Wiring diagram overview for G00491: MH800 <=> KOMTRAX Plus controller ......................... 7-272
8 TROUBLESHOOTING BY SYMPTOMS.................................................... 8-1

8.1 SYMPTOMS OF THE ENGINES AND RELATED ELECTRICAL SYSTEMS ................................... 8-2
SEL001 - Engine does not start (engine does not rotate) .................................................................. 8-2
Wiring diagram 1 (starter batteries) for trouble code SEL001 ....................................................... 8-4
Wiring diagram 2 (engine 1 start) for trouble code SEL001........................................................... 8-6
Wiring diagram 3 (engine 2 start) for trouble code SEL001........................................................... 8-8
Wiring diagram 4 (engine start & stop buttons) for trouble code SEL001.................................... 8-10
Wiring diagram 5 (engine start relays) for trouble code SEL001 ................................................. 8-12
TOC - 14 PC5500-6 TS 15110-xD-GB-0

SEL002 - Engine stops while in operation......................................................................................... 8-14
View onto the water separators and fuel filters (SEL002)............................................................ 8-16
Sectional view onto fuel filters, shut-off solenoid valves, and fuel piping (SEL002) .................... 8-18
SEL003 - Engine speed is hunting during boom-up movement...................................................... 8-20
SEL004 - Engine does not stop .......................................................................................................... 8-21
SEL005 - Engine lacks output (no power) ......................................................................................... 8-22

Judgment Table for SEL005 ..................................................................................................... 8-23
SEL006 - Exhaust smoke is black ...................................................................................................... 8-24

Judgment Table for SEL006 ........................................................................................................ 8-25
SEL007 - Oil consumption is excessive ............................................................................................ 8-26

Judgment Table for SEL007 ....................................................................................................... 8-27
SEL008 - Oil becomes contaminated quickly.................................................................................... 8-28

SEL009 - Fuel consumption is excessive.......................................................................................... 8-30

SEL010 - Oil is in engine coolant ....................................................................................................... 8-32

SEL011 - Oil level rises........................................................................................................................ 8-34

SEL012 - Coolant temperature becomes too high (overheating) .................................................... 8-36

8.2 SYMPTOMS OF THE HYDRAULIC SYSTEM ................................................................................. 8-38
SHY001 - All the work equipment shows lack of power or slow

movement (especially the "boom up" function)............................................................... 8-38
SHY002 - No work equipment, travel or swing movement............................................................... 8-40
SHY003 - Work equipment has too much hydraulic drift................................................................. 8-41
SHY004 - Work equipment has big time lag ...................................................................................... 8-43
SHY005 - Machine deviates during travel movement....................................................................... 8-44
SHY006 - Machine does not swing..................................................................................................... 8-45
SHY007 - Swing acceleration is poor................................................................................................. 8-46
SHY008 - Excessive overrun when stopping swing ......................................................................... 8-49
SHY009 - Floating system without function ...................................................................................... 8-51
SHY010 - Abnormal noise coming from SRV or MRV ...................................................................... 8-52
TS 15110-xD-GB-0 PC5500-6 TOC - 15

SHY011 - Track tensioning system without function ....................................................................... 8-53
SHY012 - Ladder does not move, or slow movement ...................................................................... 8-54
SHY013 - Refilling arm does not move, or slow movement............................................................. 8-56
SHY014 - The hydraulic driven grease pump does not move ......................................................... 8-58
SHY015 - Trouble pump bearing lubrication ..................................................................................... 8-60
SHY016 - Abnormal track chain movement during digging ............................................................ 8-61
SHY017 - Swing parking brake without function .............................................................................. 8-62
SHY018 - Travel parking brake without function .............................................................................. 8-63

8.3 SYMPTOMS OF THE MECHANICAL SYSTEM .............................................................................. 8-66
SME001 - Abnormal noise is made .................................................................................................... 8-66

Judgment Table for SME001 ....................................................................................................... 8-67
SME002 - Abnormal noise around the PTOs / hydraulic pumps ..................................................... 8-68
SME003 - Vibration is excessive (engine mountings) ...................................................................... 8-70

Judgment Table for SME003 ....................................................................................................... 8-71
SME004 - Vibration is excessive (engine torsion) ............................................................................ 8-72
SME005 - There is a big shock when stopping swing ...................................................................... 8-73
SME006 - There is a big abnormal noise when moving/stopping swing ........................................ 8-74
SME007 - Abnormal noise coming from a travel gearbox ............................................................... 8-76
SME008 - Abnormal noise coming from the work equipment (lack of grease).............................. 8-78
SME009 - Abnormal idler movement.................................................................................................. 8-80
SME010 - Leak at the PTO shaft seal ................................................................................................. 8-81

8.4 SYMPTOMS OF ADDITIONAL SYSTEMS ...................................................................................... 8-83
SAD001 - Air conditioner does not work ........................................................................................... 8-83

View onto the A/C unit (SAD001) ................................................................................................ 8-84
SAD002 - Air conditioner compressor clutch is burnt ..................................................................... 8-85

View onto the A/C compressor and its mounting (SAD002) ........................................................ 8-86
SAD003 - Air conditioning system defective (pipes and hoses full of moisture) .......................... 8-87
SAD004 - Travel alarm does not sound ............................................................................................. 8-88

Wiring diagram (60P140) for trouble code SAD004 .................................................................... 8-89
TOC - 16 PC5500-6 TS 15110-xD-GB-0

TS 15110-xD-GB-0 PC5500-6 TOC - 17
TOC - 18 PC5500-6 TS 15110-xD-GB-0
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 15110-xD-GB-0 PC5500-6 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.
The safety information in this manual does not replace any safety rules or laws in your area.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
DANGER
This signal word indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING
This signal word indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
This signal word indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
NOTICE
This signal word is used to alert you to information that must be followed to avoid damage to the machine.
This precaution is given where the machine may be damaged or the service life reduced if the precaution
is not followed.
NOTE! This word is used in regard to non-specific safety relevant information.
REMARKS: This word is used for information that is useful to know.
1 -2 PC5500-6 TS 15110-xD-GB-0
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 1.4.10 on page 1-14.
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 1-26.
1.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR

– For additional safety information for troubleshooting and adjustments refer to section 1.6 on page 1-39.
– 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 15110-xD-GB-0 PC5500-6 1 -3
SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB. SAFETY
1.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S

CAB.
Fig. 1-1
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 PC5500-6 TS 15110-xD-GB-0
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR
1.4 GENERAL PRECAUTIONS COMMON TO OPERA-

TION ON THE EXCAVATOR
WARNING
WHEN MISUSED, THESE MACHINES ARE DANGEROUS.
Mistakes in operation, inspection, or maintenance may result in personal injury or death.
Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels
on the machine carefully and obey the warnings.
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 15110-xD-GB-0 PC5500-6 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 PC5500-6 TS 15110-xD-GB-0
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 motors before adding fuel.
– Do not leave the machine while adding fuel or oil.
– Tighten all fuel and oil caps securely.
– Be careful not to spill fuel on overheated surfaces or on
parts of the electrical system.
– After adding fuel or oil, wipe up any spillage.
– Put greasy rags and other flammable materials into a safe
container to maintain safety in the workplace. Fig. 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 15110-xD-GB-0 PC5500-6 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 motors, exhaust manifold, muffler or battery, or inside the undercovers.
– Fire coming from electrical wiring
Short circuits in the electrical system can cause fire. To prevent fire, always observe the following:
– Keep all electrical connections clean and securely tightened.
– Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps.
Repair or replace any damaged wiring.
– Fire coming from piping
Check that all hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. There is a danger that this
may lead to damage to the hoses and cause high pressure oil to spurt out, leading to fire, personal injury, or
death.
– Explosion caused by lighting equipment
– When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifica-
tions.
– When taking the electrical power for the lighting from the machine itself, follow the instructions of this man-
ual.
1.4.4.2 ACTION IF FIRE OCCURS

– Activate the STOP switch to stop the motor.
– Use the access ladders and steps to get off the machine.
– 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 motor stop chains ( Fig. 1-7 Pos. 1) to shut down the
motor if they are equipped on your shovel.
Fig. 1-7
1 -8 PC5500-6 TS 15110-xD-GB-0
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 1-40.
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 1-40.
TS 15110-xD-GB-0 PC5500-6 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 motor, relieve the pressure in the hydraulic system and
set lock lever to LOCK position (Position L). If the lock is not
applied, there is danger of serious personal injury if the work
equipment control levers are touched by mistake and the
machine moves suddenly. For information on relieving the
pressure in the hydraulic system, refer to chapter ’RELIEV-
ING THE PRESSURE IN THE HYDRAULIC SYSTEM’ in the
’OPERATION’ part of this manual.
Fig. 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 motor, relieve the pres-
sure in the hydraulic system and set lock lever (1) securely to
the LOCK position (L), then stop the motor. 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 PC5500-6 TS 15110-xD-GB-0
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 15110-xD-GB-0 PC5500-6 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.
Fig. 1-13
– The above recommendations assume that the conditions are

for standard operations, but it may be necessary to add addi-
tional guards according to the operating conditions on the job-
site. Always contact your Komatsu distributor for advice.
Fig. 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 PC5500-6 TS 15110-xD-GB-0
1.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)

The use of retrofitted electrical and electronic equipment such as radars, computers, radio units and other appli-
ances, working with high frequency electromagnetic waves, can interfere with the electronic control system of the
excavator which can lead to damage to the machine and to personnel.
Only use equipment which meets the requirements of the standard ISO 13766 - Electromagnetic Compatibility for
Earth-Moving Machinery. Obtain advice from authorized electricians regarding the electromagnetic compatibility of
the equipment, prior to installation.
REMARKS: If appliances which interfere with the electronic control system of the excavator are installed, control
of the excavator will be impaired. If a malfunction is experienced, release the operating levers and
the pedals and strike the emergency shut-down button.
Komatsu can not be made liable for any injuries, accidents, product failures or other property dam-
age resulting from installation of non-EMC certified equipment.
TS 15110-xD-GB-0 PC5500-6 1 - 13
1.4.10 PRECAUTIONS AT JOBSITE
Fig. 1-15
1 - 14 PC5500-6 TS 15110-xD-GB-0
1.4.10.1 VISIBILITY FROM OPERATOR’S SEAT
WARNING
THE AREA AROUND THE EXCAVATOR DURING OPERATION IS EXTREMELY DANGER-
OUS!
Death and serious injury can occur. Make sure the job site is organized in such a way, that the safety of
man and equipment is always ensured.
Fig. 1-15 shows an example of general blind areas of large Komatsu hydraulic mining shovels.
The shaded areas (A) show the areas where the view is blocked when the operator is sitting in the operator’s seat,
and the shovel is equipped with standard mirrors. The boundary line (B) shows the distance of 1 meter from out-
side surface of the shovel. Please be fully aware that there are places that can not seen when operating the
machine.
REMARKS: The blind areas (A) differ depending on the machine type, attachment and position of attachment.
The International Standard ISO 5006 defines criteria for Operator’s visibility. This standard is not met
and does not apply to large hydraulic mining shovels.
1.4.10.2 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.
1.4.10.3 ENSURE GOOD VISIBILITY

When operating or travelling in places with poor visibility, if it is impossible to confirm the condition of the job side
or obstacle is in the area around the machine, there is danger that the machine may suffer damage or the operator
may suffer serious personal injury. When operating or travelling in places with poor visibility, always observe the
following items strictly.
– If the visibility cannot be sufficiently assured, position a flagman if necessary. The operator should pay careful
attention to the signs and follow the instructions of the flagman.
– The signals should be given only by one flagman.
– When working in dark places, turn on the working lamps and front lamps of the machine, and if necessary, set
up additional lighting in the area.
– Stop operations if there is poor visibility, such as in fog, snow, rain, or sand storms.
– Check the mirrors on the machine before starting operations every day. Clean off any dirt and adjust the view
to ensure good visibility.
– In areas where it is impossible to confirm the area around the machine and observation cameras have been
set up, clean off any dirt from the lens and make sure that the cameras give a clear view of the working area of
the machine.
1.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS

– Set up signs to inform of road shoulders or soft ground. If the visibility is not good, position a signalman if nec-
essary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
– Only one signalman should give signals.
Make sure that all workers understand the meaning of all signals and signs before starting work.
TS 15110-xD-GB-0 PC5500-6 1 - 15
1.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS

On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting opera-
tions, always check the following to confirm there are no dangers on the jobsite.
– When carrying out operations near combustible materials,

there is a hazard of fire, so be careful when operating.
– Check the terrain and condition of the ground at the worksite,
and determine the safest method of operation. Do not operate
where there is a hazard of landslides or falling rocks.
– If water lines, gas lines, or high-voltage electrical lines may be
buried under the worksite, contact each utility and identify
their locations. Be careful not to sever or damage any of
these lines (Fig. 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.
1.4.10.6 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
1 - 16 PC5500-6 TS 15110-xD-GB-0
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.
1.4.10.7 WORKING ON LOOSE GROUND

– Avoid travelling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or
after earthquakes is weak in these areas.
– When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of
the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is
safe and to prevent the machine from rolling over or falling.
1.4.10.8 GAS, DUST, STEAM AND SMOKE
WARNING
RISK OF EXPOLSION AND FIRE!
Welding, flame-cutting and grinding work on the machine increases the risk of explosion and fire which
may result in serious injury or death.
All relevent safety measures must be followed and only under expressly obtained authorization.
Special care must be taken before welding, flame-cutting and grinding operations are carried out on the
counterweight. The filling of the counterweight chambers can create explosive gases which will accumu-
late in the chambers of the counterweight.
These gases must be expelled before welding, flame-cutting and grinding operations are carried out on
the counterweight.
REMARKS: Follow the instructions given in PARTS & SERVICE NEWS No. AH04518 for expelling the gases
from the counterweight chambers. (See Volume 2 binder)
TS 15110-xD-GB-0 PC5500-6 1 - 17
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.
1.4.10.9 VENTILATION OF ENCLOSED AREAS
WARNING
POISONOUS FUMES!
Unventilated areas where poisonous fumes can accumulate can kill.
Always ensure adequate ventilation.
Refer to Fig. 1-18:
– Operate internal combustion motors and fuel operated heat-

ing systems only on adequately ventilated premises. Before
starting the machine on enclosed premises, make sure that
there is sufficient ventilation.
Observe the regulations in force at the respective site.
– If it is necessary to start the motor within an enclosed area, or
when handling fuel, flushing oil, or paint, open the doors and
windows to ensure that adequate ventilation is provided to
prevent gas poisoning.
Fig. 1-18
1 - 18 PC5500-6 TS 15110-xD-GB-0
1.4.11 STARTING MOTOR
1.4.11.1 WARNING TAG

– If there is a "DANGER DO NOT OPERATE!" warning tag dis-
played, it means that someone is carrying out inspection and
maintenance on the machine (Fig. 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 motor or touch the
levers.
Fig. 1-19
1.4.11.2 CHECKS BEFORE STARTING MOTOR

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

ensure a good view.
– Completely remove all flammable materials accumulated
around the motor and battery, and remove any dirt from the
windows, mirrors, handrails, access ladder and steps.
– Check the coolant levels, fuel levels, and oil levels, and check
for damage to the electric wiring.
– Adjust the operator's seat to a position where it is easy to
carry out operations, check the camera system functions and
check that there is no damage or wear to the seat belt or
mounting clamps.
– Check the operation of the instruments and gauges, check
the angle of the mirror, and check that the control levers are Fig. 1-20
all at the Neutral position.
– Before starting the motor, 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.
1.4.11.3 PRECAUTION WHEN STARTING MOTOR

– Start and operate the machine only while seated.
– Do not short circuit the starting motor circuit to start the motor. Short circuiting can cause fire.
– When starting the motor, sound the horn as a warning.
– Do not let any person on the machine other than the operator and the operator's assistant (1 person). For
demonstration purposes or during training, more than two people can be present in the operator’s cabin at the
same time. All personnel within the cabin at such times must secure good hand-holds and be aware of sudden
movements. All appropriate relevant safety measures are to be observed.
TS 15110-xD-GB-0 PC5500-6 1 - 19
1.4.11.4 PRECAUTION IN COLD AREAS

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

If the checks before starting are not carried out properly, the machine will be unable to display its full performance,
and there is also danger that it may lead to serious personal injury or death.
When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.
– Always fasten your seat belt.

– Check that the movement of the machine matches the display on the control pattern label in the cabin. If it
does not match, replace it immediately with the correct control pattern label.
– Check the operation of the gauges and equipment, and check the operation of the bucket, arm, boom, travel
system and swing system.
– Check for any problem in the sound of the machine, vibration, heat, smell, or gauges; check also that there is
no leakage of oil or fuel.
– If any problem is found, carry out repairs immediately.
1 - 20 PC5500-6 TS 15110-xD-GB-0
1.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE

– Before travelling, set the machine so that sprocket (1) is
behind the operator's seat (Fig. 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.
TS 15110-xD-GB-0 PC5500-6 1 - 21
1.4.12.3 PRECAUTIONS WHEN TRAVELLING

– When travelling on flat ground, keep the work equipment 100
to 150 cm (39 to 59 in) high above the ground (Fig. 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
1 - 22 PC5500-6 TS 15110-xD-GB-0
1.4.12.4 TRAVELLING ON SLOPES

To prevent the machine from tipping over or slipping to the side,
always do as follows.
– Keep the work equipment 100 - 150 cm (39 - 59 in) above the
ground surface so that the work equipment can be lowered to
the ground immediately to stop the machine in emergencies
(Fig. 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
TS 15110-xD-GB-0 PC5500-6 1 - 23
1.4.12.5 OPERATIONS ON SLOPES

– When working on slopes, there is a hazard that the machine
may lose its balance and turn over when the swing or work
equipment are operated. This may lead to serious injury or
property damage, so always provide a stable place when car-
rying out these operations, and operate carefully.
– Do not swing the work equipment from the uphill side to the
downhill side when the bucket is loaded. This operation is
dangerous, and may cause the machine to tip over.
– If the machine has to be used on a slope, pile the soil to make
a platform (A on Fig. 1-29) that will keep the machine as hori-
zontal as possible.
Fig. 1-29
1.4.12.6 PROHIBITED OPERATIONS

– Never dig the work face under an overhang. There is a haz-
ard that rocks may fall or that the overhang may collapse and
fall on top of the machine (Fig. 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
1 - 24 PC5500-6 TS 15110-xD-GB-0
– 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.
1.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES

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

– Park the machine on firm, level ground. Select a place where
there is no hazard of falling rocks or landslides, or of flooding
if the land is low.
– Lower the work equipment completely to the ground.
– When leaving the machine, set lock lever (Fig. 1-33, Pos 1) to
the LOCK position (L), then stop the motor.
– Always close the operator's cab door, and use the key to lock
all the equipment in order to prevent any unauthorized person
from moving the machine. Always remove the key, take it with
you, and leave it in the specified place.
– If it is necessary to park the machine on a slope, always set
the bucket on the downhill side, then dig it into the ground.
Fig. 1-33
1.4.12.9 TRANSPORTATION
This machine must be disassembled for transportation. When transporting the machine, please consult your
Komatsu distributor.
Use only appropriate means of transport and lifting gear of adequate capacity.
The recommissioning procedure must be strictly in accordance with the General Assembly Procedure Manual.
TS 15110-xD-GB-0 PC5500-6 1 - 25
PRECAUTION FOR MAINTENANCE SAFETY
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 motors and move all control levers through their shift positions to relieve the pressure in the hydraulic
system. Refer to ”Stopping the motors” for detailed description of the stopping procedure.
– Before any maintenance work is started, set the maintenance safety switch to 0 position.
Find to the location of the maintenance safety switch refer to section 1.5.1.3 on page 1-29. In the 0 position
the motors can not be started. Secure this position by inserting a padlock into the holes of the switch. Up to ten
padlocks can be attached to the holes provided.
– A warning plate ”Caution Machine Maintenance” must be fixed in the Operator’s cab before any lubrication or
maintenance work is started.
– Block the machine to prevent machine movement
– Always use safety devices to block hydraulic cylinders. Never rely on the machine hydraulic system to hold
when working on the loader attachment. A hydraulic line or cylinder could fail or someone could accidently
strike the control levers causing the loader to fall.
1 - 26 PC5500-6 TS 15110-xD-GB-0
SAFETY PRECAUTION FOR MAINTENANCE
– Relieve all pressure in the hydraulic system before servicing the hydraulic system.For information on relieving
the pressure in the hydraulic system, refer to chapter ’Relieving The Pressure In The Hydraulic System’ in the
’Operation’ part of this manual.
– Oily cloth and inflammable material must be removed from the machine. Clean the excavator before starting
maintenance work.
– Switch-off battery main switch and remove key, before working on the electrical system.
– Wear safety clothing, goggles, respirator and other safety devices, whenever working conditions make this
necessary. Observe the local safety rules.
– Never allow unauthorized persons access to the machine during lubrication and maintenance work.
– After servicing, remove oily cloth, inflammable material and all tools from the machine.
– Clean the Excavator with a steam jet, especially after servicing the hydraulic system and fuel system.
WARNING
BEWARE OF STEAM!
Hot steam can cause serious personal injury. When using a steam cleaner, wear safety glasses and pro-
tective clothing.
– For cleaning the Excavator and its components use only fresh water with a salt content of less than 0.05%.
– DO NOT use steam jet, high pressure cleaning device or strong water jet for cleaning headlights, solenoid
valves, sensors, cable connections and bearings.
– Be sure to reinstall safety devices, guards or shields after adjusting and/or servicing the machine.
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 motorering rules and regulations.
– Work on the chassis, brake and steering systems must be performed only by skilled personnel who have been
specifically trained for such work.
Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of
hydraulic equipment.
TS 15110-xD-GB-0 PC5500-6 1 - 27
1.5.1.2 STOP MOTOR 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 motor.
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 motor STOP switch and press the horn switch. If the horn
does not sound, it is not activated.)
Fig. 1-35
1 - 28 PC5500-6 TS 15110-xD-GB-0
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 motor, 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 motors. 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
TS 15110-xD-GB-0 PC5500-6 1 - 29
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.
1 - 30 PC5500-6 TS 15110-xD-GB-0
1.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING

– To prevent injury, do not perform maintenance or adjustments
while the motor runs. If work must be carried out with the
motor running, carry out the operation with at least two work-
ers and do as follows:
– One worker must always sit in the operator's seat and be
ready to stop the motor at any time. All workers must
maintain contact with each other and be fully aware of all
relevant safety measures.
– For safety information when working with high pressure oil in
the hydraulic system, refer to section 1.6 on page 1-39.
– When carrying out operations near rotating parts, there is a
hazard of being caught in the parts, so be careful not to come
close (Fig. 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
TS 15110-xD-GB-0 PC5500-6 1 - 31
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 motor and you are exposed to noise for long periods of time, wear ear cov-
ers or ear plugs while working. If the noise from the machine is too loud, it may cause temporary or permanent
hearing problems.
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
1 - 32 PC5500-6 TS 15110-xD-GB-0
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.
TS 15110-xD-GB-0 PC5500-6 1 - 33
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
1 - 34 PC5500-6 TS 15110-xD-GB-0
As there is a hazard that sparks will be generated, always do as follows.
– Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or
other metal objects lying around near the battery.
– When disconnecting the battery terminals, wait for approx. one minute after activating the motor STOP switch
and be sure to disconnect the grounding terminal
(negative (-) terminal) first. Conversely, when connecting them, begin with the positive (+) terminal and then
the grounding (-) terminal. Make sure that all the terminals are connected securely.
– Attach the battery terminal securely.
– Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis,
take it to a well-ventilated place, and remove the battery caps before charging it.
– Tighten the battery caps securely.
– Install the battery securely to the determined place.
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 motor fuel piping when the motor is running. When carrying out inspection or
maintenance of the fuel piping system, wait for at least 30 seconds after stopping the motor to let the internal pres-
sure go down before starting inspection or maintenance.
TS 15110-xD-GB-0 PC5500-6 1 - 35
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.
1 - 36 PC5500-6 TS 15110-xD-GB-0
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 motor is running and immediately after it is stopped, high voltage is generated inside the motor con-
troller and the motor injector.
– The headlights also operates using high voltage. Never perform maintenance on the headlights.
– If it is necessary to touch the inside of the controller or the motor injector portion, or the headlight electrics
please contact your Komatsu distributor.
– The cab base contains high voltage electrical appliances. Access to the cab base for authorized service staff
only.
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.
TS 15110-xD-GB-0 PC5500-6 1 - 37
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 motor idling over long periods. Long periods of idling

(more than 10 minutes), will not only waste fuel, but is also
harmful to the motor.
– Avoid operation against the main relief valves of the hydraulic
system. Move control lever to neutral position before the
loader attachment stalls due to overload.
– Position trucks in such a way, that loading operation can be
carried out in a safe and economic manner. Avoid swing
angles over 90°.
Maintenance Fig. 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.
1 - 38 PC5500-6 TS 15110-xD-GB-0
SAFETY ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS
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 motor is running before checking for leaks, as hydraulic fluid escaping under pressure can cause serious
injuries.
– Additional to the general personal protective clothing as described on page 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
motor is shutdown and when there is no hydraulic pressure in the system.
– When the machine is running, the areas of potential danger can only be entered when no leakages or other
irregularities have been noticed when the high pressure oil circulation has been brought up to maximum pres-
sure from a safe distance (operator’s cab, machinery house roof, ladder platform).
1.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING

DURING ADJUSTMENTS
To prevent injury, do not carry out adjustments with the motor running. If work must be carried out with the motor
running, perform the task with, at maximum, two maintenance workers and an operator and do as follows.
– An operator that has been trained on the machine he is oper-

ating, must always sit in the operator's seat and be ready to
stop the motor at any time. All workers must maintain contact
with the other workers and be fully aware of all relevant safety
measures.
– When carrying out operations near the fan, fan belt, or other
rotating parts, there is a hazard of being caught in the parts,
so be careful not to come close (Fig. 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.
TS 15110-xD-GB-0 PC5500-6 1 - 39
SPECIAL SAFETY EQUIPMENT SAFETY
1.7 SPECIAL SAFETY EQUIPMENT
Fig. 1-50
1 - 40 PC5500-6 TS 15110-xD-GB-0
SAFETY SPECIAL SAFETY EQUIPMENT
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.
TS 15110-xD-GB-0 PC5500-6 1 - 41
1 - 42 PC5500-6 TS 15110-xD-GB-0
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.
TS 15110-xD-GB-0 PC5500-6 1 - 43
1 - 44 PC5500-6 TS 15110-xD-GB-0
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.
TS 15110-xD-GB-0 PC5500-6 1 - 45
1 - 46 PC5500-6 TS 15110-xD-GB-0
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.
TS 15110-xD-GB-0 PC5500-6 1 - 47
1 - 48 PC5500-6 TS 15110-xD-GB-0
Introduction & general information for troubleshooting
2 INTRODUCTION &
GENERAL INFORMATION
FOR TROUBLESHOOTING
TS 15110-xD-GB-0 PC5500-6 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 information about mounting locations of components and illustrations of different
connector types as they are used on your machine.
Chapter 4 Provides you with charts of standard values for electrical components as a quick reference guide.
Chapter 5 Provides you with troubleshooting and monitoring features for checks of the CAN bus system.
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 KOMTRAX Plus 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 KOMTRAX Plus.
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 PC5500-6 TS 15110-xD-GB-0
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.
– 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.
– 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.
– 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.
– 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.
– Only qualified workers must carry out work and operation which require license or qualification.
– 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.
– 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.
– 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 15110-xD-GB-0 PC5500-6 2 -3
Preparations for work Introduction & general information for troubleshooting
2.3 PREPARATIONS FOR WORK

– Before adding oil or making any repairs, park the machine on hard and level ground. Isolate the machine
according to local regulations.
– 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.
– When disassembling or assembling, support the respective unit with blocks, jacks, or stands as necessary
before starting work.
– 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

– 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.
– 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.
– 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.
– Before starting work, remove the leads from the negative (–) terminal first.
– 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.
– 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.
– When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may
cause electrical fires.
– 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.
– As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular.
– 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.
– 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.
– 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.
– When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
– When measuring hydraulic pressure, check that the measuring tools are correctly assembled.
– 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.
– 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 -4 PC5500-6 TS 15110-xD-GB-0
Introduction & general information for troubleshooting Precautions when carrying out any operation
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

– If the coolant contains antifreeze, dispose of it correctly.
– After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
– When draining oil, prepare a container of adequate size to catch the oil.
– Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
– To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
– Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
– Check the number and thickness of the shims, and keep in a safe place.
– When raising components, be sure to use lifting equipment of ample strength.
– When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
– Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering
after removal.
– 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

– Tighten all bolts and nuts (sleeve nuts) to the specified torque.
– Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
– Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
– Bend the cotter pins and lock plates securely.
– When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 - 3 drops of adhesive.
– 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.
– Clean all parts, and correct any damage, dents, burrs, or rust.
– Coat rotating parts and sliding parts with engine oil.
– When press fitting parts, coat the surface with anti-friction compound (LM-P).
– After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
– When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
– When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
– When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
TS 15110-xD-GB-0 PC5500-6 2 -5
Precautions when carrying out any operation Introduction & general information for troubleshooting
– 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").
– Add the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.
2 -6 PC5500-6 TS 15110-xD-GB-0
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
– Cummins Troubleshooting and Repair Manual for the QSK 38 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 15110-xD-GB-0 PC5500-6 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 PC5500-6 TS 15110-xD-GB-0
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 15110-xD-GB-0 PC5500-6 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 PC5500-6 TS 15110-xD-GB-0
Introduction & general information for troubleshooting Points to remember when trouble-shooting
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 TROUBLE-

SHOOTING
– 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 15110-xD-GB-0 PC5500-6 2 - 11
Points to remember when trouble-shooting 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 PC5500-6 TS 15110-xD-GB-0
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 15110-xD-GB-0 PC5500-6 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
7. Check alternator voltage (engine running at over half throttle) After operating
for several
Replace
minutes:
27.5 - 29.5V
8. Check battery relay for operating sound

- Replace
(when starting switch is turned ON or OFF)
2 - 14 PC5500-6 TS 15110-xD-GB-0
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
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
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
TS 15110-xD-GB-0 PC5500-6 2 - 15
Handling of electric equipment and hydraulic components Introduction & general information for troubleshooting
– 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
– 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-
tacts will become even dirtier, so remove the oil and
Fig. 2-8 Oil or dirt stuck to connector
water from the compressed air completely before
cleaning with compressed air.
9. 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
2 - 16 PC5500-6 TS 15110-xD-GB-0
– 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)
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 remov-

ing
TS 15110-xD-GB-0 PC5500-6 2 - 17
Handling of electric equipment and hydraulic components Introduction & general information for troubleshooting
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
– 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
2 - 18 PC5500-6 TS 15110-xD-GB-0
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
– 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 15110-xD-GB-0 PC5500-6 2 - 19
General working procedures Introduction & general information for troubleshooting
2.11 GENERAL WORKING PROCEDURES
2.11.1 AIR BLEEDING OF VARIOUS YYDRAULIC 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 THE HYDRAULIC CYLINDERS

Procedure
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 PC5500-6 TS 15110-xD-GB-0
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 cylinder:
-
– No temperature increase during the test,
normal temperature approx. 70°C
REMARKS: The hydraulic oil will heat up at the MRV, REMARKS: A strong drift occurs.
not in the proper cylinder.
TS 15110-xD-GB-0 PC5500-6 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, chapter 17.7 GLOBAL LAYOUT OF THE
MTC CONTROL SYSTEM.
2 - 22 PC5500-6 TS 15110-xD-GB-0
Introduction & general information for troubleshooting Information about MTC & nodes
2.13.1.3 INFORMATION ABOUT THE LED INDICATIONS AT THE MTC

(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 17.
TS 15110-xD-GB-0 PC5500-6 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 PC5500-6 TS 15110-xD-GB-0
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 15110-xD-GB-0 PC5500-6 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 PC5500-6 TS 15110-xD-GB-0
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 17.
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 15110-xD-GB-0 PC5500-6 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 PC5500-6 TS 15110-xD-GB-0
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 15110-xD-GB-0 PC5500-6 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
Procedure
Refer to Fig. 2-27:
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.
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.
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 PC5500-6 TS 15110-xD-GB-0
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 15110-xD-GB-0 PC5500-6 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 con-
tact 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:
– Damaged wire strands

– Missing wire strands
– Wire strands not entering the contact barrel or splayed wires
– 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 PC5500-6 TS 15110-xD-GB-0
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 15110-xD-GB-0 PC5500-6 2 - 33
Cable shielding Introduction & general information for troubleshooting
2 - 34 PC5500-6 TS 15110-xD-GB-0
Mounting locations and connector types
3 MOUNTING LOCATIONS
AND CONNECTOR TYPES
TS 15110-upD-GB-0 PC5500-6 3 -1
Component location Mounting locations and connector types
3.1 COMPONENT LOCATION
3.1.1 VIEW ONTO THE SUPERSTRUCTURE
Fig. 3-1 Superstructure top view
3 -2 PC5500-6 TS 15110-upD-GB-0
Mounting locations and connector types Component location
(1) Operator’s cab with integrated FOPS
(2) Hydraulic oil cooler with hydraulic driven fans
(3) Swing gear
(4) Hydraulic oil tank
(5) Front PTO (engine 2)
(6) Main hydraulic pumps
(7) Rear PTO (engine 1)
(8) Counterweight
(9) Engine 1
(10) Engine 2
(11) Flexible coupling (oil filled)
(12) Main control blocks with high pressure filters
(13) Radiator for engine cooling system
(14) Fuel tank
(15) Cab base, containing the electronic components of the KOMTRAX Plus system and the electrical
switchboards
TS 15110-upD-GB-0 PC5500-6 3 -3
3.1.2 MACHINE HOUSE
Fig. 3-2 Machine house - side and front view
3 -4 PC5500-6 TS 15110-upD-GB-0
(1) Engine air cleaner
(2) Air duct
(3) Exhaust muffler
(4) Node box, location 56
(6) Coupling assembly
(7) Rear Diesel engine 1 - SDA12V159E-2
(8) Radiator fan
(9) Coolant radiator
(11) Rear control and filter panel
(12) Front control and filter panel
(13) Front PTO 2
(14) Radiator fan drive pump, engine 2
(15) Hydraulic cooler fan drive pump, engine 2
(16) Radiator fan drive pump, engine 1
(17) Hydraulic cooler fan drive pump, engine 1
(18) Rear PTO 1
TS 15110-upD-GB-0 PC5500-6 3 -5
3.1.3 LOCATION OF THE ELECTRICAL PARTS ON THE ENGINES
LOCATION 51
Fig. 3-3 Location of the electrical parts on engine 1
3 -6 PC5500-6 TS 15110-upD-GB-0
Engine 1
52B018-1 Engine air filter clogging sensor
52B064-1 Engine speed sensor
52G005-1.D+ Alternator terminal D+
52G045-1 Engine remote oil tank refilling system
52K030-1 Prelube switch
52Q002a-1 Starter relay
52Q030a-1 Prelube timer relay
52Q502a-1 Engine cold start aid solenoid valve
52Q502b-1 Engine cold start aid solenoid valve
57B049-1 PTO lube oil temperature sensor
60P140 Acoustic signal
Engine 2
52B064-2 Engine speed sensor
52G005-2.D+ Alternator terminal D+
52G045-2 Engine remote oil tank refilling system
52K030-2 Prelube switch
52Q002a-2 Starter relay
52Q004 Magnetic clutch compressor
52Q030a-2 Prelube timer relay
52Q502a-2 Engine cold start aid solenoid valve
52Q502b-2 Engine cold start aid solenoid valve
60P140 Acoustic signal
TS 15110-upD-GB-0 PC5500-6 3 -7
3.1.4 LOCATION OF ENGINE REMOTE OIL TANK SENSORS
Fig. 3-4 Location of Engine Remote Oil Tank Sensors
3 -8 PC5500-6 TS 15110-upD-GB-0
63B103-1 Engine remote oil tank level sensor engine 1
63B103-2 Engine remote oil tank level sensor engine 2
63B106-1 Engine oil level sensor engine 1
63B106-2 Engine oil level sensor engine 2
TS 15110-upD-GB-0 PC5500-6 3 -9
3.1.5 SUCTION OIL MANIFOLD WITH STRAINERS
Fig. 3-5 Suction oil manifold
3 - 10 PC5500-6 TS 15110-upD-GB-0
(1) Suction oil manifold
(2) Suction strainer – one for each main pump
(3) Oil suction tube
(4) Gaskets
(5) Compensator
(6) O-ring
(7) Cover plate
(8) Plug
(9) Seals
(10) Main suction oil strainer
(11) Intermediate pipe
(12) Protection cap
(13) Oil drain quick coupling
Sensors
59B015 Hydraulic oil temperature sensor
59B162 Hydraulic oil suction pressure sensor
TS 15110-upD-GB-0 PC5500-6 3 - 11
3.1.6 CONTROL AND FILTER PANELS – LOCATION OF COMPONENTS

Control and filter panel on PTO 1
Fig. 3-6 Control and filter panel on PTO 1, location of components
3 - 12 PC5500-6 TS 15110-upD-GB-0
Solenoid valves
57K506a-1 Cooler fan RPM control, minimum speed (engine 1)
57K506b-1 Cooler fan RPM control, medium speed (engine 1)
57K517 Qmin control (pump control system)
57K517a ½Qmax (reduced oil flow at cold oil [below T2])
57K548 Swing, power control / speed control
57K553-1 Reduction pre-load pressure PTO 1 gear lubrication - oil cooler
57K561-1 XLR pressure, main pump 1 – 3 (engine 1)
57K602-1 X4 pump support pressure / pump bearing lubrication, main pump 1 – 3 (engine 1)
Filters
(68.1) Pressure filter – oil cooler fan drive pump 10.2 (engine 1)
(68.2) Pressure filter – radiator fan drive pump 10.1 (engine 1)
(69.1) Pressure filter – PTO 1 gear lubrication pump 8.1 (engine 1)
(200) Pressure filter – pilot pressure and pump regulation (pumps 7.1 and 7.2)
Pressure switches
57B027-1 Filter element monitoring – PTO 1 gear lubrication pressure
Miscellaneous
(70.1) Pressure relief valve – pressure X4 (60±1 bar)
(70.2) Pressure relief valve – pressure X2, pilot pressure (35±2 bar)
(74.1) Pressure relief valve – PTO 1 gear lubrication
(79.1) Changeover valve "Electronic or hydraulic pump regulation" for pumps 1 – 3 (engine 1)
(81.1) Pressure relief valve – ½Qmax (16 bar)
(81.2) Pressure relief valve – emergency mode (~ 4 bar)
(131.1) Proportional solenoid valve, radiator fan speed (57Q636-1) – engine 1
(168.1) Pressure relief valve – max. operating pressure – hydraulic cooler fan drive (engine 1)
(168.3) Pressure relief valve – max. operating pressure – radiator fan drive (engine 1)
(169.1) Pressure relief valve – med. operating pressure – hydraulic cooler fan drive (engine 1)
TS 15110-upD-GB-0 PC5500-6 3 - 13
Control and filter panel on PTO 2
Fig. 3-7 Control and filter panel on PTO 2, location of components
3 - 14 PC5500-6 TS 15110-upD-GB-0
Solenoid valves
57Q505 Swing parking brake operating pressure
57K506a-2 Cooler fan RPM control, minimum speed (engine 2)
57K506b-2 Cooler fan RPM control, medium speed (engine 2)
57Q516 Travel parking brake operating pressure
57K553-2 Reduction pre-load pressure PTO 2 gear lubrication - oil cooler
57K561-2 XLR pressure, main pump 4 – 6 (engine 2)
57K602-2 X4 pump support pressure / pump bearing lubrication, main pump 4 – 6 (engine 2)
57K620 Emergency swing service brake control
57Q623a Hydraulic access ladder, raise
57Q623b Hydraulic access, lower
57Q625 Hydraulic access speed control
57Q627 Proportional swing brake pressure (pedal)
Filters
(68.3) Pressure filter – oil cooler fan drive pump 10.4 (engine 2)
(68.4) Pressure filter – Pressure filter – radiator fan drive pump 10.3 (engine 2)
(69.2) Pressure filter – PTO 2 gear lubrication pump 8.4 (engine 2)
Pressure switches
57B027-2 Filter element monitoring – PTO 2 gear lubrication pressure
Miscellaneous
(74.2) Pressure relief valve – PTO 2 gear lubrication
(79.2) Changeover valve "Electronic or hydraulic pump regulation" for pumps 4 – 6 (engine 2)
(83) Pressure relief valve – travel parking brake operating pressure (50 bar)
(85) Bladder accumulator (10 liters, 10 bar pre-charge pressure)
(131.2) Proportional solenoid valve, radiator fan speed (57Q636-2) – engine 2
(168.2) Pressure relief valve – max. operating pressure – hydraulic cooler fan drive (engine 2)
(168.4) Pressure relief valve – max. operating pressure – radiator fan drive (engine 2)
(169.2) Pressure relief valve – med. operating pressure – hydraulic cooler fan drive (engine 2)
(171) Pressure relief valve – hydraulic access ladder (70 bar)
TS 15110-upD-GB-0 PC5500-6 3 - 15
3.1.7 LOCATION OF THE REMOTE CONTROL VALVES
Fig. 3-8 Location of the Remote Control Valves
3 - 16 PC5500-6 TS 15110-upD-GB-0
Remote control Function

Directional sole- Proportional
unit schematic
noid solenoid BHA FSA
code
61K620a L.H. crawler forward
61K620
61K620b L.H. crawler backwards
61K621a Stick extend (out)
61K621
61K621b Stick retract (in)
(45.1)
61K622a Bucket curl (fill)
61K622
61K622b Bucket empty (dump)
61K623a Boom raise (up)
61K623
61K623b Boom lower (down)
61K624a Bucket curl (fill) Clam close

61K624
61K624b Bucket empty (dump) Clam open
61K625a Boom raise (up) Bucket curl (fill)
61K625
61K625b Boom lower (down) Bucket empty (dump)
(45.2)
61K626a (not used) Boom raise (up)
61K626
61K626b (not used) Boom lower (down)
61K627
61K628a R.H. crawler backwards

61K628
61K628b R.H. crawler forward
61K629a Boom raise (up)
61K629
61K629b Boom lower (down)
(45.3)
61K630a Bucket curl (fill)
61K630
61K630b Bucket empty (dump)
61K631
61K632a Swing right

(43) 61K632
61K632b Swing left
TS 15110-upD-GB-0 PC5500-6 3 - 17
3.1.8 HYDRAULIC OIL TANK - LOCATION OF ELECTRICAL

COMPONENTS
Fig. 3-9 Hydraulic Oil Tank - Location of Electrical Components
3 - 18 PC5500-6 TS 15110-upD-GB-0
40B004 Hydraulic oil level sensor “Hydraulic oil level too low”
40B024 Breather filter pressure switch (filter monitoring)
40B031 Shut-off gate monitoring switch
40B050 Hydraulic oil level sensor - refill level indication
40B105 Hydraulic oil level sensor (pressure switch)
40B163 Oil pressure transducer – return oil chamber
40B164 Oil pressure transducer – leak oil chamber
40B165 Oil pressure transducer – (lower) in front of oil filter in collector pipe
40B166 Oil pressure transducer – (upper) behind the oil filter in collector pipe
40G018 Transfer pump
40K601 Solenoid valve – oil cooler preload pressure reduction
40S035 Operation switch for transfer pump
TS 15110-upD-GB-0 PC5500-6 3 - 19
3.1.9 CLS1/2 & SLS LUBRICATION STATION AND THE LUBRICATION

CYCLE COMPONENTS
Fig. 3-10 View onto the CLS1/2 & SLS Lubrication Station and the Lubrication Cycle Components
3 - 20 PC5500-6 TS 15110-upD-GB-0
(1) Lubrication station
(2) Lubricant pressure gauge
(3) Lubricant pump
(4) Lubricant pressure release solenoid valve
(5) Dip stick
(6) Pressure relief valve
(7) Flow control valve (16 - 19 double strokes / min)
(8) Breather filter for lubricant container
(9) Grease level sensor (sonar sensor)*
(9a) Grease level sensor (binary sensor) - full*
(9b) Grease level sensor (binary sensor) - pre-warning*
(9c) Grease level sensor (binary sensor) - empty*
(10) Grease pump control solenoid valve (pump ON / OFF)
(11) Electrical terminal box
(12) Lubricant lines to lubrication points
(13) Lubricant in-line filter
(14) Connector plug
(15) End-line pressure switch
(16) Lubricant injector
(17) Lubricant supply line port
(18) Dummy wheel, SLS only
TS 15110-upD-GB-0 PC5500-6 3 - 21
3.1.10 ELECTRICAL COMPONENTS IN THE CAB BASE
Fig. 3-11 Exemplaric view onto the standard components and the X2 switch board in the cab base (1)
3 - 22 PC5500-6 TS 15110-upD-GB-0
(1) Cab base door
(2) Door handles
(3) Lock rod for locking the cab base door in open position
(4) Light switch
(5) KOMTRAX Plus controller (10K300)
(6) Pressure switch of the fire suppression system for shutdown of the engines (10B351).
Fire detection and suppression systems are special equipment.
(7) Signal horn compressor (10G007)
(8) X2 switch board (11a000)
(9) Master Turbo Controller MTC (11K301)
(10) CAN-Node 2 (11K302) Type ICND
(11) CAN-Node 3 (11K303) Type ICNV
(14) Electronic pump control module (10K032). The data link adapter for connecting an electronic tool to
the module is located in the Operator’s cab
REMARKS: On shovels equipped with electrical pre-heating systems there are additional components in the cab
base.
TS 15110-upD-GB-0 PC5500-6 3 - 23
-continued-
Fig. 3-12 Exemplaric view onto the standard components and the X2 switch board in the cab base (2)
3 - 24 PC5500-6 TS 15110-upD-GB-0
(1) X2 switch board (11a000)
(2) Hour meter engine running (11P001-1)
(3) Hour meter traveling operation(11P029)
(4) Connector (11X027b) for program upload to the KOMTRAX Plus controller (10K300)
(5) Plug socket 24 Volt (11X030)
(6) Switch (11S041-1) for constant engine 1 speed adjustment to 1800/min (rated speed)
(7) Switch (11S041-2) for constant engine 2 speed adjustment to 1800/min (rated speed)
(8) Switch (11S097) for upload of new program to KOMTRAX Plus controller (10K300)
(9) Engine warning LEDs and indicator LEDs (11P063, 11P138) for diagnostic of the RC4-4 (10K032)
(10) Circuit brakers

(11) Emergency motor relais (11Q044, 11Q044c, 11Q044d, 11Q122)
(12) Amplifier modules (11T013 - 11T016.)
TS 15110-upD-GB-0 PC5500-6 3 - 25
3.1.11 EMERGENCY SHUTDOWN SWITCHES & SAFETY SWITCH FOR

MAINTENANCE
Fig. 3-13 Emergency engine shutdown switches & safety switch for maintenance
3 - 26 PC5500-6 TS 15110-upD-GB-0
Emergency switches
A Push button of emergency shutdown switches (2, 3, 4 and 5) for stopping both engines
(1) 54S051/52 Pulling chains for emergency shut down from ground man (option)
(2) 70S033A Emergency engine shutdown switch at the access ladder
(3) 61S033B Emergency engine shutdown switch at the main control valves
(4) 57S033C Emergency engine shutdown switch in pump compartment on center post
(5) 51S033D Emergency engine shutdown switch at the counterweight
Safety switch for maintenance
(11) Maintenance safety switch (50S058)
(12) Rotary switch

• Switch position -0- Engine start blocked
• Switch position -1- Normal operation
(13) Securing flap for rotary switch in -0- position
(14) Holes for attaching padlocks
Other parts
(6) Counterweight
(7) Front door
(8) Access door to the oil level gauge of the front engine
(9) Access door to the pump compartment
(10) Center floor door
(15) Light switch
(16) Plug socket 24V DC
TS 15110-upD-GB-0 PC5500-6 3 - 27
3.1.12 HYDRAULICALLY OPERATED ACCESS LADDER
Fig. 3-14 Hydraulically Operated Access Ladder
3 - 28 PC5500-6 TS 15110-upD-GB-0
(R1 + R3) Access ladder up/down with decreased speed (cushioning function)
(R2) Access ladder up/down with maximum speed
(1) Access ladder
(2) Stop bar
(3) Pull chain for emergency lowering of the access ladder
(4) Hydraulic cylinder
(5) Pull chain for emergency lowering of the access ladder (engines not running)
70S084 Ladder control switch for lowering and lifting the ladder
70S084a Safety switch for emergency lowering of the access ladder.
70B091 Monitor and control sensor

This sensor monitors the lower ladder position and controls the moving speed of the ladder.
70B122 Monitor and control sensor, located on ladder pivot bracket

This sensor monitors the upper ladder position and controls the final moving speed of the ladder.
70S501 Emergency valve – access ladder emergency DOWN
REMARKS: If the ladder is not in the final upper position (70B122 not activated) the pilot control is switched off.
TS 15110-upD-GB-0 PC5500-6 3 - 29
3.1.13 SERVICE ARM
Fig. 3-15 Overview
3 - 30 PC5500-6 TS 15110-upD-GB-0
[A] Working position
[B] Refilling position
(1) Hydraulic cylinder
(2) Chain with pull switch 55S087
(3) Service arm
(4) Proximity switch 55B023
TS 15110-upD-GB-0 PC5500-6 3 - 31
Connector types overview Mounting locations and connector types
3.2 CONNECTOR TYPES OVERVIEW

Terminology declaration
The terms male & female refer to the connector pins & sockets, while the terms male housing & female housing
refer to the mating portion of the connector housing parts.
Male (female housing) Female (male housing)

2 pins DT04-2P (Deutsch) 2 sockets DT06-2S (Deutsch)
3 - 32 PC5500-6 TS 15110-upD-GB-0
Mounting locations and connector types Connector types overview
31-pole connector with aluminium housing 21-pole connector with plastic housing
Grease barrel connector CAN bus connector
CAN feed-through into node box Deutsch connectors HD 34/36-18-8-S…
Picture shows socket rear insert.
TS 15110-upD-GB-0 PC5500-6 3 - 33
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.
3 - 34 PC5500-6 TS 15110-upD-GB-0
Mounting locations and connector types Connector types overview
Phoenix Contact connector for ICN-D nodes (10-pole)
Fig. 3-16 Phoenix Contact connector for ICN-D nodes (10-pole)

(A) Mounting screw
(1 - 10) Cable port
(B) Cable clamp
TS 15110-upD-GB-0 PC5500-6 3 - 35
Connector for IVN-V nodes (55 pins)
Fig. 3-17 ICN-V connector

(1) Connector housing
(2) Pin allocation (55 pins)
3 - 36 PC5500-6 TS 15110-upD-GB-0
Standard value table for electrical components
4 STANDARD VALUE TABLE

FOR ELECTRICAL
COMPONENTS
TS 15110-upD-GB-0 PC5500-6 4 -1
Used abbreviations
Deutsch T-box Electrical Test Box for Deutsch Connectors
Eng Engine
N.C. Normally Closed
N.O. Normally Open
OM/M Operation & Maintenance Manual
S/M Service Manual
TIER 2 Engine Emission Standard
20S001 Main Key Switch
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 31Q599-1 table below, it is normal 2) Disconnect

off solenoid
31Q599-2 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

sensor 3) Insert T-box
52B064-2
4) Pick up
Between (1) - (2) 850 ± 50Ω adjustment:
refer to S/M
Engine related parts

resistance
Measure
Pre-lube oil 52B093-1 table below, it is normal. 2) Disconnect

pressure switch 52B093-2 connector
Between (1) - (2) min. 1MΩ
3) Insert T-box
52Q502a-1 If the condition is within the range shown in the 1) 20S001 OFF
resistance
Measure
Engine 52Q502a-2 table below, it is normal. 2) Disconnect

cold start aid
52Q502b-1 connector
solenoid valve Between (1) - (2) 38 ± 3Ω
52Q502b-2 3) Insert T-box
Measure voltage
52B018-1 Switch point: over 60 mbar suction pressure connector

Engine air filter
52B018-2 3) Insert T-box
clogging switch
52B019-1 4) 20S001 ON
[N.O. type] Between (1) - (2) 0V
52B019-2 5) Engine high idle
Between (1) - (2) 22 - 24V 6) Filters: clogged
4 -2 PC5500-6 TS 15110-upD-GB-0
Compo- Inspec-
System
name conditions
code method
Engine remote
oil tank level
sensor connector
3) Insert T-box
Measure voltage
[N.C. type] Between (A) - (C) 22 - 24V
4) 20S001 ON
→ with oil Between (A) - (B) 22 - 24V
63B103-1 5) Engine OFF
63B103-2 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 63B106-1 3) Insert T-box
(pressure 63B106-2 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
connector
sensor
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
If the condition is within the range shown in the
table below, it is normal.
Measure voltage
Alternator
→ between 52G005-1 When the engine is running (high idle) 1) Start engine
alternator 27.5 - 29.5 V
52G005-2 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 15110-upD-GB-0 PC5500-6 4 -3
Compo- Inspec-
System
name conditions
code method

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

voltage
57B049-1
PTO & related parts
temperature connector
sensor 57B049-2 Refer to the PT100 3) Insert T-box
Between (B) - (C)
Centigrade/Volt chart
4) 20S001 ON
resistance
Measure

PTO connector
Between (1) - (2) min. 1MΩ
lube oil filter 57B027-1 3) Insert T-box
clogging sensor 57B027-2 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 57K553-1 table below, it is normal. 2) Disconnect

pressure
57K553-2 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
Measure voltage
limit switch
connector
[N.O. type]
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 PC5500-6 TS 15110-upD-GB-0
Compo- Inspec-
System
name conditions
code method
Measure voltage
Up: connector
Ladder limit
switch 70B122 3) Insert T-box
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
solenoid valve 57Q623a
connector
→ raise Between (1) - (2) 20 ± 1.0Ω
3) Insert T-box
resistance
Measure
Swing
parking brake 57Q505
connector
3) Insert T-box
57K506a-1 If the condition is within the range shown in the 1) 20S001 OFF
resistance
Measure
Oil cooler 57K506a-2 table below, it is normal. 2) Disconnect

fan drive
57K506b-1 connector
57K506b-2 3) Insert T-box
resistance
Measure
Travel table below, it is normal. 2) Disconnect

parking brake 57Q516
connector
3) Insert T-box
Hydraulic system

resistance
Qmin
Measure

solenoid valve 57K517
connector
(Pumps 2 & 4) Between (1) - (2) 35 ± 1.0Ω
3) Insert T-box
resistance
Measure
Qmax ½ table below, it is normal. 2) Disconnect

57K517a
solenoid valve connector
Between (1) - (2) 35 ± 1.0Ω
3) Insert T-box
resistance
Measure

connector
Air filter Between (1) - (2) min. 1MΩ
3) Insert T-box
hydraulic tank 40B024
4) 20S001 ON
[N.O. type]
Measure
voltage
5) Engine high idle

Between (1) - (2) 22 - 24V 6) From switch point
0.08bar (low press.)
TS 15110-upD-GB-0 PC5500-6 4 -5
Compo- Inspec-
System
name conditions
code method

X4 pump sup- table below, it is normal.
Measure voltage
2) Insert T-box
port pressure
3) 20S001 ON
line / pump 57B097-1 Between (1) - (2) 22 - 24V
4) Engine OFF
bearing lubri- 57B097-2
cation switch 5) Engine high idle
[N.C. type] Between (1) - (2) 0V 6) From switch point
0.5bar
1) 20S001 OFF
2) Disconnect
Measure
voltage
connector
Between (1) - (2) 22 - 24V
3) Insert T-box
4) 20S001 ON
Electronic 57K561-1
pump control If the condition is within the range shown in the 1) 20S001 OFF
current/resistance
solenoid valve 57K561-2 table below, it is normal. 2) Disconnect

connector
Measure
Between (1) - (2)

18 ± 1.0Ω 3) Insert T-box
at the solenoid
4) 20S001 ON
Between (1) - (2) 463 ± 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

Hydraulic system
40K601
pressure connector
3) Insert T-box
resistance
X4 pump sup-
Measure
57K602-1 table below, it is normal. 2) Disconnect

port pressure
57K602-2 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

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
solenoid valve connector
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
resistance
Measure
Coolant fan 57K636-1 table below, it is normal. 2) Disconnect

solenoid valve 57K636-2 connector
Between (1) - (2) 10 ± 1.0Ω
3) Insert T-box
4 -6 PC5500-6 TS 15110-upD-GB-0
Compo- Inspec-
System
name conditions
code method
61K620
61K621
61K622
61K623
61K624 If the condition is within the range shown in the 1) 20S001 OFF
resistance
Measure
Remote control 61K625 table below, it is normal.
2) Disconnect
proportional 61K626
connector
solenoid valve 61K627
Between (1) - (2) 24 ± 1.0Ω 3) Insert T-box
61K628
61K629
61K630
61K631
61K632
61K620a
61K620b
61K621a
61K621b
61K622a
61K622b
61K623a
61K623b
61K624a
Hydraulic system
61K624b
61K625a
61K625b
resistance
Measure

Remote control 61K626a 2) Disconnect
solenoid valve 61K626b connector
61K627a Between (1) - (2) 20 ± 1.0Ω 3) Insert T-box
61K627b
61K628a
61K628b
61K629a
61K629b
61K630a
61K630b
61K631a
61K631b
61K632a
61K632b
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
TS 15110-upD-GB-0 PC5500-6 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
→ 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 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
Hydraulic system

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

Measure voltage
connector
High pressure 61B087-a
61B087-b 3) Insert T-box
switch 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
4 -8 PC5500-6 TS 15110-upD-GB-0
Compo- Inspec-
System
name conditions
code method
Measure voltage
X1 pressure connector
57B085-1 3) Insert T-box
sensor
57B085-2 Between (A) - (C) 22 - 24V
(analog) 4) 20S001 ON
5) Engine high idle
Between (B) - (C) 0.5 - 9.5V
6) max. 60bar
Measure voltage table below, it is normal. 2) Disconnect
X2 pressure connector
sensor 57B086 3) Insert T-box
Between (A) - (C) 22 - 24V
(analog) 4) 20S001 ON
5) Engine high idle
Between (B) - (C) 0.5 - 9.5V
6) max. 60bar
Measure voltage
Preload valve connector

pressure 3) Insert T-box
40B166 Between (A) - (C) 22 - 24V
sensor 4) 20S001 ON
(analog) 5) Depending on the
Hydraulic system
Between (B) - (C) 0.5 - 9.5V pressure

6) max. 60bar
Measure voltage
Leak oil connector

chamber
3) Insert T-box
pressure 40B164 Between (A) - (C) 22 - 24V
sensor 4) 20S001 ON

6) max. 6bar
Measure voltage
Return oil connector

chamber
3) Insert T-box
pressure 40B163 Between (A) - (C) 22 - 24V
sensor 4) 20S001 ON

6) max. 6bar
Measure voltage
Suction tank connector

pressure 3) Insert T-box
sensor 59B162 Between (A) - (C) 22 - 24V
4) 20S001 ON
(analog)
5) Engine high idle
Between (B) - (C) 0.5 - 9.5V
6) Range: -1 ~ +1bar
TS 15110-upD-GB-0 PC5500-6 4 -9
System
Compo- Inspec-
name conditions
code method

connector
Hydraulic system
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

CLS 1 connector
Measure voltage
80B043 3) Insert T-cable

End line switch Between (A) - (B) 22 - 24V
SLS 4) 20S001 ON
grease
62B046 5) Engine high idle
pressure
CLS 2 6) Grease pump
60B043 running
Between (A) - (B) 0V 7) Grease pressure
Grease system
180bar present
CLS 1 If the condition is within the range shown in the
62Q507 1) Engine high idle
resistance
Measure
2) Grease pump
Grease pump SLS
running
solenoid valve 62Q509
3) Grease pressure
CLS 2 Between (D) - (F/H) 22 ± 1.0Ω below 180bar
62Q642
CLS 1 If the condition is within the range shown in the
62Q507a 1) Engine high idle
resistance
Grease line
Measure
2) Grease pump
solenoid valve SLS
running
62Q509a
(Vent valve) 3) Grease pressure
CLS 2 Between (D) - (F/H) 22 ± 1.0Ω below 180bar
62Q642a
CLS 1
Measure current

62B108
Grease barrel connection
SLS
level sensor 3) Insert T-cable
62B109
(sonar type) 4) 20S001 ON
CLS 2
Grease system
Between (A) - (B) 4 - 20mA 5) Depending on

62B173
the grease level
Measure voltage
2) Disconnect
CLS 1 connection
Grease barrel
62B108a At connector 62X_120
level sensor 3) Insert T-cable
62B108b
(binary type) 62B108a pin B & GND 22 - 24V→ with grease 4) 20S001 ON
62B108c
62B108b pin E & GND 0V → no grease 5) Measure sensor
62B108c pin J & GND output
4 - 10 PC5500-6 TS 15110-upD-GB-0
System
Compo- Inspec-
name conditions
code method
Measure voltage
2) Disconnect
SLS connection
62B109a At connector 62X_130 3) Insert T-cable
62B109b
62B109a pin B & GND 22 - 24V→ with grease 4) 20S001 ON
62B109c
62B109b pin E & GND 0V → no grease
Grease system
5) Measure sensor
Grease barrel 62B109c pin J & GND output
level sensor
(binary type) If the condition is within the range shown in the 1) 20S001 OFF
Measure voltage table below, it is normal.
2) Disconnect
CLS 2 connection
62B112a At connector 62X_110 3) Insert T-cable
62B112b
62B112a pin B & GND 22 - 24V→ with grease 4) 20S001 ON
62B112c
62B112b pin E & GND 0V → no grease 5) Measure sensor
62B112c pin J & GND output

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
Electronic control levers
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
→ right crawler
5) Depress pedal
→ forward
6) Depress pedal
→ backward
TS 15110-upD-GB-0 PC5500-6 4 - 11
System
Compo- Inspec-
name conditions
code method
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
2) Disconnect
Betw. 11X_00 - 7 L 0 up to -10V
Measure voltage
connection
Control lever 3) Insert T-cable
→ left hand 20S020 Betw. 11X_00 - 7 R 0 up to +10V
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
Electronic control levers

table below, it is normal. 1) 20S001 OFF
2) Disconnect
Between 11X_00-9 L 0 up to -10V
Measure voltage
connection
Control lever 3) Insert T-cable
→ right hand 20S019 Between 11X_00-9 R 0 up to +10V 4) 20S001 ON
X & Y axis 5) Move lever to left
Between 11X_00-14 F 0 up to +10V & right side
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
resistance
1) 20S001 OFF
Measure
CAN bus 20R102 table below, it is normal.

CAN
2) Disconnect
resistor 40R102
Between (A) - (B) 120Ω CAN connector
4 - 12 PC5500-6 TS 15110-upD-GB-0
References for Troubleshooting (CAN Bus & Node Outputs)
5 REFERENCES FOR
TROUBLESHOOTING
(CAN BUS & NODE
OUTPUTS)
TS 15110-upD-GB-0 PC5500-6 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 REAL TIME MONITOR 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 PC5500-6 TS 15110-upD-GB-0
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":
– Trouble code G00308 is 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 7-238.
TS 15110-upD-GB-0 PC5500-6 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 PC5500-6 TS 15110-upD-GB-0
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 does not 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
feed-in – Refer to the Wiring diagram.
– 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
cable break – Find the displayed node and its affected connector/pin.
– Locate the short circuit to ground or the wiring interruption.
– Repair as necessary.
TS 15110-upD-GB-0 PC5500-6 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 KOMTRAX Plus 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 PC5500-6 TS 15110-upD-GB-0
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 (refer to section 5.3.1.1 on page 5-8).
– 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:
1. Use the following troubleshooting chart as a pattern.
2. Apply the respective Component Codes which are involved in the comparable trouble message.
3. 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
G00227 G00229 G00234 G00236 G00309 G00311
G00313 G00315 G00317 G00319 G00321 G00323
TS 15110-upD-GB-0 PC5500-6 5 -7
Troubleshooting for Relay Monitored Node Outputs References for Troubleshooting (CAN Bus & Node Outputs)
5.3.1.1 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
Message
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
G00109 56K250b 20S029 in position 1 brake applied
0V at relay 56K250a/b
0V at solenoid 57Q505
Both relay LEDs (yellow & red) OFF
20S029 in position 0 brake released
24V at relay 56K250a/b
24V at solenoid 57Q505
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 PC5500-6 TS 15110-upD-GB-0
G00107 - Trouble slew parking brake control 56K250a

G00109 - Trouble slew parking brake control 56K250b
[2/4]
Nominal
value
REAL TIME MONITOR - Relay Check
1. 20S001 ON
2. Engines OFF
3. REAL TIME MONITOR
17 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 does not 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 15110-upD-GB-0 PC5500-6 5 -9
View onto the CoDeSys HMI Visualization screen for trouble code G00107
[3/4]
Fig. 5-2 Exemplaric view onto the CoDeSys HMI Visualization screen for trouble code G00107
5 - 10 PC5500-6 TS 15110-upD-GB-0
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 15110-upD-GB-0 PC5500-6 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 (refer to section 5.3.2.1 on page 5-13).
– 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:
1. Use the following troubleshooting chart as a pattern
2. Apply the respective Component Codes which are involved in the comparable trouble message
3. 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
G00228 G00230 G00235 G00237 G00310 G00312
G00314 G00316 G00318 G00320 G00322 G00324
5 - 12 PC5500-6 TS 15110-upD-GB-0
5.3.2.1 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
Message
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 out-
Related information put) 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. Engines OFF.
17 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 15110-upD-GB-0 PC5500-6 5 - 13
G00108 - Trouble slew parking brake control Output to 56K250a

G00110 - Trouble slew parking brake control Output to 56K250b
[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. Engines OFF.
18 Output Signals
Screen 13/27
5. Verify the Output Signals on the REAL TIME MONITOR.
20S029 in position 0 Output Signal = 1
If the REAL TIME MONITOR indication does not 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 PC5500-6 TS 15110-upD-GB-0
[3/4]
Fig. 5-4 Exemplaric view onto the CoDeSys HMI Visualization screen for trouble code G00108
TS 15110-upD-GB-0 PC5500-6 5 - 15
[4/4]
5 - 16 PC5500-6 TS 15110-upD-GB-0
Tables for testing and troubleshooting
6 TABLES FOR TESTING

AND TROUBLESHOOTING
TS 15110-upD-GB-0 PC5500-6 6 -1
Test value table for temperature sensors (PT100) Centigrade - Volt Tables for testing and troubleshooting
6.1 TEST VALUE TABLE FOR TEMPERATURE SEN-

SORS (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
6 -2 PC5500-6 TS 15110-upD-GB-0
Tables for testing and troubleshooting Test Value Table for Temperature Sensors (PT100) Centigrade - Ohm
6.2 TEST VALUE TABLE FOR TEMPERATURE SEN-

SORS (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)
TS 15110-upD-GB-0 PC5500-6 6 -3
Table of trouble codes (G-Codes) Tables for testing and troubleshooting
6.3 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, 3=blue
Top Message
Instruction Number of the Instruction Message, which is displayed together with the
Column 3
Message No. 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 = KOMTRAX Plus 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 17.
Table of G-Codes
G- Code Colour
Code of
Acoustic Signal
Error Top
Message No.
Code Message Text message of G-Code

Instruction
(Message
Memory
0 = RED
Display
Code)
1 = YELLOW
G = Shovel 3 = BLUE
G00001 0 1 2 1 Trouble Shut-Off (gate) valve
G00002 3 37 2 3 Test speed 1800 1/min engine 1
G00003 1 38 1 1 Trouble pump controller
G00005 3 39 1 3 Low hydraulic oil level
G00006 3 37 2 3 Test speed 1800 1/min engine 2
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 3 0 2 Y 3 Set engine to low idle
G00032 0 2 1 1 Trouble starter
G00035 0 34 2 1 Trouble totally loss gear oil (PTO 1)
G00036 0 34 2 1 Trouble totally loss gear oil (PTO 2)
6 -4 PC5500-6 TS 15110-upD-GB-0
Tables for testing and troubleshooting Table of trouble codes (G-Codes)
G- Code Colour
Code of
Acoustic Signal
Error Top
Message No.
Instruction
(Message
Memory
Display
0 = RED
Code)
1 = YELLOW
G = Shovel 3 = BLUE
G00037 0 2 2 Y 1 Trouble monitoring, engine 2 speed too low
G00038 0 2 2 Y 1 Trouble monitoring, engine 2 speed too high
G00039 3 0 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 3 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 1 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 1 2 2 1 Trouble hydraulic oil temperature
G00067 1 2 1 1 Trouble battery voltage too high
G00068 1 2 2 Y 1 Trouble gear lubrication (PTO 2)
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
G00083 1 2 1 1 Trouble monitoring oil temperature gear (PTO 2)
G00084 1 2 2 Y 1 Trouble oil temperature gear (PTO 2)
G00086 0 12 2 Y 3 SHUTDOWN
G00087 3 2 Y 3 Stop all movements for low idle
G00090 0 8 2 Y 1 Trouble power supply
G00091 3 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
TS 15110-upD-GB-0 PC5500-6 6 -5
G- Code Colour
Code of
Acoustic Signal
Error Top
Message No.
Instruction
(Message
Memory
Display
0 = RED
Code)
1 = YELLOW
G = Shovel 3 = BLUE
G00096 3 14 2 3 Pilot control cut out
G00097 0 10 2 3 Emergency shut-down at counterweight
G00100 3 11 2 3 Maintenance Safety Switch
G00101 1 46 2 Y 1 Faulty switch 20M007
G00103 1 47 2 Y 1 Faulty switch 20M004
G00104 1 15 2 Y 1 Trouble battery current
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
G00139 1 17 1 1 Trouble monitoring X1-2 Pressure
G00140 1 17 1 1 Trouble monitoring X1-1 Pressure
G00141 1 17 1 1 Trouble monitoring X2-Pressure
G00142 1 17 1 1 Trouble monitoring pump support pressure X4-1
G00147 1 17 1 1 Trouble monitoring gear lubrication (PTO 1)
G00148 1 17 1 1 Trouble monitoring fuel level
G00149 Trouble monitoring ambient temperature
G00150 1 17 1 1 Trouble monitoring gear lubrication (PTO 2)
G00151 1 17 1 1 Trouble monitoring gear (PTO) oil filter 1
G00152 1 17 1 1 Trouble monitoring oil filter pump lubrication
G00153 1 17 1 1 Trouble monitoring oil filter pump control
6 -6 PC5500-6 TS 15110-upD-GB-0
G- Code Colour
Code of
Acoustic Signal
Error Top
Message No.
Instruction
(Message
Memory
Display
0 = RED
Code)
1 = YELLOW
G = Shovel 3 = BLUE
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)
G00167 1 17 1 1 Trouble oil filter pump lubrication
G00168 1 17 1 1 Trouble oil filter pump control
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
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
G00182 1 17 1 1 Trouble control pressure X1-2
G00183 1 17 1 1 Trouble pump support pressure X4-1
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
G00191 1 17 1 1 Trouble oil filter gear (PTO 2)
G00193 1 17 1 1 Trouble monitoring gear (PTO) oil filter 2
G00195 1 17 1 1 Trouble pump support pressure X4-2
TS 15110-upD-GB-0 PC5500-6 6 -7
G- Code Colour
Code of
Acoustic Signal
Error Top
Message No.
Instruction
(Message
Memory
Display
0 = RED
Code)
1 = YELLOW
G = Shovel 3 = BLUE
G00196 1 17 1 1 Trouble monitoring pump support pressure X4-2
G00197 1 17 1 1 Trouble monitoring engine air cleaner 2
G00198 1 17 1 1 Trouble air cleaner 2
G00201 1 20 1 Y 1 Attachment lubrication system empty
G00202 1 17 1 3 Attachment lubrication system grease level too low
G00203 1 20 1 Y 1 Trouble attachment lubrication system
G00204 1 20 1 Y 1 Trouble attachment lubrication system
G00207 1 2 1 Y 1 Engine remote oil-tank 1 empty
G00208 1 2 1 Y 1 Engine remote oil-tank 2 empty
G00216 1 2 2 Y 1 Trouble software not compatible
G00218 3 0 2 Y Switch off all motors for running transfer pump
G00219 3 0 2 Y 3 Return oil tank emty
G00220 1 2 2 Y 1 Trouble transfer pump motor overheated
G00221 1 2 1 Y 1 Trouble slew direction module defect
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
G00227 1 2 2 Y 1 Trouble starter control 51K001a-2
G00228 1 2 2 Y 1 Trouble starter control Output to 51K001a-2
G00229 1 2 2 Y 1 Trouble starter control 51K001b-2
G00230 1 2 2 Y 1 Trouble starter control Output to 51K001b-2
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
6 -8 PC5500-6 TS 15110-upD-GB-0
G- Code Colour
Code of
Acoustic Signal
Error Top
Message No.
Instruction
(Message
Memory
Display
0 = RED
Code)
1 = YELLOW
G = Shovel 3 = BLUE
G00240 3 21 1 1 Trouble hydraulic oil temperature
G00242 3 22 2 3 Engine 1 already running
G00243 3 23 1 Y 3 Fill up fuel tank
G00245 0 24 2 1 Engine shutdown from ground
G00246 3 25 2 3 Hydraulic oil temperature
G00248 3 22 2 3 Engine 2 already running
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
G00256 3 45 2 3 Operator warning system
G00257 3 30 2 3 Hydraulic oil temperature
G00258 0 10 2 1 Emergency shut-down at counterweight
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
TS 15110-upD-GB-0 PC5500-6 6 -9
G- Code Colour
Code of
Acoustic Signal
Error Top
Message No.
Instruction
(Message
Memory
Display
0 = RED
Code)
1 = YELLOW
G = Shovel 3 = BLUE
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
G00329 1 38 2 Y 1 Protection switch tripped
G00330 1 2 2 Y 1 Trouble pilot control 11Q111
G00331 3 57 2 3 Automatic after_running engine 1
G00332 3 57 2 3 Automatic after_running engine 2
G00333 1 2 2 Y 1 Trouble battery charger relay
G00336 1 2 1 Y 1 Trouble monitoring slew speed
G00349 Engine 2 running
G00350 Engine 2 standstill
G00351 Engine 1 running
G00352 Engine 1 standstill
G00401 N 5 Shutdown Engine \ Motor shutdown at bottom - off
G00402 N 5 Shutdown Engine \ Motor shutdown at bottom - on
G00417 1 2 2 Y 1 Communication failure PLC <=> KOMTRAX Plus 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 Application sys error
G00425 1 2 2 1 Settings impossible to take over into the PLC
6 - 10 PC5500-6 TS 15110-upD-GB-0
Tables for testing and troubleshooting Table of instruction messages
6.4 TABLE OF INSTRUCTION MESSAGES

Message
Instruction Message
No.
Engine stopped because of main Shut-Off

(gate) valve.
1
- Open the Shut-Off (gate) valve.
- If failure exist further, inform service.
2 Inform service.
Stop the engine.

3
- Inform service.
Start blocked because of main Shut-Off

(gate) valve.
4
- Open the Shut-Off (gate) valve.
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 15110-upD-GB-0 PC5500-6 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 KOMTRAX Plus 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 PC5500-6 TS 15110-upD-GB-0
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 15110-upD-GB-0 PC5500-6 6 - 13
Table of binary codes Tables for testing and troubleshooting
6.5 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 KOMTRAX Plus controller
05 000101 034 Trouble KOMTRAX Plus display
06 000110 035 Trouble totally loss gear oil (PTO 1)
07 000111 036 Trouble totally loss gear oil (PTO 2)
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
12 001100 068 Trouble gear lubrication (PTO 2)
13 001101 070 Trouble oil temperature gear (PTO 1)
14 001110 071 Trouble gear lubrication (PTO 1)
15 001111 084 Trouble oil temperature gear (PTO 2)
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
21 010100 097 Emergency shut-down at counterweight
22 010110 100 Maintenance Safety Switch
23 010111 147 Trouble monitoring gear lubrication (PTO 1)
6 - 14 PC5500-6 TS 15110-upD-GB-0
Tables for testing and troubleshooting Table of binary codes
24 011000 150 Trouble monitoring gear lubrication (PTO 2)
Input Digits of
Binary Code G-Code Message
No. G-Code
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
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
31 100000 258 Emergency shut-down in cab
34 100010 261 Maintenance Safety Switch
35 100011 037 Trouble monitoring, engine 2 speed too low
36 100100 038 Trouble monitoring, engine 2 speed too high
40 101000 060 Fire in the power house
46 101110 048 Trouble emergency safety circuit
49 110001 053 Reset emergency safety circuit
50 110010 090 Trouble power supply
51 110011 099 Trouble power supply
63 111111 308 Trouble CAN-Bus or CAN-Hardware
TS 15110-upD-GB-0 PC5500-6 6 - 15
Table of binary codes Tables for testing and troubleshooting
6.5.1 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 PC5500-6 TS 15110-upD-GB-0
Tables for testing and troubleshooting Binary Output Signals on the KOMTRAX Plus Monitor
6.6 BINARY OUTPUT SIGNALS ON THE KOMTRAX

PLUS MONITOR
The following table shows the Binary Output Signals which are displayed via KOMTRAX Plus.
These Output Signals can be used for testing and troubleshooting.
For more details of KOMTRAX Plus refer to the SERVICE MANUAL and to the OPERATION & MAINTENANCE
MANUAL.
Brief Instruction for switching the output signals ON/OFF
1. Enter the KOMTRAX Plus Service Level.
2. Select option "08 Setting" on the SERVICE MENU SELECT screen.
3. Open sub-screen 6/10, 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 "18 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.
Con-
Compo- dition
Location
Screen
nent at Node KOMTRAX Plus Display Text REAL TIME MONITOR
No.
Code Acti-
vation
11K050 24V 11K304 Bucket Cut-Off Output Signals Ext. Low Volt. 5/27
11K064-1 24V 11K304 Engine Enable Output Signals Ext. Low Volt. 7/27
11K064-1 24V 11K304 Engine Enable Output Signals Ext. Low Volt. 7/27
11K111a 24V 11K303 Pilot Control Supply Output Signals Ext. Low Volt. 6/27
11K111b 24V 11K303 Pilot Control Supply Redundant Output Signals Ext. Low Volt. 6/27
11K300 24V 11K304 Slew Enable Output Signals Ext. Low Volt. 7/27
11P029 24V 11K305 Crawler Operating Hour Meter Output Signals Ext. Low Volt. 8/27
11 11Q020 24V 11K304 Horn Output Signals Ext. Low Volt. 5/27
11Q023 24V 11K304 Superstructure Lighting Output Signals Ext. Low Volt. 9/27
11Q023a 24V 11K304 Superstructure Lighting Output Signals Ext. Low Volt. 9/27
11Q044 24V 11K304 Power via Key Switch Output Signals Ext. Low Volt. 5/27
11Q045 24V 11K304 Main Supply Pilot Control Output Signals Ext. Low Volt. 6/27
11Q090 24V 11K303 Emergency Lighting Ladder Output Signals Ext. Low Volt. 9/27
11Q100 24V 11K303 Self Holding Output Signals Ext. Low Volt. 5/27
11Q122 0V 11K305 Stabilized Current Supply Output Signals Ext. Low Volt. 6/27
TS 15110-upD-GB-0 PC5500-6 6 - 17
Binary Output Signals on the KOMTRAX Plus Monitor Tables for testing and troubleshooting
Con-
Compo- dition
Location
Screen
No.
Code Acti-
vation
20P022 24V 20K310 Acoustic Signal Output Signals Cab 3/27
20P056 24V 20K310 Shutdown Prewarning Output Signals Cab 3/27
20P145-1 24V 20K310 KOMTRAX Plus Lamp Red 1 Output Signals Cab 4/27
20P145-2 24V 20K310 KOMTRAX Plus Lamp Red 2 Output Signals Cab 4/27
20P146-1 24V 20K310 KOMTRAX Plus Lamp Yellow 1 Output signals cab 4/27
20
20P146-2 24V 20K310 KOMTRAX Plus Lamp Yellow 2 Output Signals Cab 4/27
20Q067 24V 20K310 Cab Blower Output Signals Cab 3/27
20Q194 24V 20K309 Upper Wiper Stop Output Signals Cab 2/27
20Q197 24V 20K309 Upper Wiper Slow Output Signals Cab 1/27
20Q198 24V 20K309 Upper Wiper Fast Output Signals Cab 1/27
40K601 24V 40K313 Oil Cooler Back-Pressure Output Signals Hydraulic Tank 18/27
40
40Q062 24V 40K313 Transfer Pump Output Signals Hydraulic Tank 18/27
51K001a-1 24V 51K318 Starter Relay 1 Output Signals Engine Room 11/27
51K001b-1 24V 51K319 Starter Relay 1 Redundant Output Signals Engine Room 11/27
51K001a-2 24V 51K318 Starter Relay 2 Output Signals Engine Room 11/27
51K001b-2 24V 51K319 Starter Relay 2 Redundant Output Signals Engine Room 11/27
51 51K045-1 24V 51K317 Relay RPM Shifting 1 Output Signals Engine Room 12/27
51K045-2 24V 51K317 Relay RPM Shifting 2 Output Signals Engine Room 12/27
51K164-1 24V 51K317 Oil Tank 1 Empty Output Signals Engine Room 12/27
51K164-2 24V 51K317 Oil Tank 2 Empty Output Signals Engine Room 12/27
51Q005 24V 51K317 Lighting Service Arm Output Signals Service Arm 22/27
52Q502a-1 24V 51K318 Cold Start 1 Output Signals Engine 10/27
52Q502b-1 24V 51K318 Cold Start 1 Output Signals Engine 10/27

52
52Q502a-2 24V 51K318 Cold Start 2 Output Signals Engine 10/27
52Q502b-2 24V 51K318 Cold Start 2 Output Signals Engine 10/27
55P052 24V 51K319 Hydraulic Oil Tank Full Output Signals Service Arm 19/27
55P076 24V 51K319 CLS 1 Grease Barrel Full Output Signals Service Arm 19/27
55P078 24V 51K319 SLS Grease Barrel Full Output Signals Service Arm 19/27
55P080 24V 51K319 CLS 2 Grease Barrel Full Output Signals Service Arm 19/27
55 55P139 24V 51K318 Fuel Level Tank Full Output Signals Service Arm 20/27
55P142-1 24V 51K318 Engine 1 Oil Tank Full Output Signals Service Arm 20/27
55P142-2 24V 51K318 Engine 2 Oil Tank Full Output signals Service arm 20/27
56K250a 24V 56K315 Parking Brake Output Signals Pump Room 13/27
56K250b 24V 56K316 Parking Brake Redundant Output Signals Pump Room 13/27
6 - 18 PC5500-6 TS 15110-upD-GB-0
Tables for testing and troubleshooting Binary Output Signals on the KOMTRAX Plus Monitor
Con-
Compo- dition
Location
Screen
No.
Code Acti-
vation
55 56K251a 24V 56K315 Travel Brake Output Signals Pump Room 13/27
56K251b 24V 56K316 Travel Brake Redundant Output Signals Pump Room 13/27
56K252a 24V 56K315 Hydraulic Slew Brake Output Signals Pump Room 14/27
56K252b 24V 56K316 Hydraulic Slew Brake Redundant Output Signals Pump Room 14/27
56K253a 24V 51K317 Ladder Up Output Signals Ladder 23/27
56K253b 24V 56K314 Ladder Up Redundant Output Signals Ladder 23/27
56 56K254a 24V 51K317 Ladder Down Output Signals Ladder 23/27
56K254b 24V 56K314 Ladder Down Redundant Output Signals Ladder 23/27
56K255a 24V 56K314 Service Arm Up Output Signals Service Arm 21/27
56K255b 24V 56K314 Service Arm Up Redundant Output Signals Service Arm 21/27
56K256a 24V 56K314 Service Arm Down Output Signals Service Arm 21/27
56K256b 24V 56K314 Service Arm Down Redundant Output Signals Service Arm 21/27
57K553-1 24V 56K316 Gear Oil Cooler Back-Pressure Output Signals Control Panel 17/27
57K553-2 24V 56K316 Gear Oil Cooler Back-PressureTS Output Signals Control Panel 17/27
57K506a-1 24V 56K316 Valve Fan Drive 1 Min. Output Signals Control Panel 16/27
57K506b-1 24V 56K316 Valve Fan Drive 1 Med. Output Signals Control Panel 16/27
57K506a-2 24V 56K316 Valve Fan Drive 1 Min. Output Signals Control Panel 16/27
57K506b-2 24V 56K316 Valve Fan Drive 1 Med. Output Signals Control Panel 16/27
57 57K646 24V 56K315 Pump Control Output Signals Control Panel 15/27
57K647 24V 56K316 Pump Control Output Signals Control Panel 15/27
57K517 24V 56K316 Pump Control Output Signals Control Panel 15/27
57K517a 24V 56K316 Pump Control Output Signals Control Panel 15/27
57K548 24V 56K316 Slew Motor Pitch Control Output Signals Control Panel 17/27
57Q624c 24V 56K315 Service Arm Enable Output Signals Service Arm 20/27
57Q625 24V 56K315 Ladder Movement Fast Output Signals Ladder 24/27
60 60P140 24V 51K318 Travel Motion Horn Output Signals Superstructure 27/27
62Q507 24V 51K318 CLS 1 Lubrication Pump Output Signals Lubric. Syst. 25/27
62Q507a 24V 51K318 CLS 1 Release Lubrication Line Output Signals Lubric. Syst. 25/27
62Q509 24V 51K318 SLS Lubrication Pump Output Signals Lubric. Syst. 26/27
62
62Q509a 24V 51K318 SLS Release Lubrication Line Output Signals Lubric. Syst. 26/27
62Q642 24V 51K319 CLS 2 Lubrication Pump Output Signals Lubric. Syst. 25/27
62Q642a 24V 51K319 CLS 2 Release Lubrication Line Output Signals Lubric. Syst. 25/27
test_leve Test Power Supply for Lever Output Signals Ext. Low Volt. 8/27
TS 15110-upD-GB-0 PC5500-6 6 - 19
Tables of Symptom Codes Tables for testing and troubleshooting
6.7 TABLES OF SYMPTOM CODES

For the troubleshooting procedures of the Symptom Codes refer to chapter 8 in this manual.
6.7.1 SYMPTOMS OF THE ENGINES AND RELATED ELECTRICAL

SYSTEMS
S-Code Trouble Description
SEL001 Engine does not start (engine does not rotate)
SEL002 Engines stop while in operation
SEL003 Engine speed is hunting during boom-up movement
SEL004 Engine does not stop
SEL005 Engine lacks output (no power)
SEL006 Exhaust smoke is black
SEL007 Oil consumption is excessive
SEL008 Oil becomes contaminated quickly
SEL009 Fuel consumption is excessive
SEL010 Oil is in engine coolant
SEL011 Oil level rises
SEL012 Coolant temperature becomes too high (overheating)
6.7.2 SYMPTOMS OF THE HYDRAULIC SYSTEM

All the work equipment shows lack of power or slow movement

SHY001
(especially the "boom up" function)
SHY002 No work equipment, travel or swing movement
SHY003 Work equipment has too much hydraulic drift
SHY004 Work equipment has big time lag
SHY005 Machine deviates during travel movement
SHY006 Machine does not swing
SHY007 Swing acceleration is poor
SHY008 Excessive overrun when stopping swing
SHY009 Floating system without function (FSA only)
SHY010 Abnormal noise coming from SRV or MRV
SHY011 Track tensioning system without function
SHY012 Ladder does not move, or slow movement
6 - 20 PC5500-6 TS 15110-upD-GB-0
Tables for testing and troubleshooting Tables of Symptom Codes
SHY013 Refilling arm does not move, or slow movement
SHY014 The hydraulic driven grease pump does not move
SHY015 Trouble pump bearing lubrication
SHY016 Abnormal track chain movement during digging
SHY017 Swing parking brake without function
SHY018 Travel parking brake without function
6.7.3 SYMPTOMS OF THE MECHANICAL SYSTEM

SME001 Abnormal noise is made
SME002 Abnormal noise around the PTO / hydraulic pumps
SME003 Vibration is excessive (engine mountings)
SME004 Vibration is excessive (engine torsion)
SME005 There is a big shock when stopping swing
SME006 There is a big abnormal noise when moving/stopping swing
SME007 Abnormal noise coming from a travel gearbox
SME008 Abnormal noise coming from the work equipment (lack of grease)
SME009 Abnormal idler movement
SME010 Leak at the PTO shaft seal
6.7.4 SYMPTOMS OF ADDITIONAL SYSTEMS

SAD001 Air conditioner does not work
SAD002 Air conditioner compressor clutch is burnt
SAD003 Air conditioning system defective (pipes and hoses full of moisture)
SAD004 Travel alarm does not sound
TS 15110-upD-GB-0 PC5500-6 6 - 21
Power Supply Tables for testing and troubleshooting
6.8 POWER SUPPLY

Circuit Electric Appliance
11F013 Binary sensors
11F013a Analog sensors
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 - 22 PC5500-6 TS 15110-upD-GB-0
Troubleshooting by trouble code
7 TROUBLESHOOTING BY
TROUBLE CODE
TS 15110-upD-GB-0 PC5500-6 7 -1
G00001 - Trouble Shut-Off (gate) valve

[1/5]
Trouble code
Message Trouble Shut-Off (gate) valve
G00001
The system assumes that the main gate valve is not completely open while the engines
Contents of trouble
are running.
– If the voltage at the proximity switch 40B031 is 0V, 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
KOMTRAX Plus monitor, the engines are shut down if the main gate valve is not completely
Related information
open. Refer to Fig. 7-3 on page 7-5.
REMARKS: For detailed information on the KOMTRAX Plus settings refer to the SERVICE
MANUAL, chapter 17, section SHUTDOWN BYPASS ON/OFF.
– Background color of the trouble code information: red
– The MTC blinks out the binary code 000001
Engine shutdown
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.
The engines are Open the main gate

stopped, because the valve completely and
main gate valve at the 1 verify that trouble code
Verify if the main gate valve is fully open or not.
hydraulic # tank is not G00001 (or G00020)
Is the main gate valve fully open? No is not set again.
fully open
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 PC5500-6 TS 15110-upD-GB-0

[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
Refer to the wiring diagram. Disconnection or short
power supply wiring
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.
KOMTRAX Plus Service Menu ON - Input check at node 11
1. Engines OFF Input
Yes Go to step 8.
2. 20S001 ON signal = 1
(refer to Fig. 7-2 on page 7-5)
05 Hydraulic
6
Screen 5/7
Malfunction in the 4. Check the input signal of 40B031 No Go to next step.

signal wiring between on the KOMTRAX Plus 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 15110-upD-GB-0 PC5500-6 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 C. 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
(1) Proximity switch (40B031)
(A) Gap 3 - 5 mm
Fig. 7-1 Gap at the proximity switch
7 -4 PC5500-6 TS 15110-upD-GB-0
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
1. In the REAL TIME MENU select item 05 Hydraulic.
2. Then select screen 5/7 of the REAL TIME MONITOR.
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus 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
TS 15110-upD-GB-0 PC5500-6 7 -5
Wiring diagram (40B031) for trouble code G00001 (Trouble Shut-Off (gate) valve)
[5/5]
Fig. 7-4 Wiring diagram (40B031) for trouble code G00001 (Trouble Shut-Off (gate) valve)
7 -6 PC5500-6 TS 15110-upD-GB-0
G00002 - Test speed 1800 1/min engine 1

[1/2]
Trouble code G00002 Test speed 1800 1/min engine 1
Message
G00002 & G00006 G00006 Test speed 1800 1/min engine 2
Contents of trouble Test speed 1800 rpm is activated by switch 11S041-1 or 11S041-2 [NO] in the cab base.
If the Quantum engine control modules are switched to ground, the engine speed is fixed
Related information
at 1800 rpm.
Action of controller Background color of the trouble code information: blue

In this condition the engine speed is not changeable.
on the machine
Instruction message 37 Switch Testspeed in cab base forces the engines to run constantly 1800 1/min.
Nominal
value
The function "test Main key switch 20S001 ON.
speed 1800 rpm" No further trouble-
If it is necessary, toggle the switch in order to Yes
is activated 1 shooting necessary.
disable the test speed function.
(switch 11S041-1 or
11S041-2 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
again. Switch
Defective switch open:
11S041-1 or 11S041-2 2 – Turn the main key switch in ON position.
R ∞Ω
(switch does not open) Toggle switch 11S041-1 or 11S041-2
and check if the message on the display
Replace switch
disappears.
11S041-1 or 11S041-2
No
Do the measurements correspond to the and verify that the
specification and does the trouble message repair was successful.
disappear?
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 or 11S041-2 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 15110-upD-GB-0 PC5500-6 7 -7
Wiring diagram (11S041-1 & 11S041-2) for trouble codes G00002 & G00006
[2/2]
Quantum Quantum
Fig. 7-5 Wiring diagram (11S041-1 & 11S041-2) for trouble codes G00002 & G00006
7 -8 PC5500-6 TS 15110-upD-GB-0
G00003 - Trouble pump controller

[1/6]
Trouble code
Message 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).
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
Engines 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 supply
may be defective to 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 15110-upD-GB-0 PC5500-6 7 -9

[2/6]
Nominal
value
The pump controller Engines 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 Error Output

Go to Possible cause Effect Procedure
code message stored
Main pumps
57K561-1, pro- Electric circuit of
Step 2a, running with Check solenoid valve
1 portional sole- Yes 57K561-1 open or short
Fig. 7-6 max. volume or the electric circuit.
noid valve (1) to ground.
(Qmax)
Engine-1 is not running
or engine rpm too low.
No signal from engine Reduced Check signal and
Step 2c,
2 Low speed (1) No speed sensor 52B064-1 hydraulic connection to 52B064-1,
Fig. 7-8
or circuit short or inter- volume or trouble code G00061.
rupted.
Malfunction of Check high idle limitation

Step 2c, Engine-1 defective or
3 High speed (1) Yes the load limiting (Cummins Service) or
Fig. 7-8 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
Main pumps
57K561-2, pro- Electric circuit of
Step 2b, running with Check solenoid valve
5 portional sole- Yes 57K561-2 open or short
Fig. 7-7 max. volume or the electric circuit.
noid valve (2) to ground.
(Qmax)
Engine-2 is not running
or engine rpm too low.
No signal from engine Reduced Check signal and
Step 2d,
6 Low speed (2) No speed sensor 52B064-2 hydraulic connection to 52B064-2,
Fig. 7-9
or circuit short or inter- volume or trouble code G00037.
rupted.
Malfunction of Check high idle limitation

Step 2d, Engine-2 defective or
7 High speed (2) Yes the load limiting (Cummins Service) or
Fig. 7-9 engine rpm too high.
control trouble code G00038.
7 - 10 PC5500-6 TS 15110-upD-GB-0

[3/6]
Engines running at high idle without hydraulic load.
Checking the output signals of the pump controller
1. Open terminal 11X_56-15.
2. Install a multi-tester at the terminals of 11X_56-15.
3. Measure the current [mA].
Standard: 670 ± 10 mA
4. Close the terminal of 11X_56-15 again.
Step 2a
Engine-1
Blink code 1
Otherwise check 57K561-1 and the wiring.
5. Check the resistance of 57K561-1 between pin 1 & 2.
Standard: 20 ± 1Ω
6. Replace proportional valve 57K561-1 if nessecary.
7. Continue with step "3" on page 7-14.
Fig. 7-6 Engine 1, blink code 1

Engines running at high idle without hydraulic load.
Checking the output signals of the pump controller
1. Open terminal 11X_56-17.
2. Install a multi-tester at the terminals of 11X_56-17.
3. Measure the current [mA].
Standard: 670 ± 10 mA
4. Close the terminal of 11X_56-17 again.
Step 2b
Engine-2
Blink code 5
Otherwise check 57K561-2 and the wiring.
5. Check the resistance of 57K561-2 between pin 1 & 2.
Standard: 20 ± 1Ω
6. Replace proportional valve 57K561-2 if nessecary.
7. Continue with step "3" on page 7-14.
Fig. 7-7 Engine 2, blink code 5
TS 15110-upD-GB-0 PC5500-6 7 - 11

[4/6]
Nominal
value
Step 2c
Engine-1
Blink code 2 & 3
Fig. 7-8 Engine-1, blink code 2 & 3

Checking the resistance of the rpm sensor 52B064-1
Engines 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
Engines 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
1. Check the voltage at 11X_51.60 to ground Standard: approx. 2.5V
2. Otherwise check the wiring to the rpm sensor 52B064-1
7 - 12 PC5500-6 TS 15110-upD-GB-0

[5/6]
Nominal
value
Step 2d
Engine-2
Blink code 6 & 7
Fig. 7-9 Engine-2, blink code 6 & 7

Checking the resistance of the rpm sensor 52B064-2
Engines OFF - Main key switch 20S001 OFF.
1. Disconnect the connector of the engine speed sensor 52B064-2
2. Check the resistance between pin 1 & 2 Standard: 850 ± 50Ω
3. Otherwise replace the sensor 52B064-2 and adjust as described above.
Checking the rpm sensor 52B064-2
Engines OFF - Main key switch 20S001 OFF - Lock out switch 50S058 locked.
1. Disconnect the engine speed sensor 52B064-2 and visually check for damage.
2. Mount 52B064-2 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
1. Check the voltage at 11X_51.62 to ground Standard: approx. 2.5V
2. Otherwise check the wiring to the rpm sensor 52B064-2
TS 15110-upD-GB-0 PC5500-6 7 - 13

[6/6]
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 step 4.
Could you locate and repair the problem?
Refer to the SERVICE MANUAL section ELECTRONIC
The proportional valve PUMP REGULATION SYSTEM subsection CHECKS
57K561-1 or 57K561-2 3 AND ADJUSTMENT. Go to final step 5.
has been 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 appro-
priate space of time, the pump regulation may be switched into the hydraulic mode tempo-
rarily.
Turn the lever (79.1 resp. 79.2) at the control and filter panel into the position (H) in order to
work in the hydraulic mode only, and put the machine back into operation.
REMARKS:
In case the electronic
pump regulation is 4
inoperative follow the
procedure beside.
Fig. 7-10
(79.1) Emergency lever for pump control, engine 1

(79.2) Emergency lever for pump control, engine 2
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 - 14 PC5500-6 TS 15110-upD-GB-0
G00005 - Low hydraulic oil level

[1/3]
Trouble code
Message 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 engines are shut off for more than 15 seconds and the attachment is in its defined position
(refer to Fig. 7-11 on page 7-17 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.
Action of controller Background color of the trouble code information: blue

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 engines 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. 7-11 on page 7-17,
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 A. 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 15110-upD-GB-0 PC5500-6 7 - 15
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
40B105 and the power Refer to the wiring diagram and check the wire connectors) between
supply line of circuit 4 segments between pressure transducer and pressure transducer
breaker 11F013a the power supply line 11F013a for continuity. and the line of the
No
(disconnection or Is continuity present? circuit breaker
defective contact in 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 B 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 9) for continuity.
in any connector) (connector 2, pin 9).
Is continuity present?
Locate the problem
and repair as
necessary.
Defective shield wiring* Disconnection or short
at the pressure trans- circuit in any wiring
ducer 40B105 segment (including
Refer to the wiring diagram and check the
(disconnection or
6 shield wiring for continuity and proper ground connector 40X340, ter-
defective contact
connection at connector 40X340, terminal 1. No minal 1) of the shield
in any connector)
Are continuity and ground connection ok? line.
*Refer to "Cable shield-
ing" on page 2-33. 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 - 16 PC5500-6 TS 15110-upD-GB-0
Wiring diagram, oil level label, and defined position of the attachment (G00005)
[3/3]
Fig. 7-11 Wiring diagram, oil level label, and defined position of the attachment (G00005)
TS 15110-upD-GB-0 PC5500-6 7 - 17

Refer to the troubleshooting procedure G00002 / G00006 on page 7-7.
G00007 - Trouble hydraulic oil level

[1/2]
Trouble code
Message 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 KOMTRAX Plus Service Level for too low hydraulic oil level:
A) If the Shutdown Bypass setting for the hydraulic oil level is set to OFF, the engines are stopped.
Related information B) If the Shutdown Bypass setting for the hydraulic oil level is set to ON, the engines are 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.
– Background color of the trouble code information: red

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.
1. Bring the machine back into the original condition.
2. Move the main key switch in OFF position until the MTC is totally shut down,
Final check 2
in order to reset the binary code 000010.
3. Start the machine and verify that the trouble code does not arise again.
7 - 18 PC5500-6 TS 15110-upD-GB-0
Wiring diagram (40B004) and the defined position of the attachment (G00007)
[2/2]
Fig. 7-12 Wiring diagram (40B004) and the defined position of the attachment (G00007)
TS 15110-upD-GB-0 PC5500-6 7 - 19
G00012 - Central lubrication system grease level too low

G00013 - Slew ring gear lubr. system grease level too low
G00202 - Attachment lubrication system grease level too low
Troubleshooting for sonar type grease level sensors
REMARKS: The grease barrels may be equipped either with sonar type sensors or with binary type sensors.
For troubleshooting the binary type sensors refer to "Troubleshooting for binary type grease level
sensors" on page 7-24.
[1/11]
Trouble code
G00012 Message G00013 - Slew ring gear lubr. system grease level too low
G00013
G00202
– Monitoring of CLS-1 grease level - 62B108
– Monitoring of SLS grease level - 62B109
Contents of trouble
– Monitoring of CLS-2 grease level - 62B173
– The reserve level in the respective 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
- Grease may be too close to the ultrasonic sensor
- Sensor may be contaminated with grease
Related information - Sensor may be defective
Overview
G-Code Lube System Lubrication Type Sensor Node

G00012 CLS-1 Central 62B108 18
G00013 SLS Slew ring gear 62B109 18
G00202 CLS-2 Attachment 62B173 19

Risk, to run out of grease.
on the machine
Instruction message 17 Inform service till end of shift and then press cancel button.
7 - 20 PC5500-6 TS 15110-upD-GB-0

[2/11]
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 to Yes Verify that trouble code
barrel (CLS-1, CLS-2, 1 the displayed message. G00012 or G00013
or SLS) needs refilling
Is the grease level too low? or G00202 is not
displayed again.
No Go to next step.
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
or G00013 or G00202
no longer displayed].
LEDs (B) & (C) of the
concerned grease level
sensor (62B108 or 2
62B109 or 62B173)
light up red
If LED (A) lights green

under these trouble
No conditions, the sensor
may be disturbed.
Go to step 8.
TS 15110-upD-GB-0 PC5500-6 7 - 21

[3/11]
Nominal
value
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 or 62B173) 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 51F013a -> 11F013a.
shooting chart for
Is supply voltage present? No trouble code G00099
"Trouble power
supply".
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 or 62B173) circuit in any wiring
and the power supply Refer to the wiring diagram and check the segment (including
line of 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 Rmax 1Ω
signal wiring between
the concerned grease Disconnection or short
Disconnect the signal line of the concerned
level sensor circuit in any wiring
grease level and the respective node.
(62B108 or 62B109 segment of the signal
62B108: V-node 18, terminal 6 line (including connec-
and node 18,
62B109: V-node 18, terminal 7 tors and junction box)
or 62B173 and
6 62B173: V-node 19, terminal 6 between the con-
node 19)
Refer to the wiring diagram and check the No cerned grease level
(disconnection or
signal wiring segments between the sensor and the relating
concerned grease level sensor and the node/connector/termi-
relating node connector/terminal for continuity. nal.
junction box on top of
the concerned grease Is continuity present? Locate the problem
barrel) and repair as
necessary.
7 - 22 PC5500-6 TS 15110-upD-GB-0

[4/11]
Nominal
value
Defective shield wiring*
at the cables of the
concerned grease level Disconnection or short
sensor (62B108 or circuit in any wiring
62B109 or 62B173) 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.
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 or 62B173) 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
If the signal current is wrong,
9 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 15110-upD-GB-0 PC5500-6 7 - 23

Troubleshooting for binary type grease level sensors
REMARKS: The grease barrels may be equipped either with sonar type sensors or with binary type sensors.
For troubleshooting the sonar type sensors refer to "Troubleshooting for sonar type grease level sen-
sors" on page 7-20.
[5/11]
Trouble code
G00012 Message G00013 - Slew ring gear lubr. system grease level too low
G00013
G00202
– Monitoring of CLS-1 grease level - 62B108b
– Monitoring of SLS grease level - 62B109b
Contents of trouble
– Monitoring of CLS-2 grease level - 62B112b
– The reserve level in the respective grease barrel is reached.
– The grease level sensors do not trigger the bucket cut-off function.
(A) Level sensor - full
(B) Level sensor - pre-warning 5%
(C) Level sensor - empty
Related information
Overview
G-Code Lube System Lubrication Type Pre-warning Sensor Node

G00012 CLS-1 Central 62B108b 17
G00013 SLS Slew ring gear 62B109b 17
G00202 CLS-2 Attachment 62B112b 17

Risk, to run out of grease.
on the machine
7 - 24 PC5500-6 TS 15110-upD-GB-0

[6/11]
Nominal
value
Using the dipstick, verify if the grease level Press the cancel
in the concerned barrel corresponds to button and refill the
the displayed message. specified grease.
Is the grease level too low? Yes Verify that trouble code
G00012 or G00013
or G00202 is not
Definition of the grease levels
displayed again.
The concerned grease

barrel (CLS-1, CLS-2, 1
or SLS) needs refilling
No Go to next step.

Remove the cover of the junction box on top Vmin 22V
2 of the concerned grease barrel. Measure the Yes Go to step 5.
Vmax 24V
supply voltage at terminal 2 of the terminal
Incorrect or no supply block inside the junction box.
No Go to next step.
voltage in the circuit of Is supply voltage present?
the concerning grease Vmin 22V
level sensor Yes Go to step 5.
(662B108b or 62B109b Vmax 24V
or 62B112b) Check if supply voltage is present at the Follow the trouble-
3 power supply line 51F013 -> 11F013. shooting chart for
trouble code G00099
Is supply voltage present? No "Trouble power
supply".
Go to next step.
TS 15110-upD-GB-0 PC5500-6 7 - 25

[7/11]
Nominal
value
Disconnection in the Main key switch 20S001 OFF.
wiring between the Yes Go to next step. Rmax 1Ω
concerned grease
level sensor (62B108b Disconnection or short
or 62B109b or circuit in any wiring
62B112b) and the Refer to the wiring diagram and check the segment (including
power supply line of wiring segments between the concerned connectors) between
circuit breaker 11F013. 4 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 11F013.
junction box on top of Locate the problem
the concerned grease and repair as
barrel) necessary.
Disconnection in the Rmax 1Ω
the concerned grease Disconnection or short
Disconnect the signal line of the concerned
level sensor circuit in any wiring
grease level and node 17.
(62B108b and node 17 segment of the signal
62B108b: D-node 17 - connector 7, terminal 7 line (including connec-
or 62B109b and node
62B109b: D-node 17 - connector 7, terminal 5 tors and junction box)
17 or 62B112b and
5 62B112b: D-node 17 - connector 7, terminal 3 between the con-
node 17)
Refer to the wiring diagram and check the No cerned grease level
(disconnection or
signal wiring segments between the sensor and the relating
concerned grease level sensor and the node/connector/termi-
relating node connector/terminal for continuity. nal.
junction box on top of
the concerned grease Is continuity present? Locate the problem
barrel) and repair as
necessary.
Wrong sensor calibra- If the re-calibration is
tion or defective grease not successful the
level sensor (62B108b Re-calibrate the lubrication sensors. grease level sensor is Upper
or 62B109b or 6 REMARKS: Calibration may only be carried out by defective. sensing
62B112b) range limit:
authorized personnel [dealer or KMG- Replace the concerned
(missing or poor signal factory staff]. grease level sensor <9.1 cm
current) and verify that the
repair was successful.
Final check 7
7 - 26 PC5500-6 TS 15110-upD-GB-0
Wiring diagram (sonar type sensors) for trouble codesG00012 / G00013 / G00202
[8/11]
Fig. 7-13 Wiring diagram (sonar type sensors 62B108 / 62B109 / 62B173) for trouble codes G00012 /
G00013 / G00202
TS 15110-upD-GB-0 PC5500-6 7 - 27
Wiring diagram (sonar sensor junction box) for trouble codes G00012 / G00013 / G00202
[9/11]
Fig. 7-14 Wiring diagram (sonar sensor junction box) for trouble codes G00012 / G00013 / G00202
7 - 28 PC5500-6 TS 15110-upD-GB-0
Wiring diagram (binary type sensors) for trouble codesG00012 / G00013 / G00202
[10/11]
Fig. 7-15 Wiring diagram (binary type sensors 62B108a/b/c, 62B109a/b/c, 62B112a/b/c for trouble codes
G00012 / G00013 / G00202
TS 15110-upD-GB-0 PC5500-6 7 - 29
Wiring diagram (binary sensor junction box) for trouble codes G00012 / G00013 / G00202
[11/11]
Fig. 7-16 Wiring diagram (binary sensor junction box) for trouble codes G00012 / G00013 / G00202
7 - 30 PC5500-6 TS 15110-upD-GB-0
G00020 - Trouble Shut-Off (gate) valve (Start blocked)

[1/5]
Trouble code
Message Trouble Shut-Off (gate) valve (Start blocked)
G00020
– After main key switch 20S001 is switched ON (engines 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.
– Background colour of the trouble code information: red

If the SHUTDOWN BYPASS setting for the option "Shut-Off (gate) valve (Start bl.)" is set to OFF
Action of controller on the KOMTRAX Plus monitor, the engine start is blocked if the main gate valve is not completely
open. Refer to illustration Fig. 7-20 on page 7-35.
For detailed information on the KOMTRAX Plus settings refer to the SERVICE MANUAL,
chapter 17, 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.
TS 15110-upD-GB-0 PC5500-6 7 - 31

[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
Refer to the wiring diagram. Disconnection or short
power supply wiring
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. Engines OFF Input
Yes Go to step 8.
2. 20S001 ON signal = 1
(refer to Fig. 7-19 on page 7-35)
05 Hydraulic
6
Screen 5/7
4. Check the input signal of 40B031 No Go to next step.
Malfunction in the
signal wiring between on the KOMTRAX Plus monitor.
proximity switch 1 = ON input
40B031 and node 11 0 = OFF no input
(40K311)
Is the input displayed?
(disconnection or
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?
7 - 32 PC5500-6 TS 15110-upD-GB-0

[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 C. 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 B with the repair was VSignal
closed and open gate valve. successful. open:
Go to final step 10. 22-24V

Final check 10
View onto the gap of proximity switch 40B031 (G00020)
(1) Proximity switch (40B031)
(A) Gap 3 - 5 mm
Fig. 7-17 Gap at the proximity switch
TS 15110-upD-GB-0 PC5500-6 7 - 33
Wiring diagram (40B031) for trouble code G00020 (Main gate valve closed)
[4/5]
Fig. 7-18 Wiring diagram (40B031) for trouble code G00020 (Main gate valve closed)
7 - 34 PC5500-6 TS 15110-upD-GB-0
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR
[5/5]
Fig. 7-19 Input signal (analog) of the proximity switch 40B031 on the REAL TIME 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

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

engine start is possible even the main gate valve
is closed! Fig. 7-20 Setting for SHUTDOWN
BYPASS
TS 15110-upD-GB-0 PC5500-6 7 - 35
G00031 - Set engine to low idle

[1/2]
Trouble code
Message Set engine to low idle
G00031
Contents of trouble Engine speed switch (20S030) is set to High Idle. Switch location: RH hand lever 20S019.
During the engine start sequence this switch prevents the engines to run directly at high idle
Related information
after engine startup.
– Background colour of the trouble code information: blue
– The KOMTRAX Plus 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. Engines OFF
2. 20S001 ON
3. REAL TIME MONITOR – In case of malfunction refer
(refer to Fig. 7-22 on page 7-37) to the Wiring diagram.
09 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 KOMTRAX Plus monitor. – If a sporadic interruption
exists, further inspection
1 = ON input High Idle
of the circuit is required.
0 = OFF no input Low Idle
The displayed input must change over (0 1)
when you toggle the switch.
Final check 3
7 - 36 PC5500-6 TS 15110-upD-GB-0
Wiring diagram (20S030) for trouble code G00031

[2/2]
Fig. 7-21 Wiring diagram (20S030) for trouble code G00031
Input signal of the engine speed switch 20S030 on the REAL TIME MONITOR
Fig. 7-22 Input signal of the engine speed switch 20S030 on the REAL TIME MONITOR
1. In the REAL TIME MENU select item 09 Manual Switch.
2. Then select screen 2/4 on the REAL TIME MONITOR.
TS 15110-upD-GB-0 PC5500-6 7 - 37
G00032 - Trouble starter

[1/3]
Trouble code
Message 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
of 20 s, message G00032 is displayed.
Related information
– If relay 51K003c/d-1 or 51K003d-2 does not close, the system recognizes that engine 1
or engine 2 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 concerned engine does not start within the specified time limit.
on the machine
Nominal
value
The concerned engine Main key switch 20S001 ON.

does not start during Verify if any engine trouble code (C-code) Contact the Cummins tcranking
1 Yes
the 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 engines using the Cold Start Aid tcranking
Yes Go to final step.
ture requires operation equipment. For operation instructions refer to max. 20s
2
of the Cold Start Aid the OPERATION & MAINTENANCE MANUAL.
equipment Do the engines start within the specified No Go to next step.
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. Repair as necessary
work properly No and restart the
Check the Cold Start Aid system for proper
function. engines.
Is the Cold Start Aid function OK?

Starter pinion and/or Main key switch 20S001 OFF.
flywheel gear teeth of Engines standing still.
the concerned engine Maintenance safety switch 50S058 OFF & locked.
4 Inspect starter pinion and flywheel gear teeth Replace worn parts as
are worn. Yes
Abnormal noise during 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
(71G001~71G006)
than 18V?
7 - 38 PC5500-6 TS 15110-upD-GB-0
G00032 - Trouble starter

[2/3]
Nominal
value
Main key switch 20S001 OFF during repair.
After repair 20S001 ON and restart engines.
Defective starter(s) 6
Replace both starters of the concerned engine and
Go to final step.
check for proper cable connections.
Final check 7
Wiring diagram (Cold Start Signal Engine 1 & 2) for trouble code G00032
Quantum Module
Engine 1
Cold start signal
Quantum Module
Engine 2
Cold start signal
Fig. 7-23 Wiring diagram (Cold Start Signal Engine 1 & 2) for trouble code G00032
TS 15110-upD-GB-0 PC5500-6 7 - 39
Wiring diagram ("Engine running" signals) for trouble code G00032

[3/3]
- Operation Hour Metr11P001

- RC4-4 (10K032), pin 12
Signal "rpm>300" to:
- Operation Hour Meter 11P001
- RC4-4 (10K032), pin 37
Signal "rpm>300" to:
Fig. 7-24 Wiring diagram ("Engine running" signals) for trouble code G00032
7 - 40 PC5500-6 TS 15110-upD-GB-0
G00033 - Trouble KOMTRAX Plus controller

[1/1]
Trouble code
Message Trouble KOMTRAX Plus-controller
G00033
Contents of trouble KOMTRAX Plus controller (hardware) defective due to internal malfunction.
Related information The KOMTRAX Plus system is frozen and the KOMTRAX Plus monitor is frozen.
– Operation of key pads and F-keys not possible.

– - The MTC blinks out the binary code 000100.
Problem that appears As the KOMTRAX Plus controller is defective, the KOMTRAX Plus monitoring system is
on the machine out of operation.
Nominal
value
KOMTRAX Plus 1. Please contact KMG or your dealer for further action.
controller inoperative A specified controller unit is needed.
1
due to an internal 2. Replace the KOMTRAX Plus controller and check the system for
malfunction proper function.
Final check 2
TS 15110-upD-GB-0 PC5500-6 7 - 41
G00034 - Trouble KOMTRAX Plus display

[1/1]
Trouble code
Message Trouble KOMTRAX Plus display
G00034
Contents of trouble KOMTRAX Plus display (20P047) inoperative due to internal malfunction (hardware).
Related information The KOMTRAX Plus display is out of operation.
– Operation of key pads and F-keys not possible.

- The MTC blinks out the binary code 000101.
As the KOMTRAX Plus display is defective, the KOMTRAX Plus monitoring system is invisible.
on the machine
Nominal
value
KOMTRAX Plus 1. Please contact KMG or your dealer for further action.
display inoperative A specified controller unit is needed.
1
due to an internal 2. Replace the KOMTRAX Plus controller and check the system for
malfunction proper function.
Final check 2
3. Start the machine and verify that the trouble code does not arise again
7 - 42 PC5500-6 TS 15110-upD-GB-0
G00035 - Trouble totally loss gear oil (PTO 1)

[1/5]
Trouble code G00035 Trouble totally loss gear oil (PTO 1)
Message
G00035 & G00036 G00036 Trouble totally loss gear oil (PTO 2)
(a) Engines standing still:
Engine start is blocked if sensor 57B175-1 or 57B175-2 doesn’t sense oil (option).
Contents of trouble
(b) Engines running:
Direct engine shutdown if sensor 57B175-1 or 57B175-2 doesn’t sense oil (option).
Sensor open signal voltage = 0 V no oil
Related information
Sensor closed signal voltage = 24 V oil present
The MTC blinks out the active binary code:
G00035 Binary code 000110
Action of controller If the SHUTDOWN BYPASS setting for the option "Trouble totally loss gear oil (PTO 1)" is set to
OFF at the KOMTRAX Plus monitor, Engine start blocked and Engine shutdown will occur if PTO 1
gear oil level is below sensor 57B175-1. Refer to illustration Fig. 7-27 on page 7-46.
For detailed information on the KOMTRAX Plus settings refer to the SERVICE MANUAL,
chapter 17, section SHUTDOWN BYPASS ON/OFF.
Engine start is blocked and/or running engine is shutdown.
on the machine
Instruction message 34 Call service because of shutdown.
Nominal
value
Check for leaks and
The PTO gear oil level refill specified gear oil.
Verify if the gear oil level in the concerned PTO
is below the sensor: Yes Verify that trouble code
1 is below sensor 57B175-1 or 57B175-2.
PTO 1 below 57B175-1 G00035 is not
Is the gear oil level too low? displayed again.
PTO 2 below 57B175-2
No Go to next step.
2 concerned gear oil level sensor, insert the Yes Go to step 4.
Vmax 24V
Deutsch T-box, and 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 or 57B175-2 Yes Go to next step.
Vmax 24V
3
shooting chart for
"Trouble power
supply".
TS 15110-upD-GB-0 PC5500-6 7 - 43

[2/5]
Nominal
value
Defective ground Disconnect the cable connector from the circuit in any wiring
connection at the concerned gear oil level sensor and check segment (including
4 connectors) between
gear oil level sensor for proper ground connection at connector
57B175-1 or 57B175-2 terminal C. No gear oil level sensor
and ground line.
Is the ground connection ok?
Locate the problem
and repair as
necessary.
51R008max
57B175-1 Yes Go to next step.
820Ω
Disconnection in the Disconnect the signal line connector 1,
signal wiring between Disconnection or
terminal 2, from node 17 (51K317).
gear oil level sensor short circuit in any
57B175-1 or 57B175-2, 57B175-2 wiring segment
terminal B, and Disconnect the signal line connector 3, (including connectors)
5
node 17 terminal 9, from node 17 (51K317). between gear oil
Refer to the wiring diagram and check the No level sensor and the
(disconnection or
signal wiring segments between the oil level belonging node
defective contact
sensor, terminal B, and the belonging node cable connector.
in any connector)
connector for continuity. Locate the problem
necessary.
Open the REAL TIME MONITOR and check Replace the concerned VSignal
Defective gear oil level
the sensor signal. gear oil level sensor open: 0V
sensor 57B175-1 or 6
Refer to illustration Fig. 7-26 on page 7-46. Yes and verify that the VSignal
57B175-2
Is the sensor signal = 0 (no oil) even there is repair was successful.
closed:
enough gear oil in the PTO 1? Go to final step. 22-24V
in order to reset the active binary code:
Final check 7
7 - 44 PC5500-6 TS 15110-upD-GB-0
View onto the location of sensor 57B175-1/-2 at the PTO1/2 (G00035)

[3/5]
Fig. 7-25 View onto the location of sensor 57B175-1 at PTO 1 (G00035)
57B049-1/-2 Location of the PTO gear oil temperature sensor
57B175-1/-2 Location of the PTO gear oil level sensor
TS 15110-upD-GB-0 PC5500-6 7 - 45
Input signal (analog) of the gear oil sensors 57B175-1/-2 on the REAL TIME MONITOR
[4/5]
Fig. 7-26 Input signal (analog) of the gear oil level sensor 57B175-1 on the REAL TIME MONITOR
1. In the REAL TIME MENU: Select item 03 PTO 1 or item 04 PTO 2.
2. Then select the REAL TIME MONITOR, sub-screen 1/1 as required.
Fig. 7-27 View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor
Setting 1: SHUTDOWN BYPASS OFF Setting 2: SHUTDOWN BYPASS ON
Standard setting for operation Exceptional setting for testing and troubleshooting
Bypass OFF = Shutdown function ON only
REMARKS: If the SHUTDOWN function is bypassed (setting 2), engine operation is possible even PTO gear oil
may be missing!
7 - 46 PC5500-6 TS 15110-upD-GB-0
Wiring diagram (57B175-1/-2) for trouble codes G00035 & G00036

[5/5]
Fig. 7-28 Wiring diagram (57B175-1/-2) for trouble codes G00035 & G00036
TS 15110-upD-GB-0 PC5500-6 7 - 47
G00037 - Trouble monitoring, engine 2 speed too low

G00038 - Trouble monitoring, engine 2 speed too high

G00039 - Actuate engine speed selector switch

[1/1]
Trouble code
Message 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) Engines 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.

Action of controller – During the Engine after-run the system prevents switching to High Idle.
– The KOMTRAX Plus buzzer (20P022) is beeping, when the cooling-down phase ends.
Engine after-run for 5 minutes.
on the machine
7 - 48 PC5500-6 TS 15110-upD-GB-0
G00043 - Trouble output short-circuit

[1/1]
Trouble code
Message 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
07 Electrical Equipm.
Related information Screen 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 (G00043).
– If trouble message G00308 is also displayed, follow the troubleshooting procedure of G00308
at first. G00308 has higher priority.
– 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
Screen 3/3 (Electr Equipment Diagnosis) Troubleshooting procedure
(according to the displayed sample)
Sample display
OUTPUT ERROR TYPE =2
CAN-NODE NUMBER =9
CONNECTOR NUMBER =6
PIN-NUMBER =2
1. Use the Wiring diagram.
2. Find node no. 9.
Short circuit in any 3. Locate connector 6, pin 2.
1
node output 4. Check the node wiring
according to the displayed
OUTPUT ERROR TYPE 2.
5. The node output section is
Check the entry in line OUTPUT ERROR TYPE: switched OFF, nevertheless
0 = All outputs OK external voltage (24V) is fed-in.
1 = No power supply Short circuit to power (+24V)
2 = External power feed-in (short ckt to 24V) occurred.
3 = Short circuit or cable break (short ckt to ground) 6. Locate the short circuit.
For further information on node output errors 7. Repair as necessary.
also refer to section 5.1.2 on page 5-4
TROUBLE OUTPUT SHORT-CIRCUIT (G00043).
Final check 2
TS 15110-upD-GB-0 PC5500-6 7 - 49
G00048 - Trouble emergency safety circuit

[1/2]
Trouble code
Message 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.

– The MTC blinks out the binary code 101110.
Action of controller – Engine shut down.
– Engine start blocked.
Running engines are 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
7 - 50 PC5500-6 TS 15110-upD-GB-0
Wiring diagram (11K044a) for trouble code G00048

[2/2]
Fig. 7-29 Wiring diagram (11K044a) for trouble code G00048
TS 15110-upD-GB-0 PC5500-6 7 - 51
G00053 - Reset emergency safety circuit

[1/1]
Trouble code
Message 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 - 52 PC5500-6 TS 15110-upD-GB-0
G00054 - Monitoring idle position cut off

[1/3]
Trouble code
Message 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. Engines OFF
2. 20S001 ON Fault
3. REAL TIME MONITOR Check relay 11K032
0
(refer to Fig. 7-31 on page 7-55) and/or its wiring. REAL
Relay 11K032 or its 16 Pilot control Repair as necessary.
1 TIME
wiring is defective Screen 5/5 MONITOR
4. Check the input signal of 11K032 Signal = 1
on the KOMTRAX Plus monitor.
0 = OFF Fault OK
1
1 = ON OK Go to next step.
Which state is displayed, 0 or 1?
KOMTRAX Plus Service Menu ON - Check Failure History
1. Engines OFF
Refer to the wiring dia-
2. 20S001 ON gram and check:
Sporadic malfunction KOMTRAX
2 3. SERVICE MENU SELECT – Wiring Plus, Wir-
of relay 11K032 (refer to Fig. 7-32 on page 7-55)
– Relay 11K032 ing dia-
05 Failure History gram
Repair or replace as
4. Check the occurrence of G00054 in the
necessary
Failure History chart.
Final check 3
TS 15110-upD-GB-0 PC5500-6 7 - 53
Wiring diagram (11K032) for trouble code G00054

[2/3]
Fig. 7-30 Wiring diagram (11K032) for trouble code G00054
7 - 54 PC5500-6 TS 15110-upD-GB-0
Input signal (analog) of relay 11K032 on the REAL TIME MONITOR (G00054)
[3/3]
Fig. 7-31 G00054 - Input signal (analog) of relay 11K032 on the REAL TIME MONITOR
Exemplary view onto the KOMTRAX Plus Failure History (G00054)
Fig. 7-32 Exemplary view onto the KOMTRAX Plus Failure History (G00054)
TS 15110-upD-GB-0 PC5500-6 7 - 55
G00060 - Fire in the power house

[1/4]
Trouble code
Message 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 engines are 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 - 56 PC5500-6 TS 15110-upD-GB-0
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 15110-upD-GB-0 PC5500-6 7 - 57
Wiring diagram (fire alarm) for trouble code G00060

[3/4]
Fig. 7-33 Wiring diagram (fire alarm) for trouble code G00060
7 - 58 PC5500-6 TS 15110-upD-GB-0
Wiring diagram (10B350 in the safety circuit) for G00060

[4/4]
Fig. 7-34 Wiring diagram (10B350 in the safety circuit) for G00060
TS 15110-upD-GB-0 PC5500-6 7 - 59

[1/4]
Trouble code G00061 Trouble monitoring, engine 1 speed too low
Message
G00061 & G00037 G00037 Trouble monitoring, engine 2 speed too low
– A malfunction in the monitoring loop for too low engine speed is detected.
Contents of trouble – The RPM-module 51T018-1 or 51T018-2 sends an RPM-signal below 160 RPM while
51K003b-1 or 51K003b-2 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 51T018-2) or its wiring causes
this trouble message.
Action of controller – The MTC blinks out the active binary code:
Engine start is impossible.
on the machine
Nominal
value
REAL TIME MONITOR - 51K003b-1 or 51K003b-2 input check
1. 20S001 ON
2. Engines OFF
3. REAL TIME MONITOR OK
Signal
(refer to Fig. 7-35 on page 7-62) Signal = 0V
0
01 Engine 1 or 02 Engine 2 Go to next step.
The concerned Screen 5/6
Cummins ECM 4. Check the input signal of 51K003b-1 REAL
transmits a wrong 1 or 51K003b-2 on the REAL TIME TIME
engine speed signal MONITOR. MONITOR
at pin E Signal = 0
0 OK (signal indicates engine OFF) Fault
No RPM-signal (<300 1/min) from
engine ECM. Signal = 0V Signal Signal = 24V
1 Check the concerned
1 Fault (signal indicates running eng.) Quantum module with
RPM-signal (>300 RPM) from engine Cummins service.
ECM is present. Signal = 24V
Which signal state is displayed, 0 or 1?
Engines at low idle (850±50 RPM).
The engine speed At this stage the RPM signal of converter 51T018-1
converter 51T018-1 or 51T018-2 is below 160 RPM, even the engine is
or 51T018-2 transmits running at low idle (inconsistent signal).
a wrong signal. 2 1. REAL TIME MONITOR
Engine speed (refer to Fig. 7-36 on page 7-62) Go to next step.
converter or its 01 Engine 1 or 02 Engine 2
wiring defective. Screen 1/6
2. Check the input signal of 51T018-1 or 51T018-2 on
the REAL TIME MONITOR.
7 - 60 PC5500-6 TS 15110-upD-GB-0

[2/4]
Nominal
value
20S001 OFF - Engines OFF - 50S058 locked.
Refer to the SERVICE MANUAL, section
MAIN HYDRAULIC PUMPS AND PUMP
REGULATION SYSTEM, and find the
adjustment procedure for engine speed
sensors (pick up). approx.
Engine speed sensor Yes Go to final step.
In the first step remove the concerned engine 10VAC
(pick up) 52B064-1
speed sensor and clean the sensor tip from
or 52B064-2,
magnetic chips and dirt as described.
possible problems: 3 Then follow the adjustment procedure and
- Wrong adjustment perform the final check.
- Contamination
If necessary replace the pick up
- Sensor defective
(52B064-1 or 52B064-2).
The terminal numbers of your shovel may
differ from the terminal numbers mentioned in No Go to next step.
the Service Manual. Refer to the wiring dia-
gram for the individual terminal numbers.
Could you rectify the problem?
Defective RPM-module Imin 0mA
51T018-1 or 51T018-2 Yes Go to next step.
4 Measure the signal current at terminals Imax 20mA
Missing or poor
signal current or I+ and I- of the concerned RPM-module. Replace the concerned
wrong setting Do the measurements meet the specification? RPM-module if neces-
No
sary and verify that the
Final check 5
TS 15110-upD-GB-0 PC5500-6 7 - 61
Input signal (analog) of 51K003b-1 & 51K003b-2 on the REAL TIME MONITOR
[3/4]
Fig. 7-35 Input signal (analog) of 51K003b-1 & 51K003b-2 on the REAL TIME MONITOR
Wrong signal of the engine 2 speed converter on the REAL TIME MONITOR
Fig. 7-36 Wrong signal of the engine 2 speed converter on the REAL TIME MONITOR
7 - 62 PC5500-6 TS 15110-upD-GB-0
Wiring diagram (engine speed) for trouble codes G00061 & G00037
[4/4]
Fig. 7-37 Wiring diagram (engine speed) for trouble code G00061 & G00037
TS 15110-upD-GB-0 PC5500-6 7 - 63

[1/2]
Trouble code G00062 Trouble monitoring, engine 1 speed too high
Message
G00062 & G00038 G00038 Trouble monitoring, engine 2 speed too high
Contents of trouble A malfunction in the monitoring loop for too high engine speed is detected (2000 RPM and higher)
– RPM-module (51T018-1 or 51T018-2) or its wiring defective.

Related information – Engine speed sensor (52B064-1 or 52B064-2) or its wiring defective.
– Wrong adjustment of 52B064-1 or 52B064-2.
– The MTC blinks out the active binary code:
Action of controller G00062 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 - Engines OFF - 50S058 locked
Refer to the SERVICE MANUAL, section
MAIN HYDRAULIC PUMPS AND PUMP
REGULATION SYSTEM, and find the
adjustment procedure for engine speed
sensors (pick up). approx.
Engine speed sensor Yes Go to final step.
In the first step remove the concerned engine 10VAC
(pick up) 52B064-1
speed sensor and clean the sensor tip from
or 52B064-2,
magnetic chips and dirt as described.
possible problems: 1 Then follow the adjustment procedure and
- Wrong adjustment perform the final check.
- Contamination
If necessary replace the pick up
- Sensor defective
(52B064-1 or 52B064-2).
The terminal numbers of your shovel may
differ from the terminal numbers mentioned in No Go to next step.
the Service Manual. Refer to the wiring dia-
gram for the individual terminal numbers.
Defective RPM-module Imin 4mA
51T018-1 or 51T018-2 Yes Go to next step.
2 Measure the signal current at terminals Imax 20mA
Missing or poor
signal current or I+ and I- of the concerned RPM-module. Replace the concerned
wrong setting Do the measurements meet the specification? RPM-module if neces-
No
sary and verify that the
Final check 3
7 - 64 PC5500-6 TS 15110-upD-GB-0
Wiring diagram (engine speed) for trouble codes G00062 & G00038
[2/2]
Fig. 7-38 Wiring diagram (engine speed) for trouble codes G00062 & G00038
TS 15110-upD-GB-0 PC5500-6 7 - 65
G00063 - Trouble monitoring hydraulic oil temp

[1/2]
Trouble code
Message 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 -50°C up to +150°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 05 Hydraulic, screen 5/7,
and check the displayed hydraulic oil temperature.
– f 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 51X452:
Wiring or connector pin 23 to shield
1
problem pin 24 to A Repair or replace
pin 25 to B No according to the actual
pin 26 to C Wiring diagram.
1. 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 2. 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?
1. 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
2. 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
7 - 66 PC5500-6 TS 15110-upD-GB-0
Wiring diagram (59B015) for trouble code G00063

[2/2]
Fig. 7-39 Wiring diagram (59B015) for trouble code G00063
TS 15110-upD-GB-0 PC5500-6 7 - 67
G00064 - Trouble monitoring hydraulic oil level

[1/3]
Trouble code
Message 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 engines 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".
Disconnection in the
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.
7 - 68 PC5500-6 TS 15110-upD-GB-0
G00064 - Trouble monitoring hydraulic oil level

[2/3]
Nominal
value
circuit in any wiring
Disconnect the cable connector from the segment (including
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
TS 15110-upD-GB-0 PC5500-6 7 - 69

[3/3]
7 - 70 PC5500-6 TS 15110-upD-GB-0
G00065 - Very low hydraulic oil level

[1/1]
Trouble code
Message 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
1. Check the hydraulic oil level at the sight glass and fill up hydraulic oil.
Hydraulic oil needs
1 Observe hydraulic oil temperature and refill oil up to the appropriate level.
refilling Sight glass
2. 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. 7-41 View onto the hydraulic oil level label
TS 15110-upD-GB-0 PC5500-6 7 - 71
G00066 - Trouble hydraulic oil temperature

[1/3]
Trouble code
Message 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 7-73.
– On condition that the engines are 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
Engines 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.
sensor 59B015.
The hydraulic oil
1 For the defined hydraulic oil temperatures refer Check for other
is overheated
to the oil temperature table in Fig. 7-42 on relating trouble codes
page 7-73. No and follow the relating
troubleshooting chart
Does the measured hydraulic oil temperature
as necessary.
indicate overheating as well?
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 settings in the service
the problem KOMTRAX Plus system. mode of the
No
KOMTRAX Plus
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±10
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.
7 - 72 PC5500-6 TS 15110-upD-GB-0

[2/3]
Nominal
value
Shut the engines OFF.
REMARKS: This test step must be performed 1. Clean the hydrau-
only if the engines are standing lic oil cooler with a
still. water pressure
Perform a visual inspection of the hydraulic oil cleaner as neces-
Any clogged hydraulic cooler. Also open the swing out doors of the sary.
oil cooler caused the cooler frame and check for deposits between
4 Yes 2. Continue to work
overheating of the these door wings.
hydraulic oil and monitor the
Is intense pollution present? hydraulic oil tem-
perature on the
KOMTRAX Plus
display.
No Go to next step.
Overheating due to any Continue to work and
malfunction in the 5 monitor the hydraulic
Check the hydraulic system by performing the PM-
hydraulic system oil temperature on
PM-Clinic. CLINIC
the KOMTRAX Plus
display.
Final check 6
Hydraulic oil temperature table
Fig. 7-42 Hydraulic oil temperature table
TS 15110-upD-GB-0 PC5500-6 7 - 73
Wiring diagram (57K506a-1/57K506b-1 & 57K506a-2/57K506b-2) and location for G00066

[3/3]
Fig. 7-43 Wiring diagram (57K506a-1 / 57K506b-1 & 57K506a-2 / 57K506b-2) and location for G00066
7 - 74 PC5500-6 TS 15110-upD-GB-0
G00067 - Trouble battery voltage too high

[1/3]
Trouble code
Message Trouble battery voltage too high
G00067
Contents of trouble Via the resistor 11T080 the system detects too high battery voltage.
– If the battery voltage at 11T080 is >=29V for 5s, the trouble code is set.
Related information – The system assumes that resistor 11T080 and its wiring are not defective, otherwise trouble
code G00161 should be displayed.

-
on the machine
Nominal
value
REAL TIME MONITOR - 11T080 input check
– Measure the charging voltage between Vcharge
alternator terminal "B+" and chassis Yes Go to next step. min. 27.5V
(body ground). max. 29V
– Also see the charging voltage value which
is shown on the REAL TIME MONITOR
(KOMTRAX Plus).
The voltage regulator
in the concerned alter- 1. 20S001 ON
nator may be defective 1 2. Engines running at high idle
and causes the battery
3. REAL TIME MONITOR Replace the concerned
over voltage No
(refer to Fig. 7-45 on page 7-77) 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
TS 15110-upD-GB-0 PC5500-6 7 - 75
Wiring diagram (11T080) and component location for G00067

[2/3]
Fig. 7-44 Wiring diagram (11T080) and component location for G00067
7 - 76 PC5500-6 TS 15110-upD-GB-0
Input signal of 11T080 on the REAL TIME MONITOR for G00067

[3/3]
PTO gear oil temperatures

Oil grade acc. to ISO T32 CLP150 Hypoid oil 75W-140
Fig. 7-45 Input signal of 11T080point
Switching on the REAL TIME MONITOR
57B049 60°C for G00067
95°C 95°C
TS 15110-upD-GB-0 PC5500-6 7 - 77
G00068 - Trouble gear lubrication (PTO 2)

7 - 78 PC5500-6 TS 15110-upD-GB-0
G00069 - Trouble monitoring oil temperature gear (PTO 1)

[1/3]
Trouble code G00069 Trouble monitoring oil temperature gear (PTO 1)
Message
G00069 & G00083 G00083 Trouble monitoring oil temperature gear (PTO 2)
– A malfunction in the monitoring loop for the gear oil temperature (PTO 1 or PTO 2) is detected.
Contents of trouble – The system assumes that the gear oil temperature sensor 57B049-1 or 57B049-2 (PT100 type)
or the wiring circuit of the monitoring system is defective.
Within the temperature range of -50°C up to +150°C sensor 57B049-1 or 57B049-2 generate
Related information
a voltage signal of 0.5 - 9.5 V.

Monitoring of the gear oil temperature (PTO 1 or PTO 2) is disabled.
on the machine
Nominal
value
G00069 G00083
Check the wiring Check the wiring
between sensor between sensor Yes Go to next step. Rmax 1Ω
57B049-1 and 57B049-2 and
Wiring or connector connector 51X552 connector 51X552
1 for continuity: for continuity:
problem
pin 23 to shield pin 27 to shield
Repair or replace the
pin 24 to A pin 28 to A
No wiring according to the
pin 25 to B pin 29 to B
Wiring diagram.
pin 26 to C pin 30 to C
– Check the input signal of 57B049-1 or
57B019-2 at node 18 (51K318). VSignal
Yes Go to final step 4.
– G00069 0.5-9.5V
Measure the input signal of 57B049-1 at
51K318, connector 0, pin 4.
No input signal at
2 – G00083
node 18
Measure the input signal of 57B049-2 at
51K318, connector 0, pin 5.
No Go to next step
– Measure the signal voltage and compare
the voltage to your Real-Time temperature.
Does the voltage signal correspond to the
Real-Time temperature?
Check the signal voltage of temperature Refer to
A sporadic malfunction
sensor 57B049-1 or 57B049-2 and compare to the PT100
Yes may exist. Further
the PT100 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 C and
pin B. Replace the concerned
No
Does the signal voltage correspond to the PT100 sensor.
PT100 voltage chart?
Final check 4
TS 15110-upD-GB-0 PC5500-6 7 - 79
Input of 57B049-1 on the REAL TIME MONITOR (G00069)

[2/3]
Fig. 7-46 Input of 57B049-1 on the REAL TIME MONITOR (G00069)
1. Select 04 PTO 2 to display the input of 57B049-2 on the REAL TIME MONITOR.
Gear oil temperature (PTO 1 & PTO 2) on the Main Gauge Screen
Fig. 7-47 Gear oil temperature (PTO 1 & PTO 2) on the Main Gauge Screen
7 - 80 PC5500-6 TS 15110-upD-GB-0
Wiring diagram (57B049-1 & 57B049-2) and component location (G00069 & G00083)
[3/3]
Fig. 7-48 Wiring diagram (57B049-1 & 57B049-2) and component location (G00069 & G00083)
TS 15110-upD-GB-0 PC5500-6 7 - 81
G00070 - Trouble oil temperature gear (PTO 1)

[1/4]
Trouble code G00070 Trouble oil temperature gear (PTO 1)
Message
G00070 & G00084 G00084 Trouble oil temperature gear (PTO 2)
– The PTO gear oil temperature sensors 57B049-1 & 57B049-2 (PT100 type) signal overheating.
Contents of trouble – The system assumes that the gear oil temperature sensors 57B049-1 & 57B049-2 or the wiring
circuits of both monitoring systems are not defective.
PTO gear oil temperature for 5 seconds above the sensor’s switching point:
Related information

Action of controller – The MTC blinks out the active binary code:
PTO (-1 or -2) gear oil is overheated.
on the machine
Nominal
value
Using a laser temperature meter, verify if the PTO gear
oil temperature at the concerned temperature sensor
57B049-1 or 57B049-2 is too high.
PTO gear oil
1 For the location of 57B049-1 or 57B049-2 refer to
overheated Go to next step.
Fig. 7-50 on page 7-85.
REMARKS: For the definition of the PTO gear oil tem-
peratures refer to the above table "PTO
gear oil temperatures".
Check the PTO (-1 or -2) 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 (-1 or -2) gear oil level within the Then monitor the PTO
specified range? gear oil temperature
again.
7 - 82 PC5500-6 TS 15110-upD-GB-0

[2/4]
Nominal
value
Check the PTO (-1 or -2) gear oil settings Adjust the PTO gear oil
Wrong PTO gear oil (oil type and viscosity) on the service level settings on the
settings may cause 3 of the KOMTRAX Plus system. service level of
the problem Refer to Fig. 7-49 on page 7-84. KOMTRAX Plus.
No
Then verify that the
Are the oil settings correct? gear oil temperature
is in normal range.
The maximum fan speed is achieved if no Yes Go to next step. RPMmax.
voltage (0V) is applied at both solenoid valves 1250±50
57K506a-1/b-1 and 57K506a-2/b-2.
Refer to the SERVICE RPMmed.
Refer to Fig. 7-50 on page 7-85.
MANUAL, section 1000±50
1. Disconnect the cable connectors from both Hydraulic Oil Cooling,
solenoid valves 57K506a-1/b-1 or and perform the setting
The fan is not driven 57K506a-2/b-2. of the max. fan speed.
4
at max. speed
2. If the fan speed does not increase, check No If the setting is not as
the hydraulic settings for the fan speed specified follow the
(refer to the SERVICE MANUAL). adjustment and/or
inspection procedures
3. Reconnect both cable connectors to the in the SERVICE
solenoid valves 57K506a-1/b-1 or MANUAL as
57K506a-2/b-2. necessary.
Is the setting for max. fan speed correct?
Engines OFF + maintenance safety switch 50S058 OFF + locked
REMARKS: This test step must only be Clean the gear oil/
performed if the engines hydraulic oil cooler with
Any clogged gear oil
are standing still. a pressure cleaner as
cooler segment in the
– Perform a visual inspection of the gear oil necessary.
hydraulic oil cooler Yes
5 cooler segments. Continue to work and
frame caused the
overheating of the verify that the PTO
– Also open the swing out doors of the cooler
PTO gear oil gear oil temperature is
frame and check for deposits between
in normal range.
these door wings.
Is intense pollution present? No Go to next step.

Carry out adjustments
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 cor-
responding
troubleshooting chart.
TS 15110-upD-GB-0 PC5500-6 7 - 83

[3/4]
Nominal
value
Carry out adjustments
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 cor-
responding
Final check 7
PTO gear oil settings (oil type and viscosity)

SERVICE MENU SELECT
08 Setting
Other settings (2/2) 6/10
Oil viscosity gear
1. Refer to the "PTO gear oil temperatures" on on page 7-77

and choose the required PTO gear oil specification according
to the specific temperature conditions.
2. Select the number of the Oil viscosity gear from the following
definition by pressing button F3 or F4.
Fig. 7-49 KOMTRAX Plus screen
1 = T32
2 = CLP150
3 = Hypoid oil 75W-140
3. Press button F6 to confirm.
7 - 84 PC5500-6 TS 15110-upD-GB-0
Location of the PTO gear oil level dipstick & temperature sensors 57B049-1/57B049-2
[4/4]
Fig. 7-50 Location of the PTO gear oil level dipstick & temperature sensors 57B049-1/57B049-2
TS 15110-upD-GB-0 PC5500-6 7 - 85

[1/2]
Trouble code G00071 Trouble gear lubrication (PTO 1)
Message
G00071 & G00068 G00068 Trouble gear lubrication (PTO 2)
Pressure sensor 57B017-1 or 57B017-2 (NC*) signals, that there is no pressure in the
Contents of trouble concerned PTO gear lubrication system, even the engines are running.
*NC = Normally Closed
Basic sensor data (57B017-1 & 57B017-2)

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

– The MTC blinks out the active binary code:
Risk, to operate the machine without PTO (-1 or -2) 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
No PTO (-1 or -2) PTO gear lubrication
Are the pressure adjustments as specified?
gear lubrication pressure is in normal
pressure present range.
Main key switch 20S001 OFF
2 Continue to work and verify

Check the PTO (-1 or -2) gear oil type &
that trouble code G00071 or
viscosity and correct if necessary.
G00068 is not set again.
Final check 3
7 - 86 PC5500-6 TS 15110-upD-GB-0
Wiring diagram (57B017-1 & 57B017-2) for trouble codes G00071 & G00068
[2/2]
Fig. 7-51 Wiring diagram (57B017-1 & 57B017-2) for trouble codes G00071 & G00068
TS 15110-upD-GB-0 PC5500-6 7 - 87
G00081 - Trouble lubrication system

[1/3]
Trouble code
Message 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.
Action of controller Background colour of the trouble code information: red
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
Engines 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
Is any trouble code for the lubrication systems code(s) and rectify the
Problem in the
present? lubrication problem.
lubrication system(s).
REMARKS: Remember the PauseTime set- After the repair manu-
A problem with the
ting is reduced to 30 s under the ally activate the lubri-
lubrication cycles 1 Yes
following conditions: cation system and
causes bucket cut-off
recheck for proper
(option) or continuous – If you entered the KOMTRAX Plus Ser-
function.
buzzer sound (20P022) vice Level or
in the cab Also verify that the
– After the first manual lubrication cycle bucket motion is no
was started. 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.
No
Bucket movement disabled If the problem is not
Does the function of relay 11K050 meet the yet rectified go to next
above specification? step.
7 - 88 PC5500-6 TS 15110-upD-GB-0
G00081 - Trouble lubrication system

[2/3]
Nominal
value
Repair the wiring or
replace any defective
Yes
electrical component
Refer to the wiring diagram: as necessary.
1. Check if B+ voltage is present Check if any other
2. Check for proper ground connection trouble code is set
Malfunction or damage which may be in cross-
in the wiring circuit of 3 3. Check the wiring for continuity correlation with the
relay 11K050 existing problem.
4. Check the diode for proper condition
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
Wiring diagram (11K050) for trouble code G00081
Fig. 7-52 Wiring diagram (11K050) for trouble code G00081
TS 15110-upD-GB-0 PC5500-6 7 - 89
Operation cycles of the lubrication systems

[3/3]
Fig. 7-53 Operation cycles of the lubrication systems
7 - 90 PC5500-6 TS 15110-upD-GB-0


G00086 - SHUTDOWN
[1/1]
Trouble code
Message 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 engines are running)
– The time delay of 10 seconds gives the operator the chance to bring the attachment in its
Related information defined parking position, before the engines are shutdown.
– The message is displayed one-time before shutdown.
– 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
KOMTRAX Plus monitor and/or a binary code is blinked out at the MTC:
Any serious trouble – G-code machine trouble or
caused a delayed 1
engine shutdown – C-code engine trouble
Follow the troubleshooting procedure of the displayed trouble code and rectify
the problem.
TS 15110-upD-GB-0 PC5500-6 7 - 91
G00087 - Stop all movements for low idle

[1/1]
Trouble code
Message Stop all movements for low idle
G00087
REMARKS: Operation of a hydraulic machine is only allowed at High Idle.
Contents of trouble If the engines are switched from High Idle to Low Idle during machine operation,
message G00087 will be displayed, in order to avoid serious trouble.
Examples
– Switching from High Idle to Low Idle during swing movement:
Related information Collision with the dump truck is possible.
– 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 - 92 PC5500-6 TS 15110-upD-GB-0
G00090 - Trouble power supply

[1/2]
Trouble code
G00090 Message 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 71G008 and 71G009.
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
– Engine start is impossible.
– The monitoring function is inoperative.
on the machine
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
Batteries 71G008 & V min 17V
1 Check the batteries. Yes Go to next step.
71G009 are defective V max 24V
Are the batteries OK?
No Replace the batteries.
The circuit between Repair or replace
batteries 71G008 & components as
Refer to the wiring diagram. necessary and verify
71G009 and the
Check the circuit (wires and electrical components) that the repair was
circuit breaker 2
between batteries 71G008 & 71G009 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
TS 15110-upD-GB-0 PC5500-6 7 - 93
Wiring diagram (stabilized power supply) for G00090 & G00099

[2/2]
Fig. 7-54 Wiring diagram (stabilized power supply) for G00090 & G00099
7 - 94 PC5500-6 TS 15110-upD-GB-0
G00091 - Pilot control cut out

[1/2]
Trouble code
Message Pilot control cut out
G00091
Contents of trouble Pilot control is locked.
Pilot control is locked if:

– Refilling arm and/or ladder is down.
Related information
– Refilling arm and/or ladder is not in end position.
– Lock lever is pulled up.
Action of controller Background colour of the trouble code information: blue

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 15110-upD-GB-0 PC5500-6 7 - 95

[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)
Legend for Fig. 7-55
(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. 7-55 Lock lever and cover of 20S105
7 - 96 PC5500-6 TS 15110-upD-GB-0
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
G00097 - Emergency shut-down at counterweight
[1/3]
Trouble code G00092 - Emergency shut-down at access ladder
G00092 ~ G00095 Message G00094 - Emergency shut-down at hydraulic control panel
& G00097 G00095 - Emergency shut-down in cabin
Emergency shut-down switch was activated when the engines are standing still.
The involved emergency shut-down switches are as follows:
Emergency shut-down switch Location Trouble code

70S033a Ladder G00092
Contents of trouble 61S033b Valve block G00093
57S033c Hydraulic control panel G00094
20S036 Operator´s cab G00095
51S033d Counterweight G00097
– Engine start is blocked.

Related information – Message G00053 (Reset emergency safety circuit) is also displayed.
Follow the instructions of G00053.
Engine start is blocked.
– The MTC blinks out the binary code:
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.
TS 15110-upD-GB-0 PC5500-6 7 - 97

[2/3]
Nominal
value
gram. 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 010000 or 010001 or 010010 or 010011
or 010100
7 - 98 PC5500-6 TS 15110-upD-GB-0
Wiring diagram (emergency switches) for G00092~G00095 & G00097

[2/3]
Fig. 7-56 Wiring diagram (emergency switches) for G00092~G00095
REMARKS: The switches 54S051 and 54S052 are an option.

Terminals 1 and 2 at terminal block 51X_00 are bridged if 54S051 and 54S052 are not equipped.
TS 15110-upD-GB-0 PC5500-6 7 - 99

[1/2]
Trouble code
Message 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 position
OFF [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 KOMTRAX Plus 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
7 - 100 PC5500-6 TS 15110-upD-GB-0


[2/2]
TS 15110-upD-GB-0 PC5500-6 7 - 101


Refer to the troubleshooting procedure G00092 / G00093 / G00094 / G00095 / G00097 on page 7-97.

G00100 - Maintenance Safety Switch

[1/2]
Trouble code
Message Maintenance Safety Switch
G00100
Contents of trouble If the maintenance safety switch 50S058 is switched OFF, the engines are 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

gram. Locate the prob-
Malfunction of the lem 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
7 - 102 PC5500-6 TS 15110-upD-GB-0


[2/2]
TS 15110-upD-GB-0 PC5500-6 7 - 103

G00103 - Faulty switch 20M004

[1/4]
Trouble code
Message Faulty switch 20M004
G00103
Contents of trouble The monitoring system detected any problem with the limit switch in the wiper motor (20M004).
Related information The limit switch in the wiper motor (20M004) may have an electrical problem.
Problem that appears – The wiper doesn't move in its initial position (end position).
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

Wiper switch 20S011 ON.
Check the conditions via KOMTRAX Plus: The system assumes
– REAL TIME MONITOR that the wiper reached
its end position, but the
– 13 Windscreen Wiper wiper arm does not
move.
Conditions:
The wiper motor When KOMTRAX Plus
(20M004), the limit Wiper arm in end position: Yes
1 displays "1", the wiring
switch, or its wiring KOMTRAX Plus display = 1
between wiper motor
is defective Wiper arm not in end position: 20M004, pin 5 and
KOMTRAX Plus display = 0 node 9, connector 3,
pin 2 is ok.
For wiper start, the wiper arm has to be in end
Go to step 3.
position.
Do the indications on the REAL TIME
MONITOR correspond to the wiper arm No Go to next step.
position?
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,
2 found and repaired,
is disturbed pin 5, and node 9, connector 3, pin 2 for
recheck the wiper
continuity. No
system for proper
Is continuity present? function.
If OK, go to final
step 5.
If no problem was
found, go to next step.
7 - 104 PC5500-6 TS 15110-upD-GB-0

G00103 - Faulty switch 20M004

[2/4]
Nominal
value
Wiper OFF (20S011 in position "0")
Replace the wiper motor 20M004. Yes Go to step 6.
During the installation of the wiper motor follow Refer to the wiring dia-
the adjustment procedures in the PARTS & gram.
The wiper motor
3 SERVICE NEWS AH06533 (latest version) Check the relating
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.
Malfunction in the Check the relating circuits and the electrical
wiring circuit of the 4 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 5
TS 15110-upD-GB-0 PC5500-6 7 - 105

Wiring diagram 1 (windscreen wiper) for trouble code G00103

[3/4]
Fig. 7-59 Wiring diagram 1 (windscreen wiper) for trouble code G00103
7 - 106 PC5500-6 TS 15110-upD-GB-0

Wiring diagram 2 (windscreen wiper) for trouble code G00103

[4/4]
Fig. 7-60 Wiring diagram 2 (windscreen wiper) for trouble code G00103
TS 15110-upD-GB-0 PC5500-6 7 - 107

G00104 - Trouble battery current

[1/3]
Trouble code
Message 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 engines are 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 - Engines OFF.
REMARKS: Before taking the following mea- Replace the concerned
surements check for the correct alternator.
order of the cable connections at Yes After repair recheck
71T003 "B" and 71T003 "L". the system for proper
In case the cable connections are mixed up, function.
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
resistor 71T003.
An alternator is
defective (52G005-1 or
52G005-2) 1
(short circuit to ground)
No Go to next step.
Do you measure a negative current flow

< -200A between 71T003 & 52G005-1
or 52G005-2 and between 71T003 &
the batteries?
7 - 108 PC5500-6 TS 15110-upD-GB-0

G00104 - Trouble battery current

[2/3]
Nominal
value
Main key switch 20S001 ON - Engines OFF
Refer to the wiring diagram. – If the current flow at one of both
Using a clamp-on ammeter: starter motors is too high, both
1. Measure the current between terminal block starter motors have to be
71X_71-5 and starter motor 52M001-1. replaced.
Starter motors After repair recheck the system
are defective 2. Measure the current between terminal block
for proper function.
2 71X_71-6 and starter motor 52M001-2.
52M001-1 & 52M002-1 – If no problem could be found,
or 3. Measure the current between terminal block
check if other trouble codes
52M001-2 & 52M002-2 71X_71-7 and starter motor 52M002-1.
relating to the charging system
4. Measure the current between terminal block are pending.
71X_71-8 and starter motor 52M002-2. If so, follow the relevant
5. Measure the current between the starter motors troubleshooting procedures.
and ground. Finally go to step 3.
Final check 3
Wiring diagram (starter motors) for trouble code G00104
Fig. 7-61 Wiring diagram (battery current) for trouble code G00104
TS 15110-upD-GB-0 PC5500-6 7 - 109

Wiring diagram (battery current) for trouble code G00104

[3/3]
Fig. 7-62 Wiring diagram (battery current) for trouble code G00104
7 - 110 PC5500-6 TS 15110-upD-GB-0

G00105 - Trouble battery charging current too low

[1/2]
Trouble code
Message Trouble battery charging current too low
G00105
– The charging current from the alternator (52G005-1 or 52G005-2) 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 (07 Electrical Equipm.)
on the service level of the KOMTRAX Plus system (for further information refer to the
SERVICE MANUAL, section 17 KOMTRAX Plus).
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: Before taking the following mea- Vmin
surements check for the correct 27.5V
order of the cable connections at Yes Go to next step.
Vmax
71T003 "B" and 71T003 "L".
29.5V
In case the cable connections are mixed up,
connect them in the correct order.
1 Replace the concerned
– B = battery side
alternator and check its
– L = alternator side wiring.
No
Measure the charging voltage between After repair recheck
alternator, terminal B+, and ground. the system for proper
Does the measurement reading meet the function.
specification?
An alternator
(52G005-1 or Using a clamp-on ammeter measure the Icharge
52G005-2) or its charging current in front of and behind the 25-35A
wiring is defective shunt resistor 71T003.
No Go to next step.
If the charging current is too low, replace the

alternator.
TS 15110-upD-GB-0 PC5500-6 7 - 111

G00105 - Trouble battery charging current too low

[2/2]
Nominal
value
(a) Measure both resistors inside the module.
(b) Refer to the wiring diagram and check for proper (a) If a resistor is defective,
cable connections: replace 11T080.
Module 11T080 or its – 11T080 power supply
3 (b) If necessary, repair or replace
wiring is defective
– 11T080 ground connections the wiring/connections
of 11T080.
– Signal line betwe)en 11T080 and node 2,
(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. 7-63 Wiring diagram (11T080) for trouble code G00105
7 - 112 PC5500-6 TS 15110-upD-GB-0


[1/4]
Trouble code G00107 - Trouble slew parking brake control 56K250a
Message
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
(5) Switch contacts (13/14)
– No power supply
(A1)
– No ground (A2)
– Relay inoperative
1
– Relay output wiring Specifications of the slew parking brake switch 20S029
(13/14) defective
20S029 in position 1 brake applied
G00107 56K250a
– 0V at relay 56K250a/b
G00109 56K250b
– 0V at solenoid 57Q505
– Both relay LEDs (yellow & red) OFF
20S029 in position 0 brake released
– 24V at relay 56K250a/b
– 24V at solenoid 57Q505
– 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 15110-upD-GB-0 PC5500-6 7 - 113


[2/4]
Nominal
value
REAL TIME MONITOR - Relay Check
1. 20S001 ON
2. Engines OFF
17 Other items
Screen 2/4
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
Continue trouble- 0 0V Applied
(cross check)

Final check 2
7 - 114 PC5500-6 TS 15110-upD-GB-0

[3/4]
Fig. 7-64 View onto the CoDeSys HMI Visualization screen for trouble code G00107
TS 15110-upD-GB-0 PC5500-6 7 - 115


[4/4]
7 - 116 PC5500-6 TS 15110-upD-GB-0


[1/4]
Trouble code G00108 - Trouble slew parking brake control Output to 56K250a
Message
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. Engines OFF.
17 Other items
Screen 2/4
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 15110-upD-GB-0 PC5500-6 7 - 117


[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. Engines OFF.
18 Output Signals
Screen 13/27
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 - 118 PC5500-6 TS 15110-upD-GB-0

[3/4]
Fig. 7-66 View onto the CoDeSys HMI Visualization screen for trouble code G00108
TS 15110-upD-GB-0 PC5500-6 7 - 119


[4/4]
7 - 120 PC5500-6 TS 15110-upD-GB-0



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
Message
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
17 Other items
Sub-screen 3/5
56K251a & 56K251b (relay check) on the REAL TIME MONITOR (G00111 & G00113)
Fig. 7-68 56K251a & 56K251b (relay check) on the REAL TIME MONITOR (G00111 & G00113)
TS 15110-upD-GB-0 PC5500-6 7 - 121

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
Message
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
17 Other items
Sub-screen 3/5
56K251a & 56K251b (output check) on the REAL TIME MONITOR (G00112 & G00114)
Fig. 7-69 56K251a & 56K251b (output check) on the REAL TIME MONITOR (G00112 & G00114)
7 - 122 PC5500-6 TS 15110-upD-GB-0

G00113 - Trouble travel parking brake control 56K251b

G00114 - Trouble travel parking brake control Output to 56K251b

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
Message
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
17 Other items
Sub-screen 4/5
TS 15110-upD-GB-0 PC5500-6 7 - 123

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
Message
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
17 Other items
Sub-screen 4/5
7 - 124 PC5500-6 TS 15110-upD-GB-0

G00117 - Trouble slew hydraulic brake control 56K252b

G00118 - Trouble slew hydraulic brake control Output to 56K252b

G00139 - Trouble monitoring X1-2 pressure

[1/3]
Trouble code G00139 - Trouble monitoring X1-2 (XLR) pressure
Message
G00140 & G00139 G00140 - Trouble monitoring X1-1 (XLR) pressure
A malfunction in the monitoring loop for the pump regulation pressure (X1-1 or X1-2) is detected.
The sensor signal is out of range (below 0.5V or higher than 9.5V)
Contents of trouble Monitoring the X1-1 or X1-2 pressure is impossible because of:
– Defective wiring or defective pressure sensor 57B085-1 or 57B085-2
– Poor terminal contact or disconnection in the wiring of pressure sensor 57B085-1 or -2
Within a pressure range of 0 - 60 bar the pressure sensor (57B085-1 or 57B085-2) generates a
Related information
signal voltage of 0.5 - 9.5V.

Monitoring of the pump regulation pressure X1-1 or X1-2 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 pressure pins A and C.
sensor 57B085-1 No Go to next step.
or 57B085-2 Is supply voltage present?
Follow the trouble-
2 (Trouble power 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 or 57B085-2 3
11F013a and connector terminal A at the circuit breaker and
(disconnection or concerned 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.
TS 15110-upD-GB-0 PC5500-6 7 - 125


[2/3]
Nominal
value
shield wiring between Refer to the wiring diagram and check the circuit in any wiring
the shield terminal and wiring segments of the concerned pressure segment (including
4 sensor between shield terminal and GND for
GND: connectors) between
57B085-1 = 56X457-A continuity. No shield terminal and
57B085-2 = 56X457-E Is continuity present? GND.
Locate the problem and
repair as necessary.
Disconnect the sensor connector and insert the Vsignal
Defective pressure Yes Go to next step.
sensor 57B085-1 or Deutsch T-box. 0.5 - 9.5V
57B085-2 5 Replace the
Measure the signal voltage at connector
terminal B of the concerned X1 pressure concerned pressure
(internal malfunction)
sensor. No sensor and verify
that the repair was
Does the measurement meet the specification? successful.
If continuity is not
Rmax 1Ω
as specified, any
Check the signal wiring for continuity between sensor malfunction in the
Disconnection in the terminal and node: wiring (including
signal wiring between connectors) between
X1 pressure sensor Node terminal B at the
57B085-1 or 57B085-2 Sensor
Sensor Node connector / concerned pressure
and node 14 6 terminal
terminal sensor and the node
(disconnection or 57B085-1 B 14 2/6 connector is the
defective contact in problem.
any connector) 57B085-2 B 14 2/5
Locate the problem and
repair as necessary.
After successful repair
go to final step 7.
Final check 7
7 - 126 PC5500-6 TS 15110-upD-GB-0

[3/3]
TS 15110-upD-GB-0 PC5500-6 7 - 127

G00141 - Trouble monitoring X2 pressure

[1/3]
Trouble code
Message 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 (Trouble power 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.
56X457-J and GND No terminal and GND.
Locate the problem
and repair as
necessary.
7 - 128 PC5500-6 TS 15110-upD-GB-0

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
Does the measurement meet the specification? repair was successful.
Disconnection in the If the resistance is too
Check for continuity in the signal wiring between high, refer to the Wiring
sensor terminal B and node 14. diagram and locate the
X2 pressure sensor and
node 14, connector 2, problem in the signal
pin 4 6 57B086 Node 14 wiring of the X2 Rmax 1Ω
terminal connector / terminal pressure sensor.
(disconnection or
defective contact in B 2/4 Repair as necessary.
any connector). After successful repair
go to final step 7.
Final check 7
TS 15110-upD-GB-0 PC5500-6 7 - 129


[3/3]
7 - 130 PC5500-6 TS 15110-upD-GB-0

G00142 - Trouble monitoring pump support pressure X4-1

[1/4]
Trouble code G00142 Trouble monitoring pump support pressure X4-1
Message
G00142 & G00196 G00196 Trouble monitoring pump support pressure X4-2
– A malfunction in the monitoring loop for pump support pressure (X4-1/-2) & pump bearing
lubrication is detected.
Contents of trouble
– Pressure sensors 57B097-1 and 57B097-2 monitor the pressure in both circuits of
pump support pressure & pump bearing lubrication.
Conditions for trouble message:
– The engines are standing still
– 20S001 ON
Example:
Pressure switch 57B097-1 or 57B097-2 signals pump support pressure (approx. 24V), even the
belonging engine is standing still.
Related information Basic sensor data (57B097-1 & 57B097-2)

REAL TIME MONITOR
Signal
Switch point 24 bar

Monitoring of pump support pressure (X4-1/-2) is inoperative.
on the machine
Nominal
value
Using the Deutsch T-box, measure the supply Vmin 22V
voltage for the concerned pressure switch: Yes Go to step 4.
Vmax 24V
1 Sensor Connector Pin

Incorrect or no supply
voltage at pressure 57B097-1 56X057 13
switch 57B097-1 No Go to next step.
57B097-2 56X257 E
or 57B097-2
Is the correct supply voltage present?

Follow the trouble-
2 "No power supply" is set.
No Go to next step.
TS 15110-upD-GB-0 PC5500-6 7 - 131


[2/4]
Nominal
value
Refer to the Wiring Diagram. Disconnection, short

Disconnection in the Using the Deutsch T-box, check the voltage circuit, or fault in the
voltage supply wiring supply wiring segments between the con- wiring (including
between circuit breaker cerned pressure switch and circuit breaker connectors and
56F013 and pressure for continuity. resistor 56R008)
switch 57B097-1 or 3 between connector
57B097-2 Sensor Connector Pin (refer to the table) and
No circuit breaker.
(disconnection or 57B097-1 56X057 13
defective contact in If necessary, check the
any connector) 57B097-2 56X257 E segments of the
voltage supply wiring
Is continuity present? separately, locate the
problem, and repair
as necessary.
The signal wiring
between pressure
Yes switch and node 14
is ok.
Check the input signal at the node connector: Go to next step.
signal wiring between Disconnection, short
Node
pressure switch circuit, or fault in the
Sensor Node connector /
57B097-1 or 57B097-2 wiring (including
4 terminal
and node 14 connectors and pins)
(disconnection or 57B097-1 14 3/5 between the con-
defective contact in cerned pressure switch
57B097-2 14 3/4
any connector) No and node connector.
If necessary, check the
Is the signal present? segments of the signal
wiring separately,
locate the problem,
and repair as
necessary.
Disconnect the concerned cable connector Yes Go to next step.
and check for proper ground connection at
the connector pin:
Defective ground
connection at the
5 Sensor Connector Pin Locate the problem
pressure switch
57B097-1 or 57B097-2 57B097-1 56X057 14 No and repair as
necessary.
57B097-2 56X257 F
7 - 132 PC5500-6 TS 15110-upD-GB-0


[3/4]
Nominal
value
Disconnect the concerned connector and Yes Go to next step. Rmax 1Ω
measure continuity of the pressure switch
between the following connector pins:
Defective pressure
switch 57B097-1
6 Sensor Connector Pins Replace the defective
or 57B097-2
pressure switch and
(switch does not close) 57B097-1 56X057 13-14 No
verify that the repair
57B097-2 56X257 E-F was successful.
Final check 7
Input signal of 57B097-1 & 57B097-2 on the REAL TIME MONITOR for G00142 & G00196
Fig. 7-74 Input signal of 57B097-1 & 57B097-2 on the REAL TIME MONITOR
TS 15110-upD-GB-0 PC5500-6 7 - 133

Wiring Diagram (57B097-1 & 57B097-2) for G00142 & G00196

[4/4]
Fig. 7-75 Wiring Diagram (57B097-1 & 57B097-2) for G00142 & G00196
7 - 134 PC5500-6 TS 15110-upD-GB-0

G00147 - Trouble monitoring gear lubrication (PTO 1)

[1/4]
Trouble code G00147 - Trouble monitoring gear lubrication (PTO 1)
Message
G00147 & G00150 G00150 - Trouble monitoring gear lubrication (PTO 2)
– A malfunction in the monitoring loop for PTO 1 or PTO 2 gear oil pressure is detected.
Contents of trouble – Pressure sensors 57B017-1 and 57B017-2 monitor the pressure in both PTO gear lubrication
systems.
Conditions for trouble message:
– 20S001 in ON position
Example:
Pressure switch 57B017-1 or 57B017-2 signals gear oil pressure (approx. 24V), even the belonging
engine is standing still.
Related information Basic sensor data (57B017-1 & 57B017-2)

REAL TIME MONITOR
Signal
Switch point 0.5 bar
Background colour of the trouble code information: yellow

Action of controller G00147 The MTC blinks out the binary code 010111
G00150 The MTC blinks out the binary code 011000
Monitoring of PTO 1 or PTO 2 gear oil pressure is inoperative.
on the machine
Nominal
value
Using the Deutsch T-box, measure the supply Vmin 22V
voltage for the concerned PTO gear oil sensor: Yes Go to step 4.
Vmax 24V

voltage at pressure 57B017-1 56X057 1
switch 57B017-1 No Go to next step.
57B017-2 56X257 C
or 57B017-2

Follow the trouble-
2 "No power supply" is set.
No Go to next step.
TS 15110-upD-GB-0 PC5500-6 7 - 135


[2/4]
Nominal
value
Refer to the wiring diagram. Disconnection, short

Disconnection in the Using the Deutsch T-box, check the voltage circuit, or fault in the
voltage supply wiring supply wiring segments between the con- wiring (including
between circuit breaker cerned pressure switch and circuit breaker connectors and
11F013 and pressure for continuity. resistor 56R008)
switch 57B017-1 or 3 between connector
57B017-2 Sensor Connector Pin (refer to the table) and
No circuit breaker.
(disconnection or 57B017-1 56X057 1
any connector) 57B017-2 56X257 C segments of the
Is continuity present? separately, locate the
problem, and repair
as necessary.
The signal wiring
between pressure
is ok.
Check the input signal at the node connector: Go to next step.
Node
pressure switch circuit, or fault in the
Sensor Node connector /
57B017-1 or 57B017-2 wiring (including
4 terminal
and node 14 connectors and pins)
(disconnection or 57B017-1 14 1/8 between the con-
defective contact in cerned pressure switch
57B017-2 14 1/7
any connector) No and node connector.
Is the signal present? segments of the signal
wiring separately,
locate the problem,
and repair as
necessary.
Disconnect the concerned cable connector Yes Go to next step.
and check for proper ground connection at
the connector pin:
Defective ground
connection at the
5 Sensor Connector Pin Locate the problem
pressure switch
57B017-1 or 57B017-2 57B017-1 56X057 2 No and repair as
necessary.
57B017-2 56X257 D
7 - 136 PC5500-6 TS 15110-upD-GB-0


[3/4]
Nominal
value
Disconnect the concerned connector and Yes Go to next step. Rmax 1Ω
measure continuity of the pressure switch
between the following connector pins:
Defective pressure
switch 57B017-1
6 Sensor Connector Pins Replace the defective
or 57B017-2
pressure switch and
(switch does not close) 57B017-1 56X057 1-2 No
verify that the repair
57B017-2 56X257 C-D was successful.
Final check 7
TS 15110-upD-GB-0 PC5500-6 7 - 137

[4/4]
7 - 138 PC5500-6 TS 15110-upD-GB-0

G00148 - Trouble monitoring fuel level

[1/3]
Trouble code
Message 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
Related information 0.5 - 9.5V
– The trouble message is displayed if the signal voltage is out of range (<0.5V or >9.5V)

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-
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.
TS 15110-upD-GB-0 PC5500-6 7 - 139

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 F and GND 5 wiring segments between connector 10X140, connectors) between
(disconnection or terminal F and GND for continuity. shield terminal F 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 the fuel level sensor
(disconnection or for 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
7 - 140 PC5500-6 TS 15110-upD-GB-0

Wiring diagram (31B063) for G00148

[3/3]
Fig. 7-77 Wiring diagram (31B063) for G00148
TS 15110-upD-GB-0 PC5500-6 7 - 141


G00151 - Trouble monitoring gear (PTO) oil filter 1

[1/4]
Trouble code G00151 - Trouble monitoring gear (PTO) oil filter 1
Message
G00151 & G00193 G00193 - Trouble monitoring gear (PTO) oil filter 2
- A malfunction in the pressure monitoring loop for PTO gear oil filter 1 or PTO gear oil filter 2
Contents of trouble is detected.
- Pressure sensor 57B027-1 or 57B027-2 monitors the pressure in the gear oil filter housing.
Conditions:
- The engines are standing still
- 20S001 ON
- Pressure switch 57B027-1 or 57B027-2 signals pressure in the PTO gear oil filter (0 V),
even the engines are standing still.
Related information Basic sensor data (NO switch 57B027-1 & 57B027-2)
No pressure present 24 V Switch open

Pressure present 0V Switch closed
Switch point 5 bar

Monitoring of the PTO gear oil filter (1 or 2) pressure is inoperative.
on the machine
Nominal
value
Measure the supply voltage for the concerned Vmin 22V
pressure switch at the following connector/pin: Yes Go to step 4.
Vmax 24V
57B027-1 56X057 3
voltage at pressure
switch 57B027-1 57B027-2 56X257 A No Go to next step.
or 57B027-2
Follow the trouble-
Check if trouble code G00090 Yes shooting table for
2 (Trouble power supply) is set. trouble code G00090.
No Go to next step.
7 - 142 PC5500-6 TS 15110-upD-GB-0


[2/4]
Nominal
value

Rmax
820Ω
Disconnection,
short circuit, or fault
Disconnection in the Refer to the wiring diagram.
in the wiring (includ-
voltage supply wiring Check the voltage supply wiring between con-
ing connectors and
between circuit breaker nector/pin of the concerned pressure switch
resistor 56R008)
(56F013) and pressure and the line of the circuit breaker for continuity.
between the circuit
switch 57B027-1 3 breaker line
or 57B027-2 Sensor Connector Pin
(56F013) and
(disconnection or 57B027-1 56X057 3 No pressure switch.
defective contact in 57B027-2 56X257 A If necessary, check
any connector) the segments of the
separately.
Locate the problem,
and repair as
necessary.
The signal wiring
between the pressure
Yes switch and node 14,
is ok.
Go to next step.
Disconnection in the Check the input signal at the node connector:
pressure switch Node circuit, or fault in the
Sensor Node wiring (including
57B027-1 or 57B027-2 connector / pin
and node 14 4 connectors and pins)
57B027-1 14 1/2 between the con-
(disconnection or
57B027-2 14 3/9 cerned pressure switch
No and node connector.
any connector)
Is the signal present?
segments of the signal
wiring separately.
Locate the problem,
and repair as
necessary.
Disconnect the concerned sensor connector Yes Go to next step.
and check for proper ground connection:
Defective ground
connection at the Sensor Connector Pin
5 Locate the problem
pressure switch 57B027-1 56X057 4
57B027-1 or 57B027-2 No and repair as
57B027-2 56X257 B necessary.
TS 15110-upD-GB-0 PC5500-6 7 - 143


[3/4]
Nominal
value
Disconnect the concerned connector and Replace the defective
measure continuity of the pressure switch pressure switch and
Yes Rmax 1Ω
Defective pressure between the following connector pins: verify that the repair
switch 57B027-1 was successful.
or 57B027-2 6 Sensor Connector Pins
(switch does not open) 57B027-1 56X057 3-4
57B027-2 56X257 A-B No Go to next step.
Final check 7
7 - 144 PC5500-6 TS 15110-upD-GB-0

Wiring diagram (57B027-1/-2) and component location for G00151 & G00193
[4/4]
Fig. 7-78 Wiring diagram (57B027-1/-2) and component location for trouble codes G00151 & G00193
TS 15110-upD-GB-0 PC5500-6 7 - 145

G00154 - Trouble monitoring return oil filter

[1/3]
Trouble code
Message 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 0.5V or higher than 9.5V

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.
Incorrect or no supply 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-
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.
Locate the problem
any connector)
and repair as
necessary.
7 - 146 PC5500-6 TS 15110-upD-GB-0

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 inspection is required. Vmax 9.5V
7 Measure the signal voltage of the pressure
(return-oil chamber Replace the pressure
sensor at the relating terminal at the Deutsch
pressure) sensor (return-oil
T-box.
No chamber pressure)
Does the measurement meet the and verify that the
specification? repair was successful.
Final check 8
TS 15110-upD-GB-0 PC5500-6 7 - 147


[3/3]
7 - 148 PC5500-6 TS 15110-upD-GB-0

G00155 - Trouble monitoring leak oil filter

[1/3]
Trouble code
Message 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 0.5V or higher than 9.5V

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-
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.
Locate the problem
any connector)
and repair as
necessary.
TS 15110-upD-GB-0 PC5500-6 7 - 149

G00155 - Trouble monitoring leak oil filter

[2/3]
Nominal
value

Disconnect the signal line of the pressure circuit in any wiring
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.
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.
A sporadic malfunction Vmin 0.5V
Defective pressure Insert the Deutsch T-box at the cable Yes may exist. Further
sensor 40B164 connector of the pressure sensor. inspection is required. Vmax 9.5V
7
(leak-oil chamber Measure the signal voltage of the pressure Replace the pressure
pressure) sensor at the relating terminal of the T-box. sensor (leak-oil cham-
Does the measurement meet the No ber pressure) and
specification? verify that the repair
was successful.
Final check 8
7 - 150 PC5500-6 TS 15110-upD-GB-0


[3/3]
TS 15110-upD-GB-0 PC5500-6 7 - 151

G00159 - Trouble monitoring breather filter

[1/3]
Trouble code
Message 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 engines
are standing still
Related information Basic sensor data (40B024) NO*

Switch point 0.08 bar (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-
No Go to next step.
40R008
820Ω
Disconnection, short
circuit, or fault in the
wiring (including
connectors and
between circuit breaker Refer to the wiring diagram. resistor 40R008)
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 - 152 PC5500-6 TS 15110-upD-GB-0

G00159 - Trouble monitoring breather filter

[2/3]
Nominal
value

The signal wiring
between pressure
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.
(disconnection or between pressure
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
Is the ground connection ok? necessary.
If continuity is present
Defective pressure the switch is closed.
switch 40B024 Disconnect connector 40X240. Replace the defective
6 Yes Rmax 1Ω
Measure the continuity of the pressure switch pressure switch and
(switch does not open) verify that the repair
between the connector pins 10 and 11.
was successful.
No Go to next step.
Final check 7
TS 15110-upD-GB-0 PC5500-6 7 - 153


[3/3]
7 - 154 PC5500-6 TS 15110-upD-GB-0

G00160 - Trouble monitoring engine air cleaner 1

[1/3]
Trouble code G00160 - Trouble monitoring engine air cleaner 1
Message
G00160 & G00197 G00197 - Trouble monitoring engine air cleaner 2
– A malfunction in the monitoring loop for the respective engine air filter pressure sensor is
detected.
Contents of trouble
– Sensors 52B018-1 & 52B019-1 and 52B018-2 & 52B019-2 monitor the (vacuum) pressure in
the inlet manifolds between air filters and engines.
Conditions:
– 20S001 in ON position
– Any of the pressure switches (52B018-1 / 52B019-1 / 52B018-2 / 52B019-2) signals vacuum
(0V) in the inlet manifold below the engine air cleaner, even the engines are standing still.
Related information Basic sensor data (52B018-1 / 52B019-1 / 52B018-2 / 52B019-2) 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 the affected Vmin 22V
pressure switch at connector / pin as follows: Yes Go to step 4.
Vmax 24V
Sensor Connector Pin
1 52B018-1 51X052 A
Incorrect or no supply 52B019-1 51X052 C
voltage at the affected No Go to next step.
52B018-2 51X252 J
pressure switch
52B019-2 51X252 L

Follow the trouble-
Check if trouble code G00090 Yes shooting table for
No Go to next step.
TS 15110-upD-GB-0 PC5500-6 7 - 155


[2/3]
Nominal
value

51R008
820Ω
Disconnection, short
Check the voltage supply wiring for the circuit, or fault in the
Disconnection in the affected pressure switch and the line of the
voltage supply wiring wiring (including con-
circuit breaker for continuity. nectors and resistor
between circuit breaker
11F013 and the 51R008) between the
Sensor Connector Pin concerned connector
affected pressure 3
switch 52B018-1 51X052 A and the circuit breaker
No line.
(disconnection or 52B019-1 51X052 C
52B018-2 51X252 J segments of the
any connector)
52B019-2 51X252 L voltage supply wiring
separately.
Is continuity present? Locate the problem,

and repair as
necessary.
The signal wiring
between the pressure
Yes switch and node 17 is
Check the input signal at node 17: ok.
Go to next step.
Disconnection in the Node Disconnection, short
signal wiring between Sensor Node
connector / pin circuit, or fault in the
the affected pressure wiring (including
switch and node 17 52B018-1 17 3/8
4 connectors and pins)
(disconnection or 52B019-1 17 3/6 between the affected
defective contact in 52B018-2 17 3/7 pressure switch and
any connector) node 17.
52B019-2 17 3/5 No
Is the signal present? wiring separately.
Locate the problem,
and repair as
necessary.
Disconnect the concerned sensor connector Yes Go to next step.
and check for proper ground connection:
Sensor Connector Terminal

Defective ground
connection at the 52B018-1 51X052 B
5 Locate the problem
affected pressure 52B019-1 51X052 D
switch No and repair as
52B018-2 51X252 K necessary.
52B019-2 51X252 M
7 - 156 PC5500-6 TS 15110-upD-GB-0


[3/3]
Nominal
value
Disconnect the concerned connector and Replace the defective
measure continuity of the pressure switch pressure switch and
Yes Rmax 1Ω
between the following connector pins: verify that the repair
was successful.
Defective pressure Sensor Connector Pins
switch 6 52B018-1 51X052 A-B
(switch does not open) 52B019-1 51X052 C-D
52B018-2 51X252 J-K No Go to next step.
52B019-2 51X252 L-M
Final check 7
Wiring diagram (52B018-1/-2 & 52B019-1/-2) for trouble codes G00160 & G00197
Fig. 7-82 Wiring diagram (52B018-1/-2 & 52B019-1/-2) for trouble codes G00160 & G00197
TS 15110-upD-GB-0 PC5500-6 7 - 157

G00161 - Trouble monitoring battery voltage

[1/3]
Trouble code
Message 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 sys-
tem 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 No resistor and ground
Is the ground connection ok? (GND).
Locate the problem
and repair as
necessary.
7 - 158 PC5500-6 TS 15110-upD-GB-0

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 15110-upD-GB-0 PC5500-6 7 - 159


[3/3]
7 - 160 PC5500-6 TS 15110-upD-GB-0

G00162 - Trouble monitoring charging-/discharging current

[1/3]
Trouble code
Message 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 or higher than +245A.
The purpose of the module 51T017 is to monitor the charging and discharging current of the
batteries.
Battery information
Battery Function Location
71G001
Related information
71G002 Engine start
71G003 & miscellaneous
Cat walk
71G004
71G008
Stabilized voltage for MTC
71G009
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 (50Q002 ~ 50Q004).
71T003
4.5±0.5Ω
Disconnect the main battery cables and the Replace the shunt
The shunt resistor signal lines (terminals B & L) from the shunt resistor.
71T003 may be 1 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 (50Q002 ~ 50Q004).
Refer to the wiring diagram and check the Yes Go to next step. Rmax 1Ω
following cables for continuity:
– Between the alternators (52G005-1 &
The wiring of the shunt 52G005-2) and the shunt resistor (input). Locate the problem
resistor 71T003 may 2 and repair as
– Between shunt resistor (output) and all
cause the problem necessary.
batteries. No
After repair recheck
– Between shunt resistor (terminals B & L)
and module 51T017, including the wire
function.
shielding.
Is the continuity as specified?
TS 15110-upD-GB-0 PC5500-6 7 - 161

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.
The signal lines Replace module

Yes 51T017 and recheck Rmax 1Ω
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 – Between module pin 4/2, and shunt necessary.
No
are disturbed connection B/L. After repair recheck
Is the continuity as specified in both cables?
function.
Final check 5
7 - 162 PC5500-6 TS 15110-upD-GB-0

Wiring diagram (battery charging current) for trouble code G00162

[3/3]
Fig. 7-84 Wiring diagram (battery charging current) for trouble code G00162
TS 15110-upD-GB-0 PC5500-6 7 - 163

G00164 - Trouble air cleaner 1

[1/2]
Trouble code G00164 - Trouble air cleaner 1
Message
G00164 & G00198 G00198 - Trouble air cleaner 2
– The message is displayed if the sensors 52B018-1 & 52B019-1 or 52B018-2 & 52B019-2 of the
engine air filters detect clogged air filters.
Contents of trouble
– The system assumes that the monitoring circuits of the engine air filter sensors are not dis-
turbed.
Sensors 52B018-1 & 52B019-1 and 52B018-2 & 52B019-2 watch the vacuum pressure in the
Related information
inlet manifolds between air filters and engines.
Air cleaners engine 1 and engine 2:

With clogged air filter(s) the following problems occur:
– Loss in rated engine power
– Poor exhaust emission quality
Problem that appears – Increased fuel consumption
on the machine
– Increased exhaust gas temperature
– Reduced engine lifetime
REMARKS: If machines are operated at locations higher than 3600 m, they sooner will be affected
by the above mentioned effects, even though the system does not yet display any
trouble message.
Nominal
value
Main key switch 20S001 OFF – Engines 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 Example:
(inner and outer Weight of a new air filter element: approx. 9 kg
elements) Weight of a clogged air filter element: approx. 20 kg
– The replacement interval depends on the respective environmental

conditions. Always monitor the engine air filter elements according to
your local operations conditions.
– After every 2nd replacement of the outer engine air filter elements the
inner air filter elements must be replaced too.
– The air filter box must be cleaned thoroughly after the period of
every 1000 operating hours.
Go to final step 2.
Final check 2
7 - 164 PC5500-6 TS 15110-upD-GB-0

View onto the engine air cleaners (G00164 & G00198)

[2/2]
Fig. 7-85 View onto the engine air cleaners (G00164 & G00198)
(1) Air cleaner housing (5) Gasket
(2) Inner filter element (6) Safety clip
(3) Maintenance indicator (7) Wing nut
(4) Outer filter element
TS 15110-upD-GB-0 PC5500-6 7 - 165

G00165 - Trouble breather filter hydraulic oil tank

[1/2]
Trouble code
Message Trouble breather filter hydraulic oil tank
G00165
– The trouble message is displayed if sensor 40B024 (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 the hydraulic oil tank is not overfilled
when the machine is in its defined position.
– consider the dependency on the temperature
range.

Final check 2
7 - 166 PC5500-6 TS 15110-upD-GB-0

Sight glass, hydraulic oil temperature information, and defined positions (G00165)
[2/2]
Fig. 7-86 Sight glass, hydraulic oil temperature information, and defined positions (G00165)
(1) Hydraulic oil tank (3) Label with temperature information
(2) Sight glass (4) Defined positions
TS 15110-upD-GB-0 PC5500-6 7 - 167

G00166 - Trouble oil filter gear (PTO 1)

[1/2]
Trouble code G00166 - Trouble oil filter gear (PTO 1)
Message
G00166 & G00191 G00191 - Trouble oil filter gear (PTO 2)
Pressure sensors 57B027-1 & 57B027-2 (NO*) signal, that the filter for the PTO (1 or 2)
Contents of trouble gear lubrication system is clogged.
*NO = Normally Open
– A problem with pressure sensor 57B027-1 or 57B027-2 or the belonging wiring (G00151/
G00193) 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
Related information
reached 67°C.

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 - Engines OFF - Maintenance safety switch
50S058 OFF & locked
Replace the filter
element if necessary.
The PTO (1 or 2) gear
1 Screw off the concerned filter case and check If the filter element was
oil filter is clogged Yes
for clogging. clogged check the
Is the filter element clogged? PTO lubrication pump
for wear.
No Go to next step.
50S058 OFF & locked
Pressure sensor The concerned pressure sensor has an internal stuck in
57B027-1 or 57B027-2 2 closed position. Remove the sensor and replace it by a
is defective Go to final step 3.
new one.
After that recheck the system for proper function.
Final check 3
7 - 168 PC5500-6 TS 15110-upD-GB-0

View onto the pressure sensors 57B027-1 & 57B027-2 (G00166/G00191)

[2/2]
Fig. 7-87 View onto the pressure sensors 57B027-1 & 57B027-2 (G00166/G00191)
TS 15110-upD-GB-0 PC5500-6 7 - 169

G00169 - Trouble return oil filter hydraulic oil tank

[1/1]
Trouble code
Message Trouble return oil filter hydraulic oil tank
G00169
– Pressure sensor 40B163 signals, that the back pressure in the return oil filter is higher than
Contents of trouble 2 bar.
– The system assumes that sensor 40B163 and the respective wiring are not defective.
– The Qmin / Qmax setting via KOMTRAX Plus must be in position AUTOMATIC.
Sample
Related information T3 67°C
Tactual 45°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 - 170 PC5500-6 TS 15110-upD-GB-0

G00170 - Trouble leak oil filter hydraulic oil tank

[1/1]
Trouble code
Message 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 2 bar.
Sample
Related information T3 67°C
Tactual 45°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
2 The pressure sensor has an internal stuck.
40B164 is defective
Remove the sensor and replace it by a new one. Go to final step 3.
Final check 3
TS 15110-upD-GB-0 PC5500-6 7 - 171

G00176 - Trouble battery voltage too low

[1/3]
Trouble code
Message Trouble battery voltage too low
G00176
Contents of trouble Via the resistor 11T080 the system detects too low battery voltage.
– If the battery voltage at 11T080 is <=18 V for 5 seconds, the trouble code is set.
– The system assumes that the resistor 11T080 and its wiring is not defective, 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
An alternator is Using a multimeter measure the charging Yes Go to next step. min. 27.5V
defective voltage at terminal B of the shunt resistor max. 29.5V
1
71T003. Replace the faulty
52G005-1 or 52G005-2
Does the charging voltage meet the alternator and recheck
No
specification? for proper charging
voltage.
Using a multimeter measure the charging Vcharge
voltage at each alternator, between alternator Yes Go to next step. min. 27.5V
terminal B+ and chassis (body ground). max. 29.5V
Also see the charging voltage value which is
displayed on the KOMTRAX Plus Monitor:
REAL TIME MONITOR
Screen 1/3
The shunt resistor

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

specification?
7 - 172 PC5500-6 TS 15110-upD-GB-0

G00176 - Trouble battery voltage too low

[2/3]
Nominal
value
Check the clamps at
Battery information the battery poles for
proper contact and
Battery Function Location
Any battery is defective secure fixation.
(or batteries) 71G001 VBATTERY
Yes In case of any poor min. 10V
71G002 condition, rework the max. 12V
Battery charging affected battery pole
REMARKS: 71G003
If the machine is Cat walk and reconnect clamps
not equipped with 3 71G004 which are not fixed
maintenance-free correctly.
71G008
batteries, first check Stabilized voltage
71G009
the battery acid level
and correct if Replace any defective
necessary. battery/batteries
Disconnect each battery and measure the No
according to your
battery voltage. local regulations.
Does the voltage of each battery meet the
specification?
Final check 4
TS 15110-upD-GB-0 PC5500-6 7 - 173

Wiring diagram (batteries) for trouble code G00176

[3/3]
Fig. 7-88 Wiring diagram (batteries) for trouble code G00176
7 - 174 PC5500-6 TS 15110-upD-GB-0

G00177 - Trouble battery charging circuit

[1/2]
Trouble code
Message Trouble battery charging circuit
G00177
– The system detected at 51T017 that the batteries are charged even the engines are standing
still.
Contents of trouble
– At the shunt resistor 71T003 a charging current of more than 4 A is detected while the engines
are standing still.
Related information – Also see the charging current on the REAL TIME MONITOR (07 Electrical Equipm. screen 1/3)

---
on the machine
Nominal
value
The shunt resistor Main key switch 20S001 ON - Engines 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. 7-89 on reading is above 4A,
mixed up page 7-176. 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 par-
the battery cables are RShunt
mixed up or damaged ticular batteries, between the starter motors, and between the alternators
4.5±0.5Ω
and 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
(a) If necessary, repair
– 51T017 ground connections
or replace the wir-
– Signal line between 51T017 and node 17, ing/connections of
connector 2, pin 7 51T017.
Wiring dia-
– Shielding of the signal line (b) If the function
Module 51T017 or its gram
3 of 51T017 is not
wiring is defective – Wiring between 51T017 and 71T003 Conver-
according to the
– Shielding of the wiring to 71T003 conversion chart, sion chart
(b) Check the converter module according to the follow- replace the con-
ing voltages: verter module.
– Input -150 mV output 0 V Finally go to step 4.
– Input 0 mV output 6 V
– Input +150 mV output 10 V
Final check 4
TS 15110-upD-GB-0 PC5500-6 7 - 175

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

[2/2]
Fig. 7-89 Wiring diagram (measuring points 1-4) for trouble code G00177
7 - 176 PC5500-6 TS 15110-upD-GB-0

G00178 - Trouble battery charging current too high

[1/2]
Trouble code
Message Trouble battery charging current too high
G00178
The system detected at 51T017 that the charging current from the alternators via the shunt resistor
Contents of trouble
71T003 is too high (higher than 200A).
Related information – Also see the charging current on the REAL TIME MONITOR (07 Electrical Equipm. screen 1/3)

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 faulty alternator(s).

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
(a) If necessary, repair
– 51T017 ground connections
or replace the wir-
– Signal line between 51T017 and node 17, ing/connections of
connector 2, pin 7 51T017.
Wiring dia-
– Shielding of the signal line (b) If the function
Module 51T017 or its gram
3 of 51T017 is not
wiring is defective – Wiring between 51T017 and 71T003 Conver-
according to the
– Shielding of the wiring to 71T003 conversion chart, sion chart
(b) Check the converter module according to the follow- replace the con-
ing voltages: verter module.
– Input -150 mV output 0 V Finally go to step 4.
– Input 0 mV output 6 V
– Input +150 mV output 10 V
Final check 3
TS 15110-upD-GB-0 PC5500-6 7 - 177


[2/2]
7 - 178 PC5500-6 TS 15110-upD-GB-0

G00179 - Trouble control pressure X1-1

[1/2]
Trouble code G00179 - Trouble control pressure X1-1 (XLR)
Message
G00179 & G00182 G00182 - Trouble control pressure X1-2 (XLR)
– The message is displayed if the pump regulation pressure X1-1 or X1-2 is too high.
Contents of trouble
– The system assumes that the monitoring circuits for the X1 pressure(-1 & -2) is not disturbed.
The pressure sensor 57B085-1 or 57B085-2 detected a pressure of more than 40 bar during
Related information
2 seconds.

A too high X1 pressure (-1 or -2) affects the pump regulation adversely (high stall speed).
on the machine
Nominal
value
Thydr.oil
Engines running at high idle & operation temperature.
>=60°C
Connect pressure gauges (0-60 bar) to the Yes Go to next step.
test ports port M20-1 (engine 1) or M20-2
Replace the faulty
(engine 2) at the control & filter panel. pressure sensor
REMARKS: Make sure the change-over 57B085-1 or
The X1-1 or X1-2
1 valve (79.1/.2) is in position 57B085-2.
pressure is too high
"E – electronic pump regula- Verify that trouble code
No
tion mode". G00179 or G00182
Measure the pump regulation pressure X1-1 is not set again.
and X1-2. If the repair was
Is the X1 pressure (-1 or -2) too high successful, go to
(above 40 bar)? final step 3.
Refer to the SERVICE MANUAL, section ELEC-

After successful
Wrong X1-1 or X1-2 TRONIC LOAD LIMIT REGULATION, XLR
2 adjustment go to
pressure adjustment BASIC ADJUSTMENT and follow the adjustment final step 3.
procedures for the X1 pressure (-1 & -2).
Final check 3
TS 15110-upD-GB-0 PC5500-6 7 - 179

The adjustment of the X1-pressure with two different methods (G00179 & G00182)
[2/2]
Fig. 7-91 The adjustment of the X1-pressure can be done with two different methods
A Adjustment method with 24 V B Adjustment method with BODAS software
7 - 180 PC5500-6 TS 15110-upD-GB-0

G00180 - Trouble pilot pressure X2 too low

[1/2]
Trouble code
Message Trouble pilot pressure X2 too low
G00180
– The message is displayed if the pilot pressure X2 is too low.
Contents of trouble
– The system assumes that the monitoring circuit for the X2 pressure is not disturbed.
– 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 arm is extended, the X2 pressure is disabled.

A too low X2 pressure affects the hydraulic system adversely.
on the machine
Nominal
value
Thydr.oil
>=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 low pressure test port M3 at the control & filter
panel and measure the pilot pressure X2. Verify that trouble code
G00180 is not set
Is the X2 pressure too low (below 30 bar)? No
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 15110-upD-GB-0 PC5500-6 7 - 181

Rear control & filter panel with X2 pressure sensor 57B086 & M3
[2/2]
Fig. 7-92 Rear control & filter panel with X2 pressure sensor 57B086 & M1.2
7 - 182 PC5500-6 TS 15110-upD-GB-0

G00181 - Trouble pilot pressure X2 too high

[1/2]
Trouble code
Message Trouble pilot pressure X2 too high
G00181
– The message is displayed if the pilot pressure X2 is too high.
Contents of trouble
– The system assumes that the monitoring circuit for the X2 pressure is not disturbed.
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
Thydr.oil
>=60°C
X2 pressure
45±2bar
Replace the pressure
The X2 pressure Connect a pressure gauge (0-60 bar) to the sensor 57B086.
1
is too high pressure test port M3 at the control & filter Verify that trouble code
panel and measure the pilot pressure X2. G00181 is not set
No
Is the X2 pressure too high (above 52 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 15110-upD-GB-0 PC5500-6 7 - 183

Rear control & filter panel with X2 pressure sensor 57B086 & M3
[2/2]
Fig. 7-93 Rear control & filter panel with X2 pressure sensor 57B086 & M1.2
7 - 184 PC5500-6 TS 15110-upD-GB-0


G00183 - Trouble pump support pressure X4-1

[1/4]
Trouble code G00183 Trouble pump support pressure X4-1
Message
G00183 & G00195 G00195 Trouble pump support pressure X4-2
Pressure sensor 57B097-1 or 57B097-2 (NC*) signals, that there is no pressure in the
Contents of trouble concerned pump support pressure circuit, even the engines are running.
*NC = Normally Closed

REAL TIME MONITOR
Signal
Related information
Switch point 24 bar

Machine operation is not possible due to missing pump support pressure.
on the machine
Nominal
value
Refer to the SERVICE MANUAL, chapter 8,
section PILOT PRESSURE SUPPLY AND Carry out adjustments
No pump support
ADJUSTMENTS and follow the given informa- as necessary.
pressure present 1
(X4-1 or X4-2) tion and instructions. No After that recheck if the
Are the pressure adjustments as specified? pump support pressure
is in normal range.
The solenoid valve Verify if the electrical function of the solenoid
57K602-1 or 57K602-2 valves is OK. Replace the defective
2 solenoid valve and
has got an electrical Is the electrical function of both solenoid No
problem verify that the X4
valves OK?
pressure is OK.
If the electrical function is OK, check the Yes
mechanical function of the solenoid valves:
If the measured X4
The solenoid valve 1. Remove the pressure switch. pressure is not 60 bar
57K602-1 or 57K602-2 replace the defective
3 2. Screw on a Minimess adapter.
has got a mechanical No solenoid valve.
problem 3. Run the engines at high idle. Verify that the X4
4. Measure the X4 pressure behind the pressure is OK after
solenoid valve. repair.
Final check 4
TS 15110-upD-GB-0 PC5500-6 7 - 185

Wiring Diagram (57B097-1 & 57B097-2) for G00183 & G00195

[2/4]
Fig. 7-94 Wiring Diagram (57B097-1 & 57B097-2) for G00183 & G00195
Input signals of 57K602-1 & 57K602-2 on the REAL TIME MONITOR for G00183 & G00195
Fig. 7-95 Input signals of 57K602-1 & 57K602-2 on the REAL TIME MONITOR
7 - 186 PC5500-6 TS 15110-upD-GB-0

Wiring Diagram (57K602-1 & 57K602-2) for G00183 & G00195

[3/4]
Fig. 7-96 Wiring Diagram (57K602-1 & 57K602-2) for G00183 & G00195
TS 15110-upD-GB-0 PC5500-6 7 - 187

Locations 57B097-1 / 57B097-2 & 57K602-1 / 57K602-2 for G00183 & G00195
[4/4]
Fig. 7-97 Locations 57B097-1 / 57B097-2 & 57K602-1 / 57K602-2 for G00183 & G00195
7 - 188 PC5500-6 TS 15110-upD-GB-0

G00184 - Central lubrication system empty

G00187 - Slew ring gear lubrication system empty
G00201 - Attachment lubrication system empty
[1/3]
Trouble code G00184 - Central lubrication system empty
G00184 & G00187 Message G00187 - Slew ring gear lubrication system empty
& G00201 G00201 - Attachment lubrication system empty
Contents of trouble The message is displayed if the corresponding grease barrel needs refilling.
– Sonar type sensors: 62B108 CLS 1 62B109 SLS 62B173 CLS 2

– The sensing range of the sonar type grease level sensors 62B108 & 62B109 & 62B173
is preadjusted ex factory. Further settings are not possible.
– For more information about the ultrasonic grease level sensors 62B108 & 62B109 & 62B173
also refer to the PARTS & SERVICE NEWS AH10510, latest version.
– Binary type sensors: 62B108c CLS 1 62B109c SLS 62B112c CLS 2
(A) Level sensor - full
(B) Level sensor - pre-warning 5%
(C) Level sensor - empty
Related information
Fig. 7-98 Binary level sensors

Action of controller – 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.
TS 15110-upD-GB-0 PC5500-6 7 - 189

G00184 - Central lubrication system empty

[2/3]
Nominal
value
Press the cancel
button and refill the
specified grease.
Using the dipstick, verify if the relating grease
Yes Verify that trouble code
barrel needs refilling.
G00184 or G00187 or
Is the grease barrel empty? G00201 is not
displayed again.
No Go to next step.
Definition of the grease level sonar type sensors:
The concerned grease

barrel needs refilling 1
(CLS 1 or SLS or CLS 2)
Fig. 7-99 Left - sonar type sensors / right - binary type sensors
The grease barrels may be equipped either Yes Go to final step 3.
with sonar type sensors or with binary type
sensors.
Refer to the trouble code description
The trouble message is G00012 / G00013 / G00202 for: Verify if other relevant
wrong. The concerned trouble codes are
– Information about the LEDs at the sonar
grease barrel doesn’t displayed.
2 type sensor
need refilling No If so, follow the trouble-
– Testing the sonar type sensor reaction shooting procedures
(CLS 1 or SLS or CLS 2)
– Calibration of the binary type sensor for the corresponding
– Troubleshooting procedures for the resp.
sensor type
Final check 3
7 - 190 PC5500-6 TS 15110-upD-GB-0

Grease level (CLS 1 & SLS & CLS 2) on the REAL TIME MONITOR
[3/3]
Fig. 7-100 Grease level (CLS 1 & SLS & CLS 2) on the REAL TIME MONITOR
TS 15110-upD-GB-0 PC5500-6 7 - 191

G00185 - Trouble central lubrication system

G00188 - Trouble slew ring gear lubrication system
G00203 - Trouble attachment lubrication system
[1/5]
Trouble code G00185 - Trouble central lubrication system
G00185 & G00188 Message G00188 - Trouble slew ring gear lubrication system
& G00203 G00203 - Trouble attachment lubrication system
Contents of trouble The grease pressure increase time (CLS 1- SLS - CLS 2) is too long (>10 minutes).
– It is not possible to build up the grease pressure (CLS 1/2 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
the pressure holding time is automatically reduced to 15 seconds if:
Action of controller – Service level, REAL TIME MONITOR for CLS 1 or SLS or CLS 2 is selected
– Manual lube cycle is started via 20S124 or 20S126 or 20S099
Problem that appears – Risk, to run the machine without CLS 1/2 or SLS lubrication.
Nominal
value
Qvolume
16-19
Check the performance of the relating grease double-
pump (CLS 1 - SLS - CLS 2) and arrange strokes/
preparations for testing the grease pressure. min
Grease pump:
For detailed test & adjustment procedures Yes Go to next step. Ppump drive
- malfunction 1 refer to the SERVICE MANUAL, section hydr.press.
- worn LUBRICATION SYSTEMS. 45±2bar
- defective
Make sure that the belonging vent valve is PGrease
closed. max.
Does the relating grease pump build up grease 180+5bar
pressure as specified? 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 respective vent 2 vent valve solenoid.
Replace the faulty vent
valve is disturbed Is the electrical function ok? No
valve solenoid.
The problem is solved,
Refill the respective grease barrel through
The grease may Yes perform the final check
3 a filter.
be soiled in step 7.
Is grease pressure built up with clean grease?
No Go to next step.
Remove the mechanical part from the
Replace the faulty
electrical part of the respective vent valve. Yes
The mechanical vent valve.
function of the Disassemble and check the lower part and
4
respective vent clean as necessary.
valve is disturbed Is the mechanical part of the vent valve No Go to next step.
blocked?
7 - 192 PC5500-6 TS 15110-upD-GB-0


[2/5]
Nominal
value
Repair or replace the mechanical part of the respective
The mechanical part vent valve as necessary.
of the respective vent 5 Go to next step.
Clean the respective contaminated grease system.
valve is 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?
2. Start the machine and verify that the trouble code (G00185/G00188/G00203)
does not arise again.
Final check 7
3. Verify that the operation cycles of the lubrication systems correspond to
the following Action chart for lube cycles (taken from the flowchart),
refer to Fig. 7-101 on page 7-194.
Allocation of vent valves and end-of-line switches

System Solenoid valve Vent valve End-line switch
SLS 62Q509 62Q509a 62B046
CLS1 62Q507 62Q507a 80B043
CLS2 62Q642 62Q642a 60B043
TS 15110-upD-GB-0 PC5500-6 7 - 193

Action chart for lube cycles

[3/5]
Lubrication system Vent valve

CLS 1 62Q507a
SLS 62Q509a
CLS 2 62Q642a
Fig. 7-101 Action chart for lube cycles
7 - 194 PC5500-6 TS 15110-upD-GB-0

View onto the vent valve (62Q507a - 62Q509a - 62Q642a)

[4/5]
Fig. 7-102 View onto the vent valve (62Q507a - 62Q509a - 62Q642a)
(1) Solenoid (5) Reset spring
(2) Valve assembly (6) Auxiliary valve cone
(3) Solenoid stem (7) Main valve cone
(4) Lever
TS 15110-upD-GB-0 PC5500-6 7 - 195

Wiring diagram (60B043/62B046/80B043) for trouble codes G00185/G00188/G00203

[5/5]
Fig. 7-103 Wiring diagram (60B043/62B046/80B043) for trouble codes G00185/G00188/G00203
7 - 196 PC5500-6 TS 15110-upD-GB-0


[1/3]
Trouble code G00186 - Trouble central lubrication system
G00186 & G00189 & Message G00189 - Trouble slew ring gear lubrication system
G00204 G00204 - Trouble attachment lubrication system
Contents of trouble The grease pressure decrease time (CLS 1or SLS or CLS 2) is too long (>4 minutes).
– It is not possible to release the grease pressure (CLS 1/2 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
the pressure holding time is automatically reduced to 15 seconds if:
Action of controller – Service level, REAL TIME MONITOR for CLS 1 or SLS or CLS 2 is selected
– Manual lube cycle is started via 20S124 or 20S126 or 20S099
Problem that appears – Risk, to run the machine without CLS 1/2 or SLS lubrication.
Nominal
value
Check the electrical function of the respective Yes Go to next step.
vent valve solenoid and its wiring. – Locate the prob-
lem and repair or
replace the faulty
The electrical function component of the
of the respective vent 1 wiring as
valve is disturbed No
necessary.
– Replace the faulty
vent valve sole-
Is the electrical function ok? noid if necessary.
1. Remove the mechanical part from the electrical part
of the respective vent valve.
The mechanical part 2. Disassemble and check the lower part and clean
of the respective as necessary.
2 Go to next step.
vent valve is blocked
or defective 3. If it is necessary repair or replace the mechanical
part.
4. Clean the respective contaminated grease system.
2. Start the machine and verify that the trouble code (G00186/G00189/G00204)
does not arise again.
Final check 3
3. Verify that the operation cycles of the lubrication systems correspond to the
following Action chart for lube cycles (taken from the flowchart),
refer to Fig. 7-104 on page 7-198.
TS 15110-upD-GB-0 PC5500-6 7 - 197

Action chart for lube cycles

[2/3]
Fig. 7-104 Action chart for lube cycles
7 - 198 PC5500-6 TS 15110-upD-GB-0

View onto the vent valve (62Q507a - 62Q509a - 62Q642a)

[3/3]
Fig. 7-105 View onto the vent valve (62Q507a - 62Q509a - 62Q642a)
(1) Solenoid (5) Reset spring
(2) Valve assembly (6) Auxiliary valve cone
(3) Solenoid stem (7) Main valve cone
(4) Lever
TS 15110-upD-GB-0 PC5500-6 7 - 199


Refer to the troubleshooting procedure G00184 / G00187 / G00201 on page 7-189.











7 - 200 PC5500-6 TS 15110-upD-GB-0


G00207 - Engine remote oil tank 1 empty

G00208 - Engine remote oil tank 2 empty
[1/1]
Trouble code G00207 - Engine remote oil tank 1 empty
Message
G00207 & G00208 G00208 - Engine remote oil tank 2 empty
– Sensors 63B103-1 and 63B103-2 in the remote engine oil tanks signal, that the respective tank
is nearly empty.
Contents of trouble
– The system assumes that the level sensors 63B103-1 and 63B103-2 in the remote engine oil
tanks or the wiring of these monitoring circuits are not defective.
The remote engine oil tanks are part of the engine oil management system.
Related information
REMARKS: The remote engine oil tanks are also equipped with oil level sight gauges.
Action of controller – Message delay time = 2 minutes
– Acoustic signal in the cab ON.
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 respective 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 respective engine If the engine oil consumption considerably exceeds the specification,
remote oil tank is contact the Cummins service.
empty
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 15110-upD-GB-0 PC5500-6 7 - 201

G00216 - Trouble software not compatible

[1/2]
Trouble code
Message 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 sample from CoDeSys HMI:
Fig. 7-106 CoDeSys HMI Visualization software
(1) Information only

(2) Information only
(3) KOMTRAX-Plus controller software and monitor software are compatible (1 = 1)
(4) KOMTRAX-Plus controller and MTC are compatible (1 = 1)
(5) KOMTRAX-Plus controller software and MTC software are compatible (1 = 1)
(6) Monitor software and MTC software configuration are not compatible in this sample (0 = 1)
(7) Monitor software 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.
---
on the machine
7 - 202 PC5500-6 TS 15110-upD-GB-0

G00216 - Trouble software not compatible

[2/2]
Nominal
value
Troubleshooting procedure according to Fig. 7-106 on page 7-202:
1. Connect your laptop with CoDeSys HMI software to the MTC.
2. Check the machine configuration according to your configuration file (pdf),
which is stored in the MTC.
Machine configuration
1 3. Correct the setting for machine configuration.
setting is wrong
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 15110-upD-GB-0 PC5500-6 7 - 203

G00218 - Switch off all motors for running transfer pump

[1/1]
Trouble code
Message 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 engines are running.
For operation instructions of the transfer pump refer to the OPERATION & MAINTENANCE
Related information
MANUAL section 3.19.
As long as the engines are running, it is not possible to switch ON the transfer pump.
on the machine
7 - 204 PC5500-6 TS 15110-upD-GB-0

G00220 - Trouble transfer pump motor overheated

[1/2]
Trouble code
Message 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 TRANSFER PUMP FOR HYDRAULIC OIL.
If 40B111 switched the transfer pump OFF, the oil transfer process can not be continued.
on the machine
Nominal
value
Engines 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 15110-upD-GB-0 PC5500-6 7 - 205

Wiring diagram (transfer pump) for trouble code G00220

[2/2]
Fig. 7-107 Wiring diagram (transfer pump) for trouble code G00220
7 - 206 PC5500-6 TS 15110-upD-GB-0

G00221 - Trouble slew direction module defect

[1/2]
Trouble code
Message Trouble slew direction module defect
G00221
Contents of trouble – The system detected a wrong input or output signal or the module setting (11B142) is wrong.
– The failure also occurs if the wiring of 11B142 is installed in a wrong way (interchanged).
– Sensors 60B098 / 60B099 may be defective or the adjustment is wrong.
Related information – For a function test refer to the REAL TIME MONITOR:
06 Slew
Sub-screen 1/2
Very slow slew speed because there is no slew speed regulation.
on the machine
Nominal
value
Check the setting/parameters at the module. Yes Go to next step.
Slew direction module For detailed information on the slew direction
11B142 defective or 1 module 11B142 refer to the SERVICE MAN- Correct the settings
wrong setting UAL, section 11 Operating Hydraulic and to and recheck the slew
No
the Wiring Diagram. monitoring system for
proper function.
Are the settings OK?
Wrong wiring
connection at the Refer to the Wiring Diagram and check the Correct the wiring
2 connection and
slew direction module wiring of 11B142.
11B142 No recheck the slew
Is the wiring OK?
monitoring system
1. Refer to the SERVICE MANUAL, Yes Go to final step.
Proximity switch(es) section 11 Operating Hydraulic for details.
60B089 & 60B099
3 2. Check function and adjustment of the prox- Replace the slew
defective or wrong
imity switches. No direction module
adjustment
3. Readjust the switch(es) if necessary. 11B142.
Is the slew monitoring system OK?
Final check 4
Legend for Fig. 7-108 (next page):
(1) Setting parameters for 11B142 - shown in 60B098 Proximity switch - sensing left swing
the Wiring Diagram direction
11B142 Slew direction module 60B099 Proximity switch - sensing right swing
direction
TS 15110-upD-GB-0 PC5500-6 7 - 207

Slew direction module 11B142 for trouble code G00221

[2/2]
Fig. 7-108 Slew direction module 11B142
7 - 208 PC5500-6 TS 15110-upD-GB-0

G00223 - Trouble starter control 51K001a-1

G00225 - Trouble starter control 51K001b-1
[1/1]
Trouble code G00223 - Trouble starter control 51K001a-1
G00223 & G00225 Message
G0025 & G00229 G00229 - Trouble starter control 51K001b-2
– This message is displayed if the electronic relay 51K001a-1 / 51K001a-2 or its wiring is defec-
tive (relay check).
Contents of trouble
– The troubleshooting procedure for the redundant relay 51K001b-1 and 51K001b-2 is analo-
gously.
If relay 51K001a-1 or 51K001b-1 / 51K001a-2 or 51K001b-2 or its wiring is defective, the electric
Related information circuit is interrupted and the function (starter) is no longer available.
REMARKS: The trouble code is only displayed once during one "Key switch ON" period.
The function (starter) is not available.
on the machine
for G00223/G00225/G00227/G00229, refer to section 5.3.1 on page 5-7.
– Refer to the wiring diagram and check for 51K001a-1/51K001b-1 and 51K001a-2/51K001b-2.
01 Engine 1 Sub-screen 6/6
51K001a-1/-2 & 51K001b-1/-2 (relay check) on the REAL TIME MONITOR
Fig. 7-109 51K001a-1/-2 & 51K001b-1/-2 (relay check) on the REAL TIME MONITOR
TS 15110-upD-GB-0 PC5500-6 7 - 209

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
G00224 & G00226 Message
G00228 & G00230 G00230 - Trouble starter control Output to 51K001b-2
– This message is displayed if the wiring between node output and solenoid (via relay
Contents of trouble 51K001a-1 / 51K001a-2) is interrupted (output check).
– The troubleshooting procedure for the redundant relay 51K001b-1 / 51K001b-2 is analogously.
– If the connection between node output and solenoid is faulty, the function (starter)
REMARKS: The trouble code is displayed at each trouble occurrence.
The function (starter) is not available.
on the machine
– Use the troubleshooting chart of G00108/G00110 as a guideline for troubleshooting of Output Check for G00224/G00226/
G00228/G00230, refer to section 5.3.2 on page 5-12.
– Refer to the wiring diagram and check for 51K001a-1/51K001b-1 and 51K001a-2/51K001b-2.
51K001a-1/-2 & 51K001b-1/-2 (output check) on the REAL TIME MONITOR
Fig. 7-110 51K001a-1/-2 & 51K001b-1/-2 (output check) on the REAL TIME MONITOR
7 - 210 PC5500-6 TS 15110-upD-GB-0


Refer to the troubleshooting procedure G00223 / G00225 / G00227 / G00229 on page 7-209.





TS 15110-upD-GB-0 PC5500-6 7 - 211

G00231 - Trouble pilot control lever 20S019

G00232 - Trouble pilot control lever 20S020
[1/3]
Trouble code G00231 - Trouble pilot control lever 20S019
Message
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:
REAL TIME MONITOR
16 Pilot control
Screen 4/5

gram.
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
final step 2.
Hand lever conditions:
Indication Voltage Hand lever

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

Final check 2
7 - 212 PC5500-6 TS 15110-upD-GB-0


[2/3]
TS 15110-upD-GB-0 PC5500-6 7 - 213


[3/3]
7 - 214 PC5500-6 TS 15110-upD-GB-0

G00233 - Trouble pilot control 11Q045

[1/2]
Trouble code
Message 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.

Action of controller – Message G00330 "Trouble pilot control 11Q111" may also be displayed if G00233 is set.
Pilot control is inoperative.
on the machine
Nominal
value
gram.
Visually check the power relay 11Q045.
Visually inspect the
Standard conditions of the LEDs:
Relay 11Q045 or its relay and its wiring.
1 LED yellow ON OK
wiring is defective Repair the wiring
LED red ON OK (contacts closed) 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
TS 15110-upD-GB-0 PC5500-6 7 - 215

Wiring diagram (11Q045) for trouble code G00233

[2/2]
Fig. 7-113 Wiring diagram (11Q045) for trouble code G00233
7 - 216 PC5500-6 TS 15110-upD-GB-0

G00234 - Trouble pilot control 11K111a

G00236 - Trouble pilot control 11K111b
[1/1]
Trouble code G00234 - Trouble pilot control 11K111a
Message
G00234 & G00236 G00236 - Trouble pilot control 11K111b
Contents of trouble
Related information
function (pilot control) is no longer available.
REMARKS: G00234/G00236 is displayed at each trouble occurrence.
The function (pilot control) is not available.
on the machine
16 Pilot control
Sub-screen 5/5
TS 15110-upD-GB-0 PC5500-6 7 - 217

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
Message
G00235 & G00237 G00237 - Trouble pilot control Output to 11K111b
– If the connection between node output and solenoid is faulty, the function (pilot control)
REMARKS: G00235/G00237 is displayed at each trouble occurrence.
on the machine
16 Pilot control
Sub-screen 5/5
7 - 218 PC5500-6 TS 15110-upD-GB-0

G00236 - Trouble pilot control 11K111b

G00237 - Trouble pilot control Output to 11K111b.

TS 15110-upD-GB-0 PC5500-6 7 - 219

G00238 - Trouble supply by key switch 11Q044

[1/2]
Trouble code
Message 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
11Q044 or its wiring is 1. Check if contacts 88b and 88y at 11Q044 are
1 or
defective closed (fault, contacts welded together).
Repair the wiring as
2. Verify if 24V are present at node #2, connec-
necessary
tor 7, pin 5 (fault, short circuit).
Final check 2
Input signal of 11Q044 on the REAL TIME MONITOR (G00238)
Fig. 7-116 Input signal of 11Q044 on the REAL TIME MONITOR (G00238)
Monitoring result = OK if 11Q044 indication on the REAL TIME MONITOR = 0

Monitoring result = Fault if 11Q044 indication on the REAL TIME MONITOR = 1
7 - 220 PC5500-6 TS 15110-upD-GB-0


[2/2]
TS 15110-upD-GB-0 PC5500-6 7 - 221


[1/1]
Trouble code
Message 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 engines are 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.
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).
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
Engines running at low idle.
1. Start to warm-up the hydraulic oil by running the engines at low idle or by pre-heating.
2. As soon as the hydraulic oil temperature T1 is reached, the trouble message G00240 is no lon-
ger displayed.
3. Continue warming-up until the hydraulic oil operating temperature T2 is reached.
4. If it is a problem to warm-up the hydraulic oil up to the operating temperature T2, check the set-
ting for the hydraulic oil specification in the service mode of KOMTRAX Plus.
5. Also verify that the correct type of hydraulic oil is used (according to the ambient temperature).
6. In case the setting for the hydraulic oil in KOMTRAX Plus would be wrong, correct the setting
The hydraulic oil according to the specification of the used hydraulic oil.
temperature (< T1) is
far below the operating Hydraulic oil temperature table
temperature (T2)
7 - 222 PC5500-6 TS 15110-upD-GB-0

G00242 - Engine 1 already running

[1/1]
Trouble code G00242 - Engine 1 already running
Message
G00242 & G00248 G00248 - Engine 2 already running
Contents of trouble This message informs the operator that the respective engine is already running.
After this message is displayed, every further start of the respective engine is blocked as long as
Related information
the engine is still running.

--
on the machine
Instruction message 22 Engine runs (starter motor inactive).
TS 15110-upD-GB-0 PC5500-6 7 - 223

G00243 - Fill up fuel tank

[1/1]
Trouble code
Message Fill up fuel tank
G00243
– The fuel tank sensor 31B063 indicates that the fuel is on minimum level.
Contents of trouble
– The system assumes that the fuel tank sensor 31B063 and its wiring circuit are not defective.
Related information ---

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 OPERATION & MAINTENANCE MANUAL. Do not overfill.
Information for Diesel fuel specifications

For the Diesel fuel specifications refer to the Cummins Operation &
The fuel tank Maintenance Manual QSK38 Series Engines,
is nearly empty 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.
7 - 224 PC5500-6 TS 15110-upD-GB-0

G00245 - Engine shutdown from ground

[1/2]
Trouble code
Message Engine shutdown from ground
G00245
– Machine configuration "Engine shutdown from ground" is selected.
– The engines were stopped from the ground manually via switch 54S007 and/or 54S008.
Contents of trouble
– The engines were stopped from the ground manually via switch 54S051 and/or 54S052
(option).
– If switch 54S007 or 54S008 (optional 54S0051 or 54S0052) is activated from ground while the
engines are running, the engines shut down.
Related information
– After switch 54S007 or 54S008 (optional 54S0051 or 54S0052) has been activated from ground
under condition "Engines OFF & main key switch 20S001 ON", engine start is not possible.
– The MTC blinks out binary code 011011.
Problem that appears The engines are shut off and restart is not possible until switch 54S007, 54S008 resp. 54S0051,
on the machine 54S0052 is manually 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 is clarified, release
Was switch 54S007 and/or 54S008 manually switch 54S007 and/or
activated from ground? 54S008 (54S0051 and/
or 54S0052) and
restart the engines.
No Go to next step.
Switche(s) may have
been activated
Yes accidently.
Actuate switch 54S007/54S008 (54S0051/
Go to final step 3.
54S0052) and verify the input signal via
KOMTRAX Plus: Refer to the wiring dia-
No input signal on the gram. Check switch
KOMTRAX Plus 2 REAL TIME MONITOR
54S007/54S008 and
monitor (refer to Fig. 7-118 on page 7-226)
its wiring.
09 Manual Switch
Screen 4/4 Locate the problem
No
and repair as
Is the input signal of the switches displayed on
necessary.
the KOMTRAX Plus monitor?
After repair, recheck
switches for proper
function.
Final check 3
TS 15110-upD-GB-0 PC5500-6 7 - 225

Input signal of 54S007/51 & 54S008/52 on the REAL TIME MONITOR (G00245)
[2/2]
Fig. 7-118 Input signal of 54S007 & 54S008 on the REAL TIME MONITOR (G00245)
7 - 226 PC5500-6 TS 15110-upD-GB-0

G00246 - Hydraulic oil temperature

[1/1]
Trouble code
Message 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 engines are 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).
– 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 below operating temperature.
Operate with reduced power!
Nominal
value
ger displayed.
5. In case the setting for the hydraulic oil in KOMTRAX Plus would be wrong, correct the setting
according to the specification of the used hydraulic oil.
The hydraulic oil is
too cold - below the Hydraulic oil temperature table
operating temperature
(T2)

TS 15110-upD-GB-0 PC5500-6 7 - 227


[1/3]
Trouble code G00252 - Emergency shut-down at access ladder

G00252 ~ G00255 Message G00254 - Emergency shut-down at hydraulic control panel
& G00258 G00255 - Emergency shut-down in cabin
An emergency shut-down switch was activated while the engines were 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
51S033d Counterweight G00258
– The engines are shut off.

Related information
– Restart is impossible.
– - If any of the emergency shut-down switches was activated, message G00053 Reset emer-
gency safety circuit is also displayed. In order tor reset the emergency condition, move the main
key switch to OFF and wait until the MTC is totally shut down. Then turn the main key switch to
ON again.
Action of controller – The MTC blinks out a binary code:
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.
7 - 228 PC5500-6 TS 15110-upD-GB-0


[2/3]
Nominal
value
gram.
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 or
100000.
TS 15110-upD-GB-0 PC5500-6 7 - 229

Wiring diagram (emergency switches) for trouble codes G00252~G00255 & G00258
[3/3]
Fig. 7-119 Wiring diagram (emergency switches) for trouble codes G00252~G00255 and G00258

7 - 230 PC5500-6 TS 15110-upD-GB-0

G00256 - Operator warning system

[1/1]
Trouble code
Message Operator warning system
G00256
Contents of trouble Pull switch 54S007 or 54S008 in the area of the counterweight was operated from ground.
G00256 is an informational message.

Related information
This message informs the operator that e.g. anybody wants to enter the machine.
Action of controller Background colour of the K+ message: blue

--
on the machine
Instruction message 45 Operator warning system from ground level.
TS 15110-upD-GB-0 PC5500-6 7 - 231

G00257 - Hydraulic oil temperature

[1/1]
Trouble code
Message 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 engines are 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).
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
ger displayed.
3. Continue warming-up until the hydraulic oil operating temperature T2 is reached.
In case the setting for the hydraulic oil in KOMTRAX Plus would be wrong, correct the setting
The hydraulic oil according to the specification of the used hydraulic oil.
temperature (<T1) is
far below the operating Hydraulic oil temperature table
temperature (T2)
7 - 232 PC5500-6 TS 15110-upD-GB-0


Refer to the troubleshooting procedure G00252 / G00253 / G00254 / G00255 / G00258 on page 7-229.
G00261 - Maintenance Safety Switch

[1/2]
Trouble code
Message 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 and movements "Service arm down" and "Ladder
down" by gravitation are not possible..
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
TS 15110-upD-GB-0 PC5500-6 7 - 233


[2/2]

7 - 234 PC5500-6 TS 15110-upD-GB-0

G00262 - Trouble screen at hydr. cooler entry clogged

[1/3]
Trouble code
Message 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.
Contents of trouble The pressure difference represents 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.
– Acoustic signal ON.
Risk, to run the machine with insufficient cooling of the hydraulic oil.
on the machine
Nominal
value
Replace the faulty
pressure sensor
Pressure sensors Check the pressure sensors for proper
Yes and recheck the
40B166 & 40B165 may 1 function.
system 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 (05 Hydraulic)
Fig. 7-121 40B166 and 40B165 on the REAL TIME MONITOR (05 Hydraulic)
TS 15110-upD-GB-0 PC5500-6 7 - 235

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

[2/3]
Fig. 7-122 Location of 40B166 and 40B165 at the hydraulic oil tank
(1) Bolt (4) Gasket
(2) Gasket (5) Self locking nut
(3) Strainer
7 - 236 PC5500-6 TS 15110-upD-GB-0

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

[3/3]
Fig. 7-123 Wiring diagram (40B166 & 40B165) for trouble code G00262
TS 15110-upD-GB-0 PC5500-6 7 - 237

G00308 - Trouble CAN-Bus or CAN-Hardware

[1/4]
Trouble code
Message 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:
– Defective or disconnected end resistor (40R101 / 20R101).
Contents of trouble
– Wrong setting of the DIP switches at any node.
– Defective node unit (hardware / firmware).
– Intermittent fault at crimps or connector terminals.
To identify the trouble location in the CAN bus quickly, use the following alternative test methods in
order to receive essential details:
– Method 1
Open the REAL TIME MONITOR (KOMTRAX Plus)
Related information Screen 3/3
– Method 2
Binary blink codes at the MTC.
– Method 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 the following page:
– Troubleshooting procedure with "Method 1" on page 7-239.

REMARKS: 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 17.
7 - 238 PC5500-6 TS 15110-upD-GB-0


[2/4]
Method 1
Nominal
value
Troubleshooting on the basis of REAL TIME MONITOR
information.
Screen 3/3
1. With the help of

beside information,
locate the problem
in the CAN bus.
2. Start troubleshoot-
ing at the displayed
node, which is the
nearest affected
node to the MTC
Legend: (node 14 in this
Cable disconnection in example).
1 (1) CAN-NODE ERROR TYPE indications
the internal CAN bus
"0" No disconnection in the CAN bus OK 3. Repair as neces-
sary.
"1" Disconnection the CAN bus Fault
4. After repair, if nec-
"2" Short circuit in the CAN bus Fault
essary continue
troubleshooting at
(2) CAN-NODE NUMBER other indicated
In case of trouble in the CAN bus, the number of nodes which are
that node with problems is indicated, which is farther away from
nearest to the MTC. the MTC.
For the sequence of nodes in the CAN bus system 5. Repair as neces-
refer to section 5.2 on page 5-6.
sary
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.
TS 15110-upD-GB-0 PC5500-6 7 - 239


[3/4]
Method 2
Nominal
value
Troubleshooting by using the MTC blink codes.
For further information on the binary blink codes refer
to the OPERATION & MAINTENANCE MANUAL.
1. With the help of

This method is used if: beside information,
– KOMTRAX Plus is not updated and the REAL TIME locate the problem
MONITOR screen 3/3, which is used in step 1, is in the CAN bus.
not available.
2. Start troubleshoot-
– The KOMTRAX Plus monitor is OFF. ing at the displayed
node, which is the
nearest affected
node to the MTC
(node 14 in this
Cable disconnection in example).
1
3. Repair as neces-
sary.
4. After repair, if nec-
essary continue
troubleshooting at
other indicated
nodes which are
farther away from
the MTC.
5. Repair as neces-
Procedure:
sary
1. Read out the binary blink codes at the MTC.
2. Put the binary codes in the system order, according
to "Sequence of the CAN nodes at the CAN bus" on
page 5-6.
7 - 240 PC5500-6 TS 15110-upD-GB-0


[4/4]
Method 3

1. With the help of beside informa-
Troubleshooting on the basis of CoDeSys HMI tion, locate the problem in the
Visualization. CAN bus.
The following sample screen "AC01 overview 2. Start troubleshooting at the dis-
CANopen Bus" shows all nodes which are played node, which is the near-
Cable disconnection in disconnected from the CAN bus. est affected node to the MTC
1 (node 14 in this example).
(Fig. 7-124, Pos. 1) Trouble at node 14 (red marked)
3. Repair as necessary.
(Fig. 7-124, Pos. 2) Trouble at node 11 (red marked)
4. After repair, if necessary con-
(Fig. 7-124, Pos. 3) MTC location at the CAN bus
tinue troubleshooting at other
indicated nodes which are far-
Node 14 is closer to the MTC than node 11. ther away from the MTC.
5. Repair as necessary.
Fig. 7-124 Wiring diagram (40B166 & 40B165) for trouble code G00262
TS 15110-upD-GB-0 PC5500-6 7 - 241

G00309 - Trouble ladder up 56K253a

G00311 - Trouble ladder up redundant 56K253b
[1/1]
Trouble code G00309 - Trouble ladder up 56K253a
Message
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
– Use the troubleshooting chart of G00107/G00109 as a guideline for troubleshooting of Relay Check for G00309/G00311,
refer to section 5.3.1 on page 5-7.
14 Ladder
Sub-screen 4/5
7 - 242 PC5500-6 TS 15110-upD-GB-0

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
Message
G00310 & G00312 G00312 - Trouble ladder up redundant Output to 56K253b
put) follow the troubleshooting procedure for G00043 first.
Related information
– If the connection between node output and solenoid is faulty, the function (pilot control)
on the machine
– Use the troubleshooting chart of G00108/G00110 as a guideline for troubleshooting of Output Check for G00310/G00312,
refer to section 5.3.2 on page 5-12.
14 Ladder
Sub-screen 3/5
TS 15110-upD-GB-0 PC5500-6 7 - 243

G00311 - Trouble ladder up redundant 56K253b

G00312 - Trouble ladder up redundant Output to 56K253b

G00313 - Trouble ladder down 56K254a

G00315 - Trouble ladder down redundant 56K254b
[1/1]
Trouble code G00313 - Trouble ladder down 56K254a
Message
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
14 Ladder
Sub-screen 4/5
7 - 244 PC5500-6 TS 15110-upD-GB-0

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
Message
G00314 & G00316 G00316 - Trouble ladder down redundant Output to 56K254b
Related information
– If the connection between node output and solenoid is faulty, the function (ladder down)
The function (ladder down) is not available.
on the machine
14 Ladder
Sub-screen 3/5
TS 15110-upD-GB-0 PC5500-6 7 - 245

G00315 - Trouble ladder down redundant 56K254b

G00316 - Trouble ladder down redundant Output to 56K254b

G00317 - Trouble service arm up 56K255a

G00319 - Trouble service arm up redundant 56K255b
[1/1]
Trouble code G00317 - Trouble service arm up 56K255a
Message
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
15 Service arm
Sub-screen 4/5
7 - 246 PC5500-6 TS 15110-upD-GB-0

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
Message
G00318 & G00320 G00320 - Trouble service arm up redundant Output to 56K255b
Related information
– 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
15 Service arm
Sub-screen 3/5
TS 15110-upD-GB-0 PC5500-6 7 - 247

G00319 - Trouble service arm up redundant 56K255b

G00320 - Trouble service arm up redundant Output to 56K255b

G00321 - Trouble service arm down 56K256a

G00323 - Trouble service arm down redundant 56K256b
[1/1]
Trouble code G00321 - Trouble service arm down 56K256a
Message
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
15 Service arm
Sub-screen 4/5
7 - 248 PC5500-6 TS 15110-upD-GB-0

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
Message
G00322 & G00324 G00324 - Trouble service arm down redundant Output to 56K256b
Related information
– 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
15 Service arm
Sub-screen 3/5
TS 15110-upD-GB-0 PC5500-6 7 - 249

G00323 - Trouble service arm down redundant 56K256b

G00324 - Trouble service arm down redundant Output to 56K256b

7 - 250 PC5500-6 TS 15110-upD-GB-0

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
G00325 G00327 Message
G00326 G00328 G00328 - Trouble start Input
These trouble codes monitor the primary or redundant input of the switches at the nodes.
Overview switch location and trouble codes:
Trouble code Switch Location

G00325 55S087 Refilling arm
Contents of trouble
G00326 70S084 Access ladder
G00327 20S029 Cab
20S004-1
G00328 Dashboard in cab
20S004-2
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
15 Service arm
Screen 1/5
1. Refer to the wiring
diagram.
2. Visually inspect the
concerned switch,
the switch contact,
Displayed: and the respective
wiring.
G00325 1
Trouble service arm 3. Locate the prob-
Input lem.
4. Repair or replace
the concerned
switch or its wiring
If the displayed value is "1" the function is OK/available. as necessary.
If G00325 is displayed, the input signal of 55S087 or 5. After repair go to
55S087r is missing. In this case "0" is indicated on final step 2.
the REAL TIME MONITOR, and the function is not
available.
TS 15110-upD-GB-0 PC5500-6 7 - 251


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

09 Manual Switch
Screen 2/4

diagram.
concerned switch,
the switch contact,
Displayed: and the respective
wiring.
G00327 1
Trouble parking brake 3. Locate the prob-
Input lem.
If the displayed value is "1" the function is OK/available. the concerned
If G00327 is displayed, the input signal of 20S029 or switch or its wiring
20S029r is missing. In this case "0" is indicated on as necessary.
the REAL TIME MONITOR, and the function is not 5. After repair go to
available.
final step 2.
Indication
Switch condition Brake
REAL TIME MONITOR
1 ON Released
0 OFF Applied
7 - 252 PC5500-6 TS 15110-upD-GB-0


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

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

Final check 2
TS 15110-upD-GB-0 PC5500-6 7 - 253


[1/3]
Trouble code
Message 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.
– 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:
16 Pilot control
Screen 4/5
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)
7 - 254 PC5500-6 TS 15110-upD-GB-0


[2/3]
Nominal
value
Visually check 11K126.

gram 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
Both relay LEDs (yellow & red) OFF
24V at relay 11K126

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

Final check 3
TS 15110-upD-GB-0 PC5500-6 7 - 255

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

[3/3]
Fig. 7-133 Wiring diagram (11Q111/11K126) for trouble code G00330
7 - 256 PC5500-6 TS 15110-upD-GB-0

G00331 - Automatic after_running engine 1

G00332 - Automatic after_running engine 2
[1/1]
Trouble code G00331 - Automatic after_running engine 1
Message
G00331 & G00332 G00332 - Automatic after_running engine 2
– 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 or 20S005-2 is pressed, this message remembers
the operator that the engines needs to run at low idle for cooling down, before the engines
are 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, messages G00352 (Engine 1 standstill) and
G00350 (Engine 2 standstill) are displayed for 5 seconds.
---
on the machine
Instruction message 57 Cool down period !
TS 15110-upD-GB-0 PC5500-6 7 - 257

G00333 - Trouble battery charger relay

[1/2]
Trouble code
Message Trouble battery charger relay
G00333
– Relay 11Q122 switches the stabilized power supply.
Contents of trouble
– Power supply comes from the circuit breaker 11F013.
This trouble message is displayed, if the wiring circuit from 11F013 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 11F013 to:
Relay 11Q122 or its → 11Q122 (contacts 87y & 87b) Locate the problem.
1 Node 2
wiring is defective Repair the wiring
→ node 2 (connector 1, pin 5) connector 1
or replace the relay
pin 5 = 24V
If the condition is normal, 24V are present at node 2 as necessary.
(connector 1, pin 5)

Final check 2
7 - 258 PC5500-6 TS 15110-upD-GB-0


[2/2]
TS 15110-upD-GB-0 PC5500-6 7 - 259

G00336 - Trouble monitoring slew speed

[1/x]
Trouble code
Message Trouble monitoring slew speed
G00336
– Module 11B143 converts the slew speed information (120 pulses/minute)
Contents of trouble
– For the function description refer to the SERVICE MANUAL, section 11 Operating Hydraulic.
– For testing the binary output signal of 11B143 (terminal 13) refer to the REAL TIME MONITOR:
06 Slew
Related information Sub-screen 1/2
– If no binary signal is present at the module terminal 13, the slew speed will be extremely slow.
Problem that appears Only an extremely slow slew speed is available as the proportional swing speed control is not
on the machine possible.
Nominal
value
Check the setting/parameters at the module. Yes Go to next step.
Wrong setting of the For detailed information on the slew direction
slew speed module 1 module 11B143 refer to the SERVICE MAN- Correct the settings
11B143 UAL, section 11 Operating Hydraulic and to and recheck the slew
No
the Wiring Diagram. speed control system
Are the settings OK?
Wrong wiring
connection at the Refer to the Wiring Diagram and check the Correct the wiring
2 connection and
slew speed module wiring of 11B143.
11B143 No recheck the slew
Is the wiring OK?
speed control system
1. Refer to the SERVICE MANUAL, Yes Go to next step.
section 11 Operating Hydraulic for details.
Proximity switch
60B099 defective or 3 2. Check function and adjustment of the prox- Replace the slew
wrong adjustment imity switch. No direction module
3. Readjust the switch if necessary. 11B143.
Is the slew speed control system OK?
Final check 4
7 - 260 PC5500-6 TS 15110-upD-GB-0

Slew speed module 11B143 for trouble code G00336

[2/2]
Fig. 7-135 Slew speed module 11B143
TS 15110-upD-GB-0 PC5500-6 7 - 261

G00349 - Engine 2 running

G00350 - Engine 2 standstill
G00351 - Engine 1 running
[1/1]
Trouble code G00349 - Engine 2 running
Message
G00351 & G00349 G00351 - Engine 1 running
Contents of trouble When the engines start running, these messages are displayed for 5 seconds.
– G00349 to G00352 are informational messages.

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

---
on the machine
Instruction message --- ---
7 - 262 PC5500-6 TS 15110-upD-GB-0

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

[1/2]
Trouble code
Message Communication failure PLC [MTC] <=> KOMTRAX Plus controller
G00417
Contents of trouble The CAN bus communication between MTC and KOMTRAX Plus controller is impossible.
– Communication between MTC and KOMTRAX Plus controller takes place via a serial connec-
tion.
Related information
– At the MTC the serial cable is connected to the COM2 port.
– At the KOMTRAX Plus controller the serial cable is connected to the CN3A port.
Problem that appears Data exchange between MTC and KOMTRAX Plus controller, e.g. the monitoring function and the
on the machine memory function, are disabled.
Nominal
value
Disconnection in the 1. Visually check the serial harness and its Yes Go to next step.
serial wiring between connectors.
Reconnect the serial
MTC and KOMTRAX 2. Verify that the serial connector at the MTC connector orderly to
1
Plus controller or the side is connected to the COM2 port. the COM2 port of the
contact in any connec- No
Is the serial harness in proper condition and is MTC or locate the
tor is defective problem and repair as
the connector at the MTC side plugged into the
COM2 port? necessary.

Check the MTC & Rmax 1Ω
KOMTRAX Plus
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 KOMTRAX Plus controller and measure required:
(no continuity) the wiring harness for continuity. Please note the serial
Is continuity present? numbers of KOMTRAX
Plus monitor & control-
ler and contact your
dealer or KMG.
Replace the CAN bus
No
harness.
Final check 3
TS 15110-upD-GB-0 PC5500-6 7 - 263

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

[2/2]
Serial harness and ports between MTC and KOMTRAX Plus controller
Fig. 7-136 Serial harness and ports between MTC and KOMTRAX Plus controller
7 - 264 PC5500-6 TS 15110-upD-GB-0

G00420 - Connector sel error

[1/1]
Trouble code
Message Connector sel error
G00420
– The cable connectors at the KOMTRAX Plus controller are mixed up.
It is also possible that single wires of any wire harness at the KOMTRAX Plus controller are
Contents of trouble connected to wrong connector pins.
– The wiring to the KOMTRAX Plus controller may be damaged (or short cut).
– It is necessary to check the repair history.
– In case any repair has been done at the KOMTRAX Plus wiring, the wiring needs a double-
Related information check.
For detailed information on the wiring of the KOMTRAX Plus controller refer to the SERVICE
MANUAL, chapter 17.7
The monitoring system is disturbed.
on the machine
Nominal
value
The cable connectors Refer to the wiring diagram and to the S/M and Yes Go to next step.
at the KOMTRAX Plus check the cable connectors at the KOMTRAX SERVICE
1 MANUAL
controller may be Plus controller for their correct Plug in the connectors
mixed up. connection order. No chapter
in their correct order. 17.7
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 17.7
pins.
pins?
Refer to the wiring diagram and check the cables
The wiring at the
and their connectors at the KOMTRAX Plus controller Replace any defective
KOMTRAX Plus
3 for any damage. component or repair Wiring dia-
controller is damaged
(or short cut) Disconnect the connectors from the KOMTRAX Plus any wiring malfunction gram
controller and measure the wire harnesses for as necessary.
continuity.
Final check 4
TS 15110-upD-GB-0 PC5500-6 7 - 265

G00421 - Farm sys error

[1/1]
Trouble code
Message Farm sys error
G00421
– The firmware of the KOMTRAX Plus controller has a problem.
Contents of trouble
– A new upload is necessary or the KOMTRAX Plus controller needs replacement.
– The operation system has a basic problem.
Related information
– For further information contact your dealer or KMG.
– No KOMTRAX Plus/monitoring operation.
The KOMTRAX Plus system is inoperative.
on the machine
Nominal
value
The firmware has
1 Upload new firmware or replace the KOMTRAX Plus controller.
a problem
Final check 2
7 - 266 PC5500-6 TS 15110-upD-GB-0

G00422 - Can-net sys (J1939)

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

Real time monitoring of the engines is not possible.
on the machine
Nominal
value
The connection Main key switch 20S001 ON.
between KOMTRAX
Plus and the engine Check wiring, connectors, and pins between KOMTRAX Plus and the engine
1 Wiring dia-
control systems control systems (QUANTUM) for proper order and connection.
(QUANTUM) gram
Repair or replace components according to the Wiring diagram.
is inoperative
Final check 2
TS 15110-upD-GB-0 PC5500-6 7 - 267

G00423 - Application sys error

[1/1]
Trouble code
Message Application sys error
G00423
– The software application of to the KOMTRAX Plus controller has a problem.
Contents of trouble
– A new software release is necessary.
Related information The KOMTRAX Plus software is inoperative.
– No KOMTRAX Plus/monitoring operation.

Action of controller – Background colour of the trouble code information: yellow
The KOMTRAX Plus system is inoperative.
on the machine
Nominal
value
The software has A new release of the KOMTRAX Plus software is necessary - change the
1
a problem KOMTRAX Plus controller. Contact your dealer for further details.
Final check 2
7 - 268 PC5500-6 TS 15110-upD-GB-0

G00425 - Settings impossible to take over into the PLC [MTC]

[1/2]
Trouble code
Message 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 KOMTRAX Plus monitor.
– That means: any modification of the settings is impossible.
After the system failed 10 times to build up a connection between
KOMTRAX Plus monitor → KOMTRAX Plus 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 KOMTRAX Plus monitor.
on the machine
Nominal
value
On condition that
trouble codes G00417 Program re-load (MTC / KOMTRAX Plus controller) or replacement of the units is
& G00491 are not necessary.
displayed, any If further information is required in this case:
software or hardware Note the serial numbers of the KOMTRAX Plus controller and KOMTRAX Plus monitor
problem may be and contact your dealer or KMG.
present
Final check
TS 15110-upD-GB-0 PC5500-6 7 - 269

Wiring diagram overview for G00425:

KOMTRAX Plus monitor → KOMTRAX Plus controller → MTC
[2/2]
Fig. 7-137 W/D overview for G00425: KOMTRAX Plus monitor → KOMTRAX Plus controller → MTC
7 - 270 PC5500-6 TS 15110-upD-GB-0

G00491 - Communication failure MH800 <=> KOMTRAX Plus controller

[1/2]
Trouble code
Message Communication failure MH800 <=> KOMTRAX Plus controller
G00491
The CAN bus (#0) communication between KOMTRAX Plus monitor and KOMTRAX Plus
Contents of trouble
controller is inoperative.
Communication between KOMTRAX Plus monitor and KOMTRAX Plus controller takes place
via CAN bus #0.
Related information At the KOMTRAX Plus monitor the CAN bus is connected to the CN2 port via connectors:
20X335f-1, 20X335e, 20X335d, 10X335c, 10X335b, and- 10X300a.
At the KOMTRAX Plus controller the CAN bus is connected to the CN4A port.

Communication between KOMTRAX Plus monitor and KOMTRAX Plus controller is impossible.
on the machine
Nominal
value
1. Visually check the condition of the CAN Yes Go to next step.
bus harness.
CAN bus wiring 2. Visually check all connectors/pins for
between KOMTRAX Locate the problem
proper crimping and connection.
Plus monitor and and repair as
1 3. Make sure that the cables are fixed in the necessary.
KOMTRAX Plus
controller, or the correct sequence inside the connectors. No If any CAN bus
contact in any Is the CAN bus harness in good condition? segment is damaged,
connector is defective. replace the relating
Is the contact of connectors/pins alright?
cable segment.
Is the cable allocation in the connectors
correct?
Re-program MH801 CAN bus:
and/or the KOMTRAX Rmax 1Ω
Plus controller, or
replace the units if
necessary.
The CAN bus harness If further information is
Separate the CAN bus segments and measure Yes
may be defective required:
2 their continuity.
(no continuity, wrong Please note the serial
resistance) Is the continuity of the CAN bus segments numbers of KOMTRAX
alright? Plus monitor & control-
ler and contact your
dealer or KMG.
Replace the defective
No CAN bus segment as
necessary.
Final check 3
TS 15110-upD-GB-0 PC5500-6 7 - 271

Wiring diagram overview for G00491: MH800 <=> KOMTRAX Plus controller
[2/2]
Fig. 7-138 Wiring diagram overview for G00491: MH800 <=> KOMTRAX Plus controller
7 - 272 PC5500-6 TS 15110-upD-GB-0

Troubleshooting by symptoms
8 TROUBLESHOOTING BY
SYMPTOMS
TS 15110-upD-GB-0 PC5500-6 8 -1
Symptoms of the engines and related electrical systems Troubleshooting by symptoms
8.1 SYMPTOMS OF THE ENGINES AND RELATED

ELECTRICAL SYSTEMS
SEL001 - Engine does not start (engine does not rotate)
[1/11]
Trouble code
Trouble Engine does not start (engine does not rotate)
SEL001
– An engine does not start (the engine does not rotate).
Contents of trouble
– Corresponding trouble messages are not displayed.
If engine start is impossible (engine does not rotate), the following provided engine start blocking
mechanisms or malfunctions may be the cause:
– No or not enough battery power is present (below 17 Volt).
– The safety lock lever is in down position during engine start.
Related information
– The safety lock lever switch (20S105) is faulty.
– The pre-lube process is not started or stopped.
– The starter motors have an internal short circuit.
– The starter motors are mechanically blocked (breakdown).
An 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
Internal short circuit in Check the capacity and condition of the drop below
1 Replace the concerned 20V)
any battery or low starter batteries 71G001 – 71G006 and Yes
battery/batteries.
battery voltage the controller batteries 71G008 - 71G009. Electrolyte
(below 17 V) Is any battery defective? specific
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 dia-
faulty belonging wiring. Repair or replace as
No gram
Are safety lock switch 20S105 and its wiring necessary.
ok?
8 -2 PC5500-6 TS 15110-upD-GB-0
Troubleshooting by symptoms Symptoms of the engines and related electrical systems
SEL001 - Engine does not start (engine does not rotate)

[2/11]
Nominal
value
Main key switch 20S001 ON &
Engine start switch 20S004-1/2 activated.
Refer to Wiring dia-
When the start switch 20S004-1/2 is activated, gram.
the pre-lube pump 52G006-1/2 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 52B093-1/2, 52G006-1/2
(it is not started or the pre-lube switch 52K030-1/2 initiates the Wiring dia-
stopped) No - Engine oil gram
start signal to the starter relays 52Q002a-1/2
pressure switch
and 52Q002b-1/2 of the starter motors.
52B093-1/2 (incl.
Refer to the Wiring diagram and check the pre- switch function)
lube process.
- Pre-lube timing relay
Is the pre-lube process ok 52K030-1/2
(including pre-lube start and stop)?
- Starter relays
52Q002a-1/2 and
52Q002b-1/2
Main key switch 20S001 ON &
Engine start switch 20S004-1/2 activated.
Component's lifetime Replace the starter
exceeded Check the relays 52Q002a-1/2 & 52Q002b-1/2 Yes
for Vbatt (approx. 24 V) input/power supply. motors.
(starter motors internal 5 V
Refer to the Wiring dia- batt
disconnection or short Is Vbatt present at the input and output of these (approx.
gram.
circuit) relays? No 24V)
Repair/ replace the
Is Vbatt present at the starter motors? wiring as necessary.
Battery switches 50Q003 & 50Q004 OFF.
Replace the starter
motors and recheck
Yes
function.
Component's lifetime
Check the flywheel of
exceeded
the concerned engine
(starter motors internal 6 Disassemble or replace both starter motors
for free mechanical
disconnection or and inspect them.
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 15110-upD-GB-0 PC5500-6 8 -3
Wiring diagram 1 (starter batteries) for trouble code SEL001

[3/11]
Fig. 8-1 Wiring diagram 1 (starter batteries) for trouble code SEL001
8 -4 PC5500-6 TS 15110-upD-GB-0
Legend for Fig. 8-1: [4/11]
50Q002 Battery switch (for controller batteries)

50Q003 Battery switch (for starter batteries)
50Q004 Battery switch (for starter batteries)
71G001 Starter battery
71G008 Controller battery (stabilized control voltage)
71G009 Controller battery (stabilized control voltage)
71T003 Shunt resistor (for measuring the charging current)
TS 15110-upD-GB-0 PC5500-6 8 -5
Wiring diagram 2 (engine 1 start) for trouble code SEL001

[5/11]
Fig. 8-2 Wiring diagram 2 (engine 1 start) for trouble code SEL001
8 -6 PC5500-6 TS 15110-upD-GB-0
52B093-1 Oil pressure switch engine 1

52G006-1 Pre-lube pump engine 1
52K030-1 Pre-lube timing relay engine 1
52M001-1 Starter 1 engine 1
52Q002a-1 Starter relay engine 1
52Q030a-1 Pre-lube pump relay engine 1
TS 15110-upD-GB-0 PC5500-6 8 -7
Wiring diagram 3 (engine 2 start) for trouble code SEL001

[7/11]
Fig. 8-3
4. Wiring diagram 3 (engine 2 start) for trouble code SEL001
8 -8 PC5500-6 TS 15110-upD-GB-0
52B093-2 Oil pressure switch engine 2

52G006-2 Pre-lube pump engine 2
52K030-2 Pre-lube timing relay engine 2
52Q002a-2 Starter relay engine 2
52Q030a-2 Pre-lube pump relay engine 2
TS 15110-upD-GB-0 PC5500-6 8 -9
Wiring diagram 4 (engine start & stop buttons) for trouble code SEL001
[9/11]
Fig. 8-4 Wiring diagram 4 (engine start & stop buttons) for trouble code SEL001
8 - 10 PC5500-6 TS 15110-upD-GB-0
20S004-1 Start switch engine 1

20S004-2 Start switch engine 2
20S005-1 Stop switch engine 1
20S005-2 Stop switch engine 2
20S105 Lock lever
TS 15110-upD-GB-0 PC5500-6 8 - 11
Wiring diagram 5 (engine start relays) for trouble code SEL001

[11/11]
Fig. 8-5 Wiring diagram 5 (engine start relays) for trouble code SEL001
51K001a-1 Start relay engine 1

51K001b-1 Start relay engine 1 redundant
51K001a-2 Start relay engine 2
51K001b-2 Start relay engine 2 redundant
8 - 12 PC5500-6 TS 15110-upD-GB-0
Please continue reading on the next page.
TS 15110-upD-GB-0 PC5500-6 8 - 13
SEL002 - Engine stops while in operation

[1/6]
Trouble code
Trouble Engine stops while in operation
SEL002
– During operation the engines suddenly stop.
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.
1. Check the fuel level
and refuel if neces-
sary.
Check the level in the fuel tank.
2. Inspect the fuel
Lack of Diesel fuel Check the fuel solenoid valve 31Q599-1/-2 for
tank and the bot-
1 proper function (31Q599-1/-2 must be open
at the fuel filters tom fuel line con-
during engine start).
nection for
Is fuel supply present at the Racor and at the contamination.
fuel filters? No
3. Check
31Q599-1/-2 for
proper function and
repair if necessary.
4. Check the fuel sup-
ply line for free pas-
sage and repair if
necessary.
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 Check the supply
function. hoses and unions for
No free passage and
Is fuel present at the fuel pump? repair if necessary.
Go to next step.
8 - 14 PC5500-6 TS 15110-upD-GB-0
SEL002 - Engine stops while in operation

[2/6]
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.
1. Check the fuel
specification and
Mechanical problems measure the water
3 Monitor and check the starting process content in the Die-
at the fuel system
(fuel supply) with the "Insite" software. sel fuel. Replace
Could you locate the problem? the fuel when nec-
No essary.
2. Inspect the fuel
system together
with the Cummins
Service and repair
or replace as nec-
essary.
Final check 4
TS 15110-upD-GB-0 PC5500-6 8 - 15
View onto the water separators and fuel filters (SEL002)

[3/6]
Fig. 8-6 View onto the water separators and fuel filters (SEL002)
8 - 16 PC5500-6 TS 15110-upD-GB-0
(1) RH section of counterweight viewed from (10) Lower cover for second stage filters of front
rear engine 1 engine 2
(2) Filter box of the first stage fuel filters with (11) Second stage fuel filters for front engine 2
water separators
(3) Upper cover for first stage filters of rear F1 Fuel flow from fuel tank
engine 1
(4) First stage fuel filters with water separators F2 Fuel flow to fuel lift pump of rear engine 1
for rear engine 1
(5) Lower cover for first stage filters of front F3 Fuel flow from fuel lift pump of rear engine 1
engine 2
(6) First stage fuel filters with water separators F4 Fuel flow to rear engine 1 fuel pump
for front engine 2
(7) Filter box of the second stage fuel filters F5 Fuel flow to fuel lift pump of front engine 2
(8) Upper cover for second stage filters of rear F6 Fuel flow from fuel lift pump of front
engine 1 engine 2
(9) Second stage fuel filters for rear engine 1 F7 Fuel flow to front engine 2 fuel pump
REMARKS: The sectional views (B - B) and (C - C) are shown on Fig. 8-7on next page.
TS 15110-upD-GB-0 PC5500-6 8 - 17
Sectional view onto fuel filters, shut-off solenoid valves, and fuel piping (SEL002)
[5/6]
Fig. 8-7 Sectional view onto fuel filters, shut-off solenoid valves, and fuel piping (SEL002)
8 - 18 PC5500-6 TS 15110-upD-GB-0
(1) RH section of counterweight viewed from (10) Lower cover for second stage filters of front
rear engine 1 engine 2
(2) Filter box of the first stage fuel filters with (11) Second stage fuel filters for front engine 2
water separators
(3) Upper cover for first stage filters of rear F1 Fuel flow from fuel tank
engine 1
(4) First stage fuel filters with water separators F2 Fuel flow to fuel lift pump of rear engine 1
for rear engine 1
(5) Lower cover for first stage filters of front F3 Fuel flow from fuel lift pump of rear engine 1
engine 2
(6) First stage fuel filters with water separators F4 Fuel flow to rear engine 1 fuel pump
for front engine 2
(7) Filter box of the second stage fuel filters F5 Fuel flow to fuel lift pump of front engine 2
(8) Upper cover for second stage filters of rear F6 Fuel flow from fuel lift pump of front
engine 1 engine 2
(9) Second stage fuel filters for rear engine 1 F7 Fuel flow to front engine 2 fuel pump
TS 15110-upD-GB-0 PC5500-6 8 - 19
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 to the PM-CLINIC sheets.
adjustments Together with the
Was the RPM adjustment successful?
Cummins Service work
No
out the complete Fuel
System sheet.
Final check 4
8 - 20 PC5500-6 TS 15110-upD-GB-0
SEL004 - Engine does not stop

[1/1]
Trouble code
Trouble Engine does not stop
SEL004
Contents of trouble When the engine stop switch 20S005-1/2 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
Possible causes When the engine stop switch 20S005-1/2 is pressed the engine stop is not activated.
Nominal
value
REAL TIME MONITOR - Input check
Confirm the input signal of 20S005-1/2 on the REAL
TIME MONITOR.
1. Engines running
09 Manual Switch
Screen 1/4
3. Press switch 20S005-1 or 20S0085-2 and check
the displayed input signal:
1 = ON input
Refer to the Wiring
0 = OFF no input
diagram.
When the engine stop
switch 20S005-1/2 is Locate the problem 20S005-1/2
1 and repair as Input signal
pressed, the engine
stop is not activated necessary. = 1 when
pressed
After that recheck
function.
4. If necessary check the circuits of 20S005-1/2 and

the engine stop via node 20K309 for proper func-
tion.
Final check 2
TS 15110-upD-GB-0 PC5500-6 8 - 21
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 (refer to the Cummins service literature)
– 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.
1. 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.
2. After that recheck
the system for
proper function.
3. Go to final step 2.
Final check 2
8 - 22 PC5500-6 TS 15110-upD-GB-0
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)
◊ : Possible causes due to length of use (used for a long period)
Overheating
● : 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 temperature 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 15110-upD-GB-0 PC5500-6 8 - 23
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
1. Inspect the
suspicious system,
unit, or component
Exhaust smoke is black for malfunction and
(incomplete 1 repair or replace as
Refer to the following judgment table and identify the
combustion) necessary.
appropriate trouble cause(s).
the system for
proper function.
Final check 2
8 - 24 PC5500-6 TS 15110-upD-GB-0
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
Legend
Crushed, clogged muffler


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 15110-upD-GB-0 PC5500-6 8 - 25
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
1. Inspect the
suspicious system,
unit, or component
The oil consumption is for malfunction and
excessive (or the 1 repair or replace as
Refer to the following judgment table and identify
exhaust smoke is blue) necessary.
the appropriate trouble cause(s).
the system for
proper function.
Final check 2
8 - 26 PC5500-6 TS 15110-upD-GB-0
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

Legend
Worn seal at turbine end

Leakage at the oil piping
Worn seal at blower end

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 15110-upD-GB-0 PC5500-6 8 - 27
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
1. Inspect the
suspicious system,
unit, or component
The engine oil is for malfunction and
contaminated quickly Refer to the following judgment table and identify
the system for
proper function.
Final check 2
8 - 28 PC5500-6 TS 15110-upD-GB-0
SEL008 - Oil becomes contaminated quickly

[2/2]
Defective seal at turbocharger turbine end

Clogged breather or breather hose
Clogged turbocharger drain pipe

Legend
Worn valve, valve guide
Exhaust smoke is black

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 15110-upD-GB-0 PC5500-6 8 - 29
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 (both engines)

Fuel density (kg/l) = 0.86
Mining Conditions Max. Con-
Engine Spec. sumption
easy average heavy
Shovel Output Fuel Con-
Engine Model SAE 1995 sumption load fac- load fac- load fac- load fac-
Type
[kW] [g/kWh] tor 70% tor 75% tor 83% tor 100%
[Liter/h] [Liter/h] [Liter/h] [Liter/h]
Related information
SDA12V159E-2
PC5500-6 1880 214 327 351 388 468
(QSK38)
– 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
1. Inspect the
suspicious system,
unit, or component
Fuel consumption for malfunction and
highly exceeds the 1 repair or replace as
standard values Refer to the following judgment table and identify the
appropriate trouble cause(s). necessary.
the system for
proper function.
Final check 2
8 - 30 PC5500-6 TS 15110-upD-GB-0
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 ◙
cylinders 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 15110-upD-GB-0 PC5500-6 8 - 31
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
1. 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
coolant level goes necessary.
down
the system for
proper function.
Final check 2
8 - 32 PC5500-6 TS 15110-upD-GB-0
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 15110-upD-GB-0 PC5500-6 8 - 33
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
1. Inspect the
suspicious system,
unit, or component
The engine oil level for malfunction and
rises Refer to the following judgment table and identify
the system for
proper function.
Final check 2
8 - 34 PC5500-6 TS 15110-upD-GB-0
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 engines are first started, drops of water come from the mufflers ◙
Exhaust smoke is white ◙ Ο Ο
There is oil in the engine coolant Ο Ο Ο Ο
Leave the radiator cap open. When the engines are 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 15110-upD-GB-0 PC5500-6 8 - 35
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
1. Inspect the
suspicious system,
unit, or component
The engine coolant for malfunction and
temperature becomes 1 repair or replace as
too high (overheating) necessary.
the system for
proper function.
Final check 2
8 - 36 PC5500-6 TS 15110-upD-GB-0
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 15110-upD-GB-0 PC5500-6 8 - 37
Symptoms of the hydraulic system Troubleshooting by symptoms
8.2 SYMPTOMS OF THE HYDRAULIC SYSTEM

SHY001 - All the work equipment shows lack of power or slow movement
[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 val-
ues.
– 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 (79.1 / 79.2) for the hydraulic pump regulation
mode at the valve and filter plate
– Wrong adjustment of the pump regulation system
Possible causes
– 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 (79.1 / 79.2) to E
1
(253.1 / 254.1) at the No position and bring
valve 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 79.1 SERVICE
the pump regulation 2 regulation system
/ 79.2 at the valve and filter plate must be set MANUAL
system according to the PM-
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.
8 - 38 PC5500-6 TS 15110-upD-GB-0
Troubleshooting by symptoms Symptoms of the hydraulic system
SHY001 - All the work equipment shows lack of power or slow movement
[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
3 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.
4
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
to the PM-CLINIC sheet. replace the fuel filter
elements as
Even all adjustments are correctly done and necessary.
Yes PM-CLINIC
Low engine power even they correspond to the default values, the
5 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 6
TS 15110-upD-GB-0 PC5500-6 8 - 39
SHY002 - No work equipment, travel or swing movement

[1/1]
Trouble code
Trouble No work equipment, travel or swing movement
SHY002
– 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 engines are running at high idle and all safety functions are unlocked.
No movement is possible.
on the machine
– 11K111a and 11K111b are inoperative or defective.
Possible causes
– Pilot pressure is not available (PPC pump defective).
Nominal
value
1. Check the circuits of 11K111a and 11K111b Repair or replace
Relays 11K111a and for proper function. relays 11K111a & Output
11K111b are Yes
1 11K111b and/or their 24V
inoperative 2. Check the function of relays 11K111a and
sockets if damaged.
or defective 11K111b manually.
Could you identify any problem in the electrical No Go to next step.
system?
Check the pilot pressure at the valve and X4=60bar
cartridge block as described in the Check for proper X2=35bar
SERVICE MANUAL. Yes movement of the
work equipment. SERVICE
Make sure that the pilot pressure is in the MANUAL
specified working range.
Also confirm the pilot pressure values
on the REAL TIME MONITOR
05 Hydraulic
Screen 2/7
Pilot pressure is
not available 2 Check the drive input
(PPC pump defective) of the pilot pump.
Check the pilot pump
No for damage (internal
fault).
necessary.
Is specified pilot pressure available?

Final check 3
8 - 40 PC5500-6 TS 15110-upD-GB-0
SHY003 - Work equipment has too much hydraulic drift

[1/2]
Trouble code
Trouble Work equipment has too much hydraulic drift
SHY003
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.
25-35bar
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 spools "Stick in" or "Boom down" Replace the affected
FSA - Floating spools valve and adjust as SERVICE
2 any damage is possible.
internal leak or damage Yes described in the MANUAL
Inspect the floating spools as described in the SERVICE MANUAL PM-CLINIC
SERVICE MANUAL. and PM-CLINIC.
Can you identify any leakage or damage? No Go to next step.
TS 15110-upD-GB-0 PC5500-6 8 - 41
SHY003 - 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 - 42 PC5500-6 TS 15110-upD-GB-0
SHY004 - Work equipment has big time lag

[1/1]
Trouble code
Trouble Work equipment has big time lag
SHY004
– The work equipment has a big time lag between lever actuation and movement of the attach-
Contents of trouble ment.
– The PM-CLINIC procedures are done and all settings are adjusted to the nominal values.
The reaction time of the attachment after lever movement is 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 dia-
Time Modules according to the procedures Yes Refer to the SERVICE gram
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 15110-upD-GB-0 PC5500-6 8 - 43
SHY005 - Machine deviates during travel movement

[1/1]
Trouble code
Trouble Machine deviates during travel movement
SHY005
– 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.
on the machine – The operator has to stop the shovel after a couple of meters in order to correct the direction
of travel to straight forward.
– Defective hydraulic travel motor.
Possible causes
– Internal leak in the rotary joint.
Nominal
value
1. Disconnect the
ports A and B at
the travel motors
(in order to exclude
the travel motors).
2. Plug the hoses and
Connect high pressure gauges (400 bar) to the SRV
the inlet ports of the 310bar
main blocks.
Defective hydraulic Yes travel motors.
Disconnect the parking brake solenoid valve MRV
travel motor 3. Now check the 310+5bar
1 57Q516 in order to close the brake.
Internal leak in the pressure again.
rotary joint Actuate the travel pedals and read the current If the pressure val-
pressure at the gauges. ues are still the
Is there any pressure difference between left same as before,
and right, or loss of pressure? replace the 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 - 44 PC5500-6 TS 15110-upD-GB-0
SHY006 - Machine does not swing

[1/1]
Trouble code
Trouble Machine does not swing
SHY006
– The machine does not swing when the lever is moved.
– The swing parking brake is released (otherwise a corresponding info message is displayed on
Contents of trouble
the KOMTRAX Plus monitor)
– All other operating functions are going well.
– The electrical lever signal on the amplifier and/or the ramp time modules is present
Related information (otherwise a corresponding error message is displayed on the KOMTRAX Plus 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
For better adjustment of the 2-stage valves pressure hoses to
Yes the 2-stage valves.
disconnect and plug the pilot lines of the
2-stage valves. Go to final step 2.
No pressure increase 1. Adjustment of the 330 bar stage
1
at the 2-stage valve SERVICE
2. Adjustment of the 130 bar stage MANUAL
REMARKS: Remember that there are 2 swing PM-CLINIC
gearboxes with mounted swing Replace both 2-stage
motors and the 2-stage valves. valves and perform the
Both valves need to have the basic adjustments.
No
same pressure (synchronisation). For the adjustment
procedures refer to the
Could you successfully adjust the 2-stage SERVICE MANUAL.
valves?
Final check 2
TS 15110-upD-GB-0 PC5500-6 8 - 45
SHY007 - Swing acceleration is poor

[1/3]
Trouble code
Trouble Swing acceleration is poor
SHY007
– The machine swing acceleration is poor (too long acceleration time or too short acceleration
time).
Contents of trouble – The swing parking brake is released (otherwise a corresponding info message is displayed on
the KOMTRAX Plus 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 Qmin / Qmax Adjustment at the swing motor is is wrong
– The 2-stage valve is defective or its adjustment is wrong.
Possible causes – The swing brake valve is defective (internal leak in the anti-cavitation/suction valves).
– 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
Engines running at high idle &
Swing lock switch 20S029 ON.
Check the Qmin / Qmax stop bolt setting at the Yes Go to next step
The Qmin / Qmax swing motors. Perform the basic
adjustment at the 1 REMARKS: Normaly the swing motors are adjustments of the
Qmin /Qmax stop bolts SERVICE
swing motor is wrong bench adjusted. A wrong stop bolt
No MANUAL
adjustment may also cause according to the SER-
severe motor damage. VICE MANUAL.
Is the Qmin / Qmax stop bolt setting correct? Go to next step.
Engines 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 2 circuit according to 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.
8 - 46 PC5500-6 TS 15110-upD-GB-0

[2/3]
Nominal
value
Perform the following steps according to the
Safety Notes in the SERVICE MANUAL.
Disconnect the high pressure hoses from the
swing brake block. Yes Go to final step 6.
The swing brake valve NOTE! Before mounting the new block
is defective in the next work step, also see
(internal leak in the 3 step 4 in this troubleshooting SERVICE
anti-cavitation/suction chart. MANUAL
valves) PM-CLINIC
Replace the complete block with new 2-stage
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)?
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 Replace the O-rings SERVICE
on 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.
4
(oil flows from A to B
side)
Legend:
(1) Swing brake valve

(2) O-ring
(3) Spacer plate
(4) Swing motor (example view)
TS 15110-upD-GB-0 PC5500-6 8 - 47

[3/3]
Nominal
value
For testing the leak oil keep the engines running at high idle.
1. Check the leak oil flow at the swing motors. Replace the defective
Yes
swing motor(s).
2. Disconnect the leak oil hose from each
swing motor and plug the hose opening. Go to troubleshooting
chart "SME006 - There
3. Mount an external hose to the swing motor
The swing motor is is a big abnormal noise
leak oil port and drain the leak oil into a when moving/stopping
defective 5
suitable container swing" on page 8-74.
(internal leakage)
(min. volume: 20 liters).
No Check the swing motor
4. 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 as
recommendation? necessary.
Final check 6
8 - 48 PC5500-6 TS 15110-upD-GB-0
SHY008 - Excessive overrun when stopping swing

[1/2]
Trouble code
Trouble Excessive overrun when stopping swing
SHY008
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 consid-
ered 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 to 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
swing brake block.
The swing brake valve
NOTE! Before mounting the new block in
is defective
the next work step, also see step
(internal leak in the 2 SERVICE
3 in this troubleshooting chart.
anti-cavitation/suction 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?
TS 15110-upD-GB-0 PC5500-6 8 - 49
SHY008 - 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 (example view)

For testing the leak oil, keep the engines running at high idle.
1. Check the leak oil flow at the swing motors. Replace the defective
Yes
swing motor(s).
2. Disconnect the leak oil hose from each
swing motor and plug the hose opening. Go to troubleshooting
chart "SME006 - There
3. Mount an external hose to the swing motor
The swing motor is is a big abnormal noise
leak oil port and drain the leak oil into a when moving/stopping
defective 4
suitable container swing" on page 8-74.
(internal leakage)
(min. volume: 20 liters).
No Check the swing motor
4. 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
8 - 50 PC5500-6 TS 15110-upD-GB-0
SHY009 - Floating system without function

[1/1]
Trouble code
Trouble Floating system without function (FSA only)
SHY009
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 spools installed in the boom circuit.
Related information – Floating spools installed in the stick circuit.
– The electric circuit is faultless, but the floating system is inoperative and/or its deactivation
is impossible.
No floating function for "Stick In" and/or "Boom Down".
on the machine
Possible causes The spools in the main block are mechanically stuck.
Nominal
value
The attachment must be in down and full reach position.
Replace or repair the

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

Final check 2
TS 15110-upD-GB-0 PC5500-6 8 - 51
SHY010 - Abnormal noise coming from SRV or MRV

[1/1]
Trouble code
Trouble Abnormal noise coming from SRV or MRV
SHY010
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
Adjust or replace as MANUAL
Wrong adjustment or the adjustment of SRV and MRV. Yes
necessary.
malfunction of SRV 1 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 2
the main blocks and locate the problem (temperature differ- Perform the complete
or at the manifold ence) with the infrared thermometer gun. No PM-CLINIC PM-CLINIC
procedures
Final check 3
8 - 52 PC5500-6 TS 15110-upD-GB-0
SHY011 - Track tensioning system without function

[1/1]
Trouble code
Trouble Track tensioning system without function
SHY011
Contents of trouble The automatic track tensioning system does not work.
– The automatic track tensioning system works under the following condition: the engines are
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 engines are 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
No or too low track according to the instructions and specifications Yes Go to final step 4. MANUAL
1 in the SERVICE MANUAL and PM-CLINIC
tensioning pressure 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 Yes Go to final step 4. SERVICE
Also refer to the latest version of PARTS &
or defective 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
TS 15110-upD-GB-0 PC5500-6 8 - 53
SHY012 - Ladder does not move, or slow movement

[1/2]
Trouble code
Trouble Ladder does not move, or slow movement
SHY012
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. 35bar
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?
8 - 54 PC5500-6 TS 15110-upD-GB-0
SHY012 - Ladder does not move, or slow movement

[2/2]
Nominal
value
Inspect:
1. Is the standard lad-
der frame used
(standard weight &
size)?
The ladder bearing Check the ladder bearing for proper condition Yes 2. Is the ladder or the
is defective or it is 5 and for the hand-tight tightening torque. ladder support
defective or dam- ASSEMBLY
tightened too firmly Also refer to the ASSEMBLY MANUAL.
aged by an acci- MANUAL
Are the bearings in good condition and are
dent?
they tightened correctly?
necessary.
bearings as necessary
No
and/or correct the
tightening torque.
Final check 6
TS 15110-upD-GB-0 PC5500-6 8 - 55
SHY013 - Refilling arm does not move, or slow movement

[1/2]
Trouble code
Trouble Refilling arm does not move, or slow movement
SHY013
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. 35 bar
Valve 57K624a/b is Disassemble the solenoid valve 57Q624a/b Yes Go to next step.
2 and check the inner part of the spool for proper
mechanically stuck
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?
8 - 56 PC5500-6 TS 15110-upD-GB-0
SHY013 - Refilling arm does not move, or slow movement

[2/2]
Nominal
value
Inspect:
1. Is the standard
refilling arm used
(standard weight &
size)?
The refilling arm
connection Check the refilling arm for proper function. Yes 2. Is the refilling arm
4 or its support
(pin and bushing) Disconnect the hydraulic cylinder and check SERVICE
is defective the free movement of the refilling arm. defective MANUAL
or damaged by
Is the refilling arm movement ok?
an accident?
Replace or repair
as necessary.
No refilling arm or the pin/
bushing as necessary.
Final check 5
TS 15110-upD-GB-0 PC5500-6 8 - 57
SHY014 - The hydraulic driven grease pump does not move

[1/2]
Trouble code
Trouble The hydraulic driven grease pumps do not move
SHY014
Contents of trouble The hydraulic driven grease pumps do 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 pumps is reduced.
– Also refer to the information in the SERVICE MANUAL, section "Lubrication Systems".
Problem that appears – The grease system is inoperative because the pumps do not work.
on the machine – Any relevant trouble message may be displayed on KOMTRAX Plus monitor.
– No or insufficient performance of the relief valve on the grease pumps.
– No or insufficient performance of the "Q" volume reducing valve on the grease pumps.
Possible causes – Internal leakage or damage at the grease pumps.
– Wrong grease pressure adjustment (grease pressure too high).
– The vent valves (62Q507a, 62Q509a or 62Q642a) cause a mechanical jam (grease pump
overload).
Nominal
value
Keep the engines running at high idle. Yes Go to next step.
SERVICE
No or too low Check the X4 pressure according to the MANUAL
1 Readjust and verify
X4 pressure instructions and specifications in the
No that the grease pump PM-CLINIC
SERVICE MANUAL and PM-CLINIC sheets.
operation is orderly. 60bar
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 SERVICE
valve according to the instructions and
2 MANUAL
relief valve on the specifications in the SERVICE MANUAL. Readjust and verify
grease pump No that the grease pump max.
Is the pressure adjustment of the grease pump
operation is orderly. 45bar
relief valve correct?
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
Is the volume adjustment correct? operation is orderly. per minute
Check the adjustment and operation of the Yes Go to next step.
Internal leakage
grease pumps according to the instructions
or damage at the 4 SERVICE
and 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?
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 pressure
too high) No
Is the grease pressure correct? the end of line switch. max.
180 bar
8 - 58 PC5500-6 TS 15110-upD-GB-0
SHY014 - The hydraulic driven grease pump does not move

[2/2]
Nominal
value
The vent valves Engines running at high idle.
(62Q507a, 62Q509a or
62Q642a) cause a Test the vent valve operation according to Repair or replace the vent
6 SERVICE
mechanical jam the instructions and specifications in the valves and test and adjust
(grease pump MANUAL
SERVICE MANUAL. the grease system if necessary.
overload)
Final check 7
TS 15110-upD-GB-0 PC5500-6 8 - 59
SHY015 - Trouble pump bearing lubrication

[1/1]
Trouble code
Trouble Trouble pump bearing lubrication
SHY015
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.
PARTS &
Wrong adjustment
Verify that the pump bearing SERVICE
of the main pump 2 Follow the instructions in the
lubrication is working orderly. NEWS
bearing throttle valve PARTS & SERVICE NEWS AH05510
AH05510
(latest version). Go to final step 3. (latest
version)
Final check 3
8 - 60 PC5500-6 TS 15110-upD-GB-0
SHY016 - Abnormal track chain movement during digging

[1/1]
Trouble code
Trouble Abnormal track chain movement during digging
SHY016
– 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
direction. 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 the travel system
Yes
during loading.
Perform the following
work steps:
1. Measure the SRV
pressure at the
Test and adjust the SRV pressure according to travel system with
the instructions and specifications in the SER- plugged (closed) SERVICE
Internal leakage VICE MANUAL and PM-CLINIC sheets. travel main lines MANUAL
1
at the rotary joint REMARKS: Measure the SRV pressure at the before the rotary PM-CLINIC
travel system with connected No joint inlet
SRV press
travel main lines (310±5 bar). (310±5 bar). 310±5 bar
Is the SRV pressure reached? 2. If the pressure is ok
replace or re-seal
the rotary joint.
3. Test and adjust the
MRVs of the travel
system on the main
blocks II & IV.
Final check 2
TS 15110-upD-GB-0 PC5500-6 8 - 61
SHY017 - Swing parking brake without function

[1/1]
Trouble code
Trouble Swing parking brake without function
SHY017
– 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 (35 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
gearbox oil.
Related information
– 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.
– Precondition: Air is properly removed from the system by bleeding.
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
1. Disconnect the pilot pressure supply hoses
for the swing parking 15 minutes
for the swing parking brakes from the brake system.
swing gearboxes.
2. 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
gearboxes).
the swing parking
3. Use a manual pump and increase the brake(s).
pressure up to 45 bar. SERVICE
No 2. Bleed the air from
MANUAL
4. The built-up pressure must be kept up the swing parking
for 15 minutes. brake(s).
Can you build-up 45 bar and is the pressure 3. Then check the
kept up for 15 minutes without further action? swing parking
brakes for proper
operation.
Final check 3
8 - 62 PC5500-6 TS 15110-upD-GB-0
SHY018 - Travel parking brake without function

[1/2]
Trouble code
Trouble Travel parking brake without function
SHY018
– The travel parking brake is inoperative.
– The X2 pressure circuit is already tested and ok (X2 pressure (35 bar) at solenoid valve
Contents of trouble
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.
– The travel parking brake at the L&S gearbox is a wet brake.
– The travel parking brake at the Zollern gearbox is a dry brake.
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.
– Precondition: Air is properly removed from the system by bleeding.
Problem that appears There is no automatic travel parking brake function when the ladder is down or the engines
on the machine are 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 70.2 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?
Check and adjust the pressure at valve 70.2 SERVICE
The pressure
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 70.2 is defec-
sheets. 35±2 bar
tive
Is it possible to adjust the pressure as
specified? No Replace valve 70.2.
TS 15110-upD-GB-0 PC5500-6 8 - 63
SHY018 - Travel parking brake without function

[2/2]
Nominal
value
Main key switch 20S001 OFF
Check for leaks or
mixed-up connections 45bar,
Perform the following steps: Yes in the pilot supply lines kept up for
1. Disconnect the pilot pressure supply hoses for the travel parking 15 minutes
from the travel parking brake housings. brake system.
2. Install a manual hydraulic pump with Refer to the
60 bar manometer in order to test the travel instructions in the
The brake discs are SERVICE MANUAL.
parking brake piston seals
burnt and/or the piston 3 (perform the test for both travel brake 1. Repair or replace
seals are defective the swing parking
housings).
brake(s).
3. Using the manual pump increase the SERVICE
pressure up to 45 bar. No 2. Bleed the air from
MANUAL
the swing parking
4. The built-up pressure must be kept up for
brake(s).
15 minutes.
3. Then check the
Can you build-up 45 bar and is the pressure
swing parking
kept up for 15 minutes without further action?
brakes for proper
operation.
Final check 4
8 - 64 PC5500-6 TS 15110-upD-GB-0
Please continue reading on the next page.
TS 15110-upD-GB-0 PC5500-6 8 - 65
Symptoms of the Mechanical System Troubleshooting by symptoms
8.3 SYMPTOMS OF THE MECHANICAL SYSTEM
SME001 - Abnormal noise is made

[1/2]
Trouble code
Trouble Abnormal noise is made
SME001
Contents of trouble Abnormal noise coming from any engines 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 engines and PTO
– Abnormal combustion
Nominal
value
1. Refer to the follow-
ing judgment table
and locate the
External noise Check all related parts and components for problem.
(the abnormal noise is proper function. 2. When the cause for
1
not coming from inside Check suspicious screw connections and the noise is deter-
the engines) mountings for proper tightening condition. No mined, perform the
Could you locate and rectify the cause for the appropriate repair
abnormal noise? procedures as
necessary.
3. After the repair is
completed, go to
final step 2.
Final check 2
8 - 66 PC5500-6 TS 15110-upD-GB-0
Troubleshooting by symptoms Symptoms of the Mechanical System
SME001 - Abnormal noise is made

[2/2]
Judgment Table for SME001 Causes
Broken dynamic valve syst. (valve, rocker lever etc)
Defect inside muffler (dividing board out of position)

Air leakage between turbocharger & cylinder head
Excessive wear of piston ring, cylinder liner

Improper gear train backlash

Legend
Clogged, seized injector

Missing, seized bushing
Defective fuel pump

Deformed fan

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 engines 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 ●
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
TS 15110-upD-GB-0 PC5500-6 8 - 67
SME002 - Abnormal noise around the PTOs / hydraulic pumps

[1/2]
Trouble code
Trouble Abnormal noise around the PTOs / hydraulic pumps
SME002
Contents of trouble Abnormal or excessive noise coming from the PTOs 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 PTOs.
– 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 housings 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
Check the oil level in the PTO housings Yes Go to next step. MIN &
No oil or the oil level using the dipstick. MAX
1
is too low in the PTOs For details refer to the OPERATION & MAIN- Refill specified oil up
TENANCE 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 housings of the PTO gearboxes. refill level
No oil or the oil level reference:
is too low in the pump 2 For details refer to the OPERATION & Refill specified oil up
bearing housings MAINTENANCE MANUAL and to the to the specified level O/MM,
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)
8 - 68 PC5500-6 TS 15110-upD-GB-0
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 housings 4 is X4 pressure present? fully open position.
is not opened enough REMARKS: If the pumps were operated after pump replacement, with the
or it is closed throttle valve closed or not fully open, the pump bearings were
not enough lubricated!
In this case, replace the complete main pumps again and
make sure that the throttle valves are set to "fully open"
before operating the pumps.
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 pumps 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
refer to the latest There is no
version of PARTS & air in the
Check the sight glass at the hydraulic tank hydraulic
SERVICE NEWS
for air bubbles. Yes oil tank
– AH01513 &
Air entering the Also check the suction lines and clamps of and in the
hydraulic system or sealed connections for air leakage. – AH00504 & suction
6 lines.
air bubbles inside the NOTE! Suction lines always must be – 21.531
hydraulic suction lines mounted with silicon applied
for bleeding the
to the pipes and they must hydraulic cylinders.
be fixed with double-clamps.
Check the lifetime of
Could you locate air in the hydraulic tank or air the PTOs and the main
bubbles in the suction lines? pumps.
No The abnormal noise
may be caused by
normal wear due to
component aging.
Final check 7
TS 15110-upD-GB-0 PC5500-6 8 - 69
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 engines or related parts.
– At first check all related parts for function and proper tightening.
– Measure the alignment/incline of the engines (& 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 engines and PTO.
– Improper alignment
Possible causes → mixed mounting of old (worn and/or defective) and new mounting supports.
– Abnormal combustion.
– Defective front damper.
– Defective rear damper (coupling to PTO).
Nominal
value
– Defective parts Yes Go to final step 2.
→ mounting supports of engines and PTO.
– Improper alignment 1. Refer to the follow-
→ mixed mounting of old (worn and/or ing judgment table
defective) and new mounting supports. and locate the
Abnormal or excessive – Abnormal combustion. problem.
vibration coming from – Defective front damper. 2. When the cause for
1
the engines or related the noise is deter-
parts – Defective rear damper (coupling to PTO).
No mined, perform the
1. Check all related parts and components of appropriate repair
the above items for proper function and procedures as
condition. necessary.
2. Check suspicious screw connections and 3. After the repair is
mountings for proper tightening. completed, go to
Could you locate and rectify the cause for final step 2.
the abnormal vibration?
Final check 2
8 - 70 PC5500-6 TS 15110-upD-GB-0
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
TS 15110-upD-GB-0 PC5500-6 8 - 71
SME004 - Vibration is excessive (engine torsion)

[1/1]
Trouble code
Trouble Vibration is excessive (engine torsion)
SME004
Vibration is excessive (abnormal vibration at the front engine damper or at the coupling)
Contents of trouble
at engine 1 or engine 2.
In order to eliminate abnormal vibration and torque of the engines, the following components are
mounted:
– A damper at the engine front side → double-mass vibration damper
– A damper at the engine rear side → coupling
Related information
The front damper (cooler side) is mounted on the crankshaft.
For inspection and references refer to the Cummins Troubleshooting & Repair Manual for the
QSK38 Engine (SDA12V159E-2 Komatsu Engines).
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 engines.
Final check 3
8 - 72 PC5500-6 TS 15110-upD-GB-0
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
1. Replace pins
and bushings at Boom foot
the connection bushings &
between boom pins, max.
and superstructure. clearance
2.5mm
2. After replacement
Wear in vertical & measure the axial
horizontal direction Move the attachment smoothly and check for clearance at the
1 Yes Axial play
at the boom foot excessive wear at the boom foot bushings. connection
bushings and pins between
Is the movement too large? between boom and
boom and
superstructure.
super-
3. If the axial play is structure,
still out of range max.
repair with the clearance
welding and lathe 2.5mm
tool.
No Go to next step.
P&S
NEWS
Replace the swing
Yes AH02513
circle.
(latest
version)
1. Check the teeth
around the swing
Move the attachment smoothly and check for circle.
Excessive wear of the excessive wear and movement of the swing
circle and backlash. 2. Also check the
swing circle (causing 2
grease dummy
heavy backlash) Also refer to the latest version of
wheel for the swing
circle teeth (tight-
Is the wear out of range? No
ening).
3. Go to "SME006 -
There is a big
abnormal noise
when moving/stop-
ping swing" on
page 8-74.
Final check 3
TS 15110-upD-GB-0 PC5500-6 8 - 73
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 (HLP 32 only).
– Verify the oil level and the used oil viscosity in the motor adapter housing (HLP 32 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
pinion 2 and grease
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?
8 - 74 PC5500-6 TS 15110-upD-GB-0
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
stopping or starting the
Check the swing parking brake for proper swing movement.
Swing parking brake condition 1. Inspect and replace
internal damage (parking brake switch in position "1" = brake the defective swing
3 closed). SERVICE
(discs are welded Yes parking brakes as MANUAL
together) Carefully move the control lever to start swing necessary.
movement.
2. Also check for
Can you identify any abnormal noise or contamination of
abnormal swing movement? the gearbox oil.
3. 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
connection between SERVICE
Yes both components. MANUAL
If the connection is
damaged, replace the
Check the swing movement for proper swing gearbox and the
condition: hydraulic motor.
Damaged mechanical Check the hydraulic
– starting swing
connection between swing adjustment
the swing hydraulic – stopping swing (two stage valve).
motor and the swing – counter swing
4 Also see:
gearbox
(motor adapter – foot brake actuation – "SME007 - Abnor-
housing, excessive – fast swing speed mal noise coming
wear at the connection) from a travel gear-
– low swing speed)
box" on page 8-76 SERVICE
Can you identify any abnormal noise, MANUAL
No – "SME008 - Abnor-
abnormal swing movement, or abnormal & PM-
mal noise coming
vibration? CLINIC
from the work
equipment (lack of
grease)" on
page 8-78
– "SME009 - Abnor-
mal idler move-
ment" on
page 8-80
Final check 5
TS 15110-upD-GB-0 PC5500-6 8 - 75
SME007 - Abnormal noise coming from a travel gearbox

[1/2]
Trouble code
Trouble Abnormal noise coming from a travel gearbox
SME007
– 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 - 76 PC5500-6 TS 15110-upD-GB-0
SME007 - 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
gearbox.
Hydraulic travel motor Disconnect the concerning travel motor from Check the travel
connection defective the adapter housing and check the connection motor(s) for internal
3
(no oil in the motor at the motor and inside the motor adapter and external leakage
adapter housing) housing for any damage. and replace if
Can you identify any damage (because of necessary.
missing oil)? No Also refer to the
troubleshooting chart
"SHY005 - Machine
deviates during travel
movement" on
page 8-44.
Final check 4
TS 15110-upD-GB-0 PC5500-6 8 - 77
SME008 - 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)
SME008
– Abnormal noise occurs when the attachment is moving.
Contents of trouble – The abnormal noise occurs due to lack of grease (CLS1, CLS2) at the pins and the bushings of
the work equipment.
– First check the grease level at the CLS1 and CLS2 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 (KOMTRAX Plus 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 CLS1 or CLS2 system occurs - download the history data via
KOMTRAX Plus 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 Replace wrong grease
1 tions in the OPERATION & MAINTENANCE
is used by specified grease
MANUAL and in the latest version of the
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 - 78 PC5500-6 TS 15110-upD-GB-0
SME008 - 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
barrel as necessary.
Contaminated grease The injectors are worn out due to
contaminated grease in the barrel. Replace the defective
is used
pins and bushings on
(grease barrel refilling 2 No or not enough grease causes early wear Yes the attachment side.
without refilling the and noise at the pins and bushings of the
filter) attachment. Check all grease
injectors for proper
Are pins and bushings worn out due to lacking 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
Daily fault messages of parts of the CLS system as
the CLS1 or CLS2 sys- necessary.
tem occurs. Download the history data via KOMTRAX Plus
and verify the system status. Replace the defective pins and
Download the history 3 bushings on the attachment
data via KOMTRAX Do the history data show a lot of side (standardization of
Plus and verify the "bucket cut-off" messages due to overriding importance).
system status 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 15110-upD-GB-0 PC5500-6 8 - 79
SME009 - Abnormal idler movement

[1/1]
Trouble code
Trouble Abnormal idler movement
SME009
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.
- Also refer to the OPERATION & MAINTENANCE MANUAL and to the SERVICE MANUAL.
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 - 80 PC5500-6 TS 15110-upD-GB-0
SME010 - Leak at the PTO shaft seal

[1/2]
Trouble code
Trouble Leak at the PTO shaft seal
SME010
Contents of trouble Leak at the PTO shaft seal (after changing the oil viscosity).
PTO gear oil temperatures

Oil grade acc. to ISO T32 CLP150 Hypoid oil 75W-140
TG2 60°C 95°C 95°C

Related information
TG1 15°C 48°C 54°C
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
necessary.
Recommendation
(Diesel only)
For the removal of
the input drive shaft
it is beneficial to
The bearing of the Remove the coupling. Movement
remove the complete
drive shaft is defective max.
1 Check the input shaft bearing of the PTO gearbox and to
(too much movement), Yes 1.2 mm
PTO gearbox. remanufacture the
check the PTO lifetime horizontal
removed one
Is abnormal bearing movement (horizontal & & vertical
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 15110-upD-GB-0 PC5500-6 8 - 81
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
KMG is not available. PTO according to the Oil specifi-
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 80°C) 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 65°C
during normal
operation.
Final check 4
8 - 82 PC5500-6 TS 15110-upD-GB-0
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.
1. Check the A/C
WARNING system together
AIR CONDITIONING REFRIGERANT IS HARMFUL! with an A/C spe-
If air conditioner refrigerant gets into your eyes, it cialist and repair
may cause blindness. If it touches your skin, it may as necessary.
cause frostbite. Never touch refrigerant. 2. Refer to the A/C
manual and follow P&S
Any electrical problem NEWS
causes a disconnection 1. Using the A/C test tools perform a standard check the given proce-
AH05537
or short circuit in the of the A/C system. dures.
2 (latest
wiring or in any 2. Check for trouble codes displayed at the A/C 3. Refer to the Wiring version)
component of the control unit (for details refer to the A/C manual). diagram and check A/C
A/C system the main fuse box Manual
3. Check for electrical problems.
and the relays in
Could you identify any problem? Wiring dia-
the A/C unit.
grams
4. Check the wiring
for disconnection or
short circuit.
Locate the problem
and repair as
necessary.
Final check 3
TS 15110-upD-GB-0 PC5500-6 8 - 83
Symptoms of Additional Systems Troubleshooting by symptoms
View onto the A/C unit (SAD001)

[2/2]
Fig. 8-8 View onto the A/C unit (SAD001)
(1) Relays (3) A/C control unit
(2) Fuse box
8 - 84 PC5500-6 TS 15110-upD-GB-0
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).
- Wrong or no maintenance of the A/C system.
Possible causes - A wrong refilling procedure has been performed.
- Wrong installation or alignment of the A/C compressor support.
Nominal
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)
A wrong refilling Engines running at high idle.
procedure has A/C switched ON.
been performed P&S
WARNING NEWS
In compliance with Yes Go to next step. AH05537
AIR CONDITIONING REFRIGERANT IS
the regulations: (latest
HARMFUL!
When working at the If air conditioner refrigerant gets into your version)
A/C circuit or when eyes, it may cause blindness. If it touches
handling refrigerant Repair and replace defective parts
your skin, it may cause frostbite. as necessary.
R134a always
observe the safety
hints given in the A/ Details for repair or replacement
C manual and in the 1. Using the A/C test tools perform a – Is the specified amount of the
data sheet of standard check of the A/C system.
2 specified compressor oil filled
the refrigerant manu- 2. Follow the appropriate filling procedure in?
facturer. and consider the filling capacity in the
Work on the air con- cooling circuit. Make sure that the No compressor oil or the wrong
ditioning system may pressure safety valve at the compressor No
is open before filling the A/C circuit. amount of it causes early
only be carried out defects of the A/C compressor.
by persons having – Is the specified amount of the specified
special knowledge compressor oil filled in? – Is the specified amount of refrig-
and experience in erant R134a filled in?
– Is the specified amount of refrigerant
these systems.
R134a filled in? Too much R134a (only refilled
Always wear Safety
over the system pressure)
Glasses and Safety – Has the system been evacuated
causes an early defect of the
Gloves when work- and is it free of moisture?
ing on the A/C cir- A/C compressor shaft seal or
– Is the A/C system dry and clean? a burnt clutch.
cuit.
TS 15110-upD-GB-0 PC5500-6 8 - 85
SAD002 - Air conditioner compressor clutch is burnt

[2/2]
Nominal
value
1. 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
2. Check the drive belts for wear and correct Yes Manual and follow the NEWS
alignment of the A/C 3
maintenance hints. AH05537
compressor support tension.
(latest
3. Check for the correct V-belt running version)
direction between the pulleys.
Adjust, repair, or
No
Are the above items ok? replace as necessary.
Final check 4
View onto the A/C compressor and its mounting (SAD002)
Fig. 8-9 View onto the A/C compressor and its mounting (SAD002)
(1) A/C compressor (3) Mounting bracket
(2) Belt running direction (4) Mounting bolt
8 - 86 PC5500-6 TS 15110-upD-GB-0
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).
– Wrong or no maintenance of the A/C system.
Possible causes – Maintenance or repair is impossible because of too much moisture in the pipes and hoses
of the A/C system.
Nominal
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
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.
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
1. Disassemble the A/C system and check all parts for moisture.
If hoses and pipes are full of moisture, this is an indication that no version)
or not enough maintenance of the A/C system has been done.
2. Replace any defective or contaminated parts.
Assemble and evacuate the system.
3. Refill the specified amount of the specified compressor oil and
the specified volume of the R134a refrigerant.
4. Carry out the regular maintenance as described in the
PARTS & SERVICE NEWS and use the appropriate tools
for testing and refilling the A/C system.
Final check 3
TS 15110-upD-GB-0 PC5500-6 8 - 87
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.
1. Check if battery voltage and ground Vmin 22V
Replace the signal
is present at connector 60X155, Yes
beeper 60P140. Vmax 24V
terminals 16, 17.
The signal beeper 2. Main key switch 20S001 in OFF position.
1
60P140 is defective 3. Disconnect connector 60X155 and insert
the T-cable.
No Go to next step.
4. Measure the voltage.
5. Measure ground at 60X155 terminal 17.
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
1. Check the signal wiring of the travel pedals.
or any wiring problem and repair or replace
occurred 2. Check the wiring leading to the signal beeper as necessary. Vmax 24V
60P140.
Final check 3
8 - 88 PC5500-6 TS 15110-upD-GB-0
Wiring diagram (60P140) for trouble code SAD004

[2/2]
Fig. 8-10 Wiring diagram (60P140) for trouble code SAD004
TS 15110-upD-GB-0 PC5500-6 8 - 89
8 - 90 PC5500-6 TS 15110-upD-GB-0

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TS 15110-xD-GB-0

Unsafe use of this machine may cause serious

Komatsu has Service Manuals written in other

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

TS 15110-xD-GB-0 PC5500-6 TOC - 1

TOC - 2 PC5500-6 TS 15110-xD-GB-0

2 INTRODUCTION & GENERAL INFORMATION FOR

TS 15110-xD-GB-0 PC5500-6 TOC - 3

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

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

5 REFERENCES FOR TROUBLESHOOTING (CAN BUS & NODE

TOC - 4 PC5500-6 TS 15110-xD-GB-0

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......................................................................................................... 7-15

G00006 - Test speed 1800 1/min engine 2 ......................................................................................... 7-18

G00007 - Trouble hydraulic oil level................................................................................................... 7-18

G00012 - Central lubrication system grease level too low............................................................... 7-20

TS 15110-xD-GB-0 PC5500-6 TOC - 5

G00020 - Trouble Shut-Off (gate) valve (Start blocked) ................................................................... 7-31

G00031 - Set engine to low idle .......................................................................................................... 7-36

G00032 - Trouble starter...................................................................................................................... 7-38

G00033 - Trouble KOMTRAX Plus controller .................................................................................... 7-41

G00034 - Trouble KOMTRAX Plus display......................................................................................... 7-42

G00035 - Trouble totally loss gear oil (PTO 1) .................................................................................. 7-43

G00036 - Trouble totally loss gear oil (PTO 2) .................................................................................. 7-43

G00037 - Trouble monitoring, engine 2 speed too low .................................................................... 7-48

G00038 - Trouble monitoring, engine 2 speed too high ................................................................... 7-48

G00039 - Actuate engine speed selector switch ............................................................................... 7-48

G00043 - Trouble output short-circuit................................................................................................ 7-49

G00048 - Trouble emergency safety circuit....................................................................................... 7-50

G00053 - Reset emergency safety circuit .......................................................................................... 7-52

G00054 - Monitoring idle position cut off .......................................................................................... 7-53

G00060 - Fire in the power house....................................................................................................... 7-56

TOC - 6 PC5500-6 TS 15110-xD-GB-0

G00062 - Trouble monitoring, engine 1 speed too high................................................................... 7-64

G00063 - Trouble monitoring hydraulic oil temp .............................................................................. 7-66

G00064 - Trouble monitoring hydraulic oil level............................................................................... 7-68

G00065 - Very low hydraulic oil level ................................................................................................. 7-71

G00066 - Trouble hydraulic oil temperature...................................................................................... 7-72

G00067 - Trouble battery voltage too high ........................................................................................ 7-75

G00068 - Trouble gear lubrication (PTO 2) ........................................................................................ 7-78

G00069 - Trouble monitoring oil temperature gear (PTO 1)............................................................. 7-79

G00070 - Trouble oil temperature gear (PTO 1) ................................................................................ 7-82

G00071 - Trouble gear lubrication (PTO 1) ........................................................................................ 7-86

G00081 - Trouble lubrication system ................................................................................................. 7-88

G00083 - Trouble monitoring oil temperature gear (PTO 2)............................................................. 7-91

G00084 - Trouble oil temperature gear (PTO 2) ................................................................................ 7-91

G00086 - SHUTDOWN.......................................................................................................................... 7-91

G00087 - Stop all movements for low idle ......................................................................................... 7-92

TS 15110-xD-GB-0 PC5500-6 TOC - 7

G00091 - Pilot control cut out ............................................................................................................. 7-95

G00092 - Emergency shut-down at access ladder ........................................................................... 7-97

G00093 - Emergency shut-down at valve block ................................................................................ 7-97

G00094 - Emergency shut-down at hydraulic control panel............................................................ 7-97

G00095 - Emergency shut-down in cabin.......................................................................................... 7-97

G00096 - Pilot control cut out ........................................................................................................... 7-100

G00097 - Emergency shut-down at counterweight......................................................................... 7-102

G00099 - Trouble power supply........................................................................................................ 7-102

G00100 - Maintenance Safety Switch............................................................................................... 7-102

G00103 - Faulty switch 20M004 ........................................................................................................ 7-104

G00104 - Trouble battery current ..................................................................................................... 7-108