Komatsu HYDRAULIC MINING SHOVEL PC3000E-6 Shop Manual PDF

Description

Komatsu HYDRAULIC MINING SHOVEL PC3000E-6 Shop Manual – PDF DOWNLOAD

FILE DETAILS:

Komatsu HYDRAULIC MINING SHOVEL PC3000E-6 Shop Manual – PDF DOWNLOAD

Language : English
Pages :1557
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC MINING SHOVEL PC3000E-6 Shop Manual – PDF DOWNLOAD

SERIAL NUMBER 06249 and up SERIAL NUMBER 46225 and up

TABLE OF CONTENTS:

Komatsu HYDRAULIC MINING SHOVEL PC3000E-6 Shop Manual – PDF DOWNLOAD

SERIAL NUMBER 06249 and up SERIAL NUMBER 46225 and up

Shop Manual 1
00 Foreword & Safety 3
1 Foreword 5
11 BEFORE READING THIS MANUAL 6
12 CONTENTS OF THIS BINDER 7
121 Contacting the Service 7
122 Guarantee 7
13 DIVISION OF THE BINDER 8
2 SAFETY 9
TOC 10
21 SAFETY INFORMATION 11
22 OVERVIEW 12
221 NORMAL OPERATIONS 12
222 REGULAR MAINTENANCE 12
223 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 12
224 ADDITIONAL SAFETY PRECAUTIONS 12
23 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB 13
231 SOUND 13
232 VIBRATION 13
24 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 14
241 UNDERSTANDING THE MACHINE 14
242 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 14
2421 ENSURING SAFE OPERATION 14
243 PREPARATIONS FOR SAFE OPERATION 14
2431 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 14
2432 INSPECTING THE MACHINE 14
2433 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 15
2434 KEEP MACHINE CLEAN 15
2435 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 15
2436 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 16
2437 IF A PROBLEM IS FOUND 16
244 FIRE PREVENTION 16
2441 PRECAUTIONS TO PREVENT FIRE 16
2442 ACTION IF FIRE OCCURS 18
2443 EMERGENCY EXIT FROM OPERATOR’S CAB 18
245 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 19
2451 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 19
2452 NO JUMPING ON OR OFF THE MACHINE 19
2453 NO PEOPLE ON THE ATTACHMENT 19
2454 WORKING IN HIGH PLACES 19
2455 LEAVING OPERATOR’S SEAT WITH LOCK 20
2456 LEAVING THE MACHINE 20
246 BURN PREVENTION 20
2461 Hot coolant 20
2462 Hot oil 21
247 PRECAUTIONS WHEN CLEANING CAB GLASS 21
248 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 21
249 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS 22
2491 UNAUTHORIZED MODIFICATION 22
2492 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 22
2410 ELECTROMAGNETIC COMPATIBILITY (EMC) 22
2411 PRECAUTIONS AT JOBSITE 23
24111 VISIBILITY FROM OPERATOR’S SEAT 24
24112 CAMERA SYSTEM WITH MONITORS 24
24113 ENSURE GOOD VISIBILITY 24
24114 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 24
24115 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 25
24116 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 25
24117 Lightning Strikes 26
24118 WORKING ON LOOSE GROUND 26
24119 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES 27
241110 VENTILATION OF ENCLOSED AREAS 28
2412 STARTING motor 29
24121 WARNING TAG 29
24122 CHECKS BEFORE STARTING motor 29
24123 PRECAUTION WHEN STARTING motor 29
24124 PRECAUTION IN COLD AREAS 30
2413 OPERATION 30
24131 CHECKS BEFORE OPERATION 30
24132 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 31
24133 PRECAUTIONS WHEN traveling 32
24134 TRAVELING ON SLOPES 33
24135 OPERATIONS ON SLOPES 34
24136 PROHIBITED OPERATIONS 34
24137 TRAVELING ON FROZEN OR SNOW COVERED SURFACES 35
24138 PARKING THE MACHINE 35
24139 TRANSPORTATION 35
25 PRECAUTION FOR MAINTENANCE 36
251 GENERAL PRECAUTIONS 36
2511 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 37
2512 STOP motor FOR MAINTENANCE 38
2513 WARNING TAG 39
2514 KEEP WORKPLACE CLEAN AND TIDY 40
2515 APPOINT LEADER WHEN WORKING WITH OTHERS 40
2516 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 41
2517 INSTALLING, REMOVING OR STORING ATTACHMENTS 41
2518 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 42
2519 NOISE 42
25110 WHEN USING A HAMMER 42
25111 PROPER TOOLS 43
25112 ACCUMULATOR 43
25113 PERSONNEL 43
252 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 44
2521 PRECAUTION WHEN WELDING 44
2522 BATTERY HANDLING 44
253 PRECAUTIONS WITH HIGH PRESSURE FLUID 45
2531 PRECAUTIONS WITH HIGH FUEL PRESSURE 46
2532 HANDLING HIGH PRESSURES HOSES OR PIPES 47
2533 REPLACEMENT OF HOSE LINES 47
2534 INSPECTION OF HOSE LINES 47
2535 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 48
2536 PRECAUTIONS FOR HIGH VOLTAGE 48
2537 AIR CONDITIONING MAINTENANCE 48
2538 COMPRESSED AIR 49
2539 WASTE MATERIALS 49
26 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 50
261 INSPECTION OF THE HYDRAULIC SYSTEM 50
262 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 50
263 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 50
27 SPECIAL SAFETY EQUIPMENT 51
271 FRONT GUARD PROTECTIVE STRUCTURe ’FOPS’ FOR OPERATOR’S CAB 52
272 OBJECT HANDLING 52
273 LIGHTING 52
274 WARNING BEACON 52
275 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 52
2751 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 52
2752 INSTRUCTIONS FOR USE 54
2753 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 56
2754 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS 56
2755 INSTRUCTIONS FOR USE 58
28 HIGH VOLTAGE SAFETY INSTRUCTIONS FOR MACHINES WITH ELECTRIC MOTOR 59
281 QUALIFICATION OF PERSONNEL 59
282 ELECTRICAL TOOLS 59
283 GENERAL PREPARATION BEFORE WORKING ON ELECTRICAL EQUIPMENT 60
284 CONNECTION OF PILOT LINE (GROUND CHECK WIRE) 60
285 PREPARATION BEFORE WORKING ON THE CABLE DRUM 60
286 PREPARATION BEFORE WORKING ON THE CABLE GUIDE 61
287 MODIFICATION OF THE ELECTRICAL SYSTEM 61
288 FIRE 61
289 GENERAL INSTRUCTIONS 62
2810 GROUNDING PROCEDURE FOR THE HIGH VOLTAGE SYSTEM 62
28101 INTRODUCTION 62
28102 GENERAL PREPARATION BEFORE WORKING ON ELECTRICAL EQUIPMENT 63
28103 WORKING EQUIPMENT & PERSONAL PROTECTION 63
28104 SPECIAL TOOLS REQUIRED 63
28105 PERSONAL PROTECTION EQUIPMENT (PPE) 64
28106 PREPARING THE MACHINE FOR HIGH VOLTAGE MAINTENANCE 64
28107 POWER DISCONNECTION AND EARTHING 65
28108 THE THREE STEPS To DEACTIVATE POWER 66
28109 EARTHING PROCEDURES IN THE HV CABINET 68
281010 THREE STEPS TO RECONNECTING THE POWER AFTER MAINTENANCE WORK 76
281011 Step 1, inserting the key 76
281012 Step 2, Switching earthing off 76
281013 Step 3, Switching load on 77
01 Specification 79
Specification PC3000 80
10 Structure & Function 90
TOC 92
1 Introduction 102
11 Foreword 103
12 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 104
13 Explanation of abbreviations 105
14 Diagrams and illustrations in this manual 106
2 Specifications 108
21 Lifting Gears 109
22 Safety hints for sling accessory 111
23 Standard Tightening Torque Chart 112
24 Conversion Tables 113
25 PT100 TEMPERATURE CHARTS (PT100) g Centigrade – Ohm 119
26 Blind plugs 120
27 Classification of threads to the nominal width 122
28 Plugs and fittings according to ISO 8434-1 / DIN 2353 123
3 Main Assembly Groups 124
31 General layout 125
32 Superstructure 127
33 Power house 129
34 Hydraulic Oil Reservoir 131
35 Hydraulic Oil cooler 133
36 High Voltage switch cabinet 135
37 Cab base 137
38 Operator’s cab 139
39 Control blocks 141
310 Slew gear 143
3101 Slew gear of type 2063 143
3102 Slew gear of type 632770 145
311 Slip ring unit & rotary joint 147
3111 Slip ring unit in detail 149
312 Slew ring 151
313 Attachment 153
3131 Front shovel attachment (FSA) 153
3132 Backhoe Attachment (BHA)) 155
314 Counterweight 157
315 Undercarriage 159
316 Safety circuit PPC control 161
4 Drive 164
41 Electric drive – Safety and operation instruction documents 165
42 Prime drive assembly 167
43 Electric motor 168
431 Motor type plate 168
432 TYPE PLATE FOR THE MOTOR BEARINGS 169
433 Motor bearings & grease equipment 170
434 Monitoring of the motor temperatures 172
435 Checking of the bearing condition 174
436 Capacitor assembly 175
44 Air – to – air motor cooling system 177
45 Initial Start-up procedure 178
451 Main supply cable 179
452 Motor protection relay (Spam 150C) 181
453 Motor alignment 185
454 Motor rotation direction 187
455 Starting & Re-starting the electro motor 187
456 Supervision during the first motor running period 188
46 Flexible Coupling 189
461 Coupling handling 191
462 Coupling inspection 191
463 Coupling replacement 192
47 Pump distributor gearbox (PTO) 193
471 Spline shaft housing 195
472 PTO lubrication and cooling 197
473 Checks and adjustments 199
474 PTO gear oil temperature control 203
4741 Temperature adjustment (oil viscosity) 204
48 Hydraulic pumps – arrangement 205
5 Hydraulic oil tank 208
51 General layout 209
52 Hydraulic oil tank, location of the electric equipment 211
53 Suction oil manifold with strainers 213
54 Return oil collector manifold with strainer 215
55 Back pressure valve 217
56 Transfer pump 219
57 Return and leak oil filter 221
58 Breather filter 223
6 Hydraulic oil cooling 226
61 Overall view of the hydraulic oil cooling 227
62 Function of the hydraulic oil cooling circuit 229
63 Adjustment of the back pressure valve 231
64 Two stage cooler fan RPM control 233
641 Solenoid valve for fan speed control 235
642 Pressure reducing valve 237
643 Temperature converter relays 239
6431 Function check of cooler fan RPM-control 240
65 Fan pump 241
66 Checks and Adjustments of the cooler fan drive speeds 243
661 Function Check of Fan Speed Control 246
7 Controlling 248
71 General layout 249
72 Control and filter plate – location of components 251
73 Pilot control frame – location of components 255
74 Pilot pressure supply and adjustments 257
741 Pilot pressure circuit 257
742 Checks and adjustment of pilot pressure 259
8 Components 262
81 Main control blocks and high pressure filters (FSA) 263
82 Main control blocks and high pressure Screens (BHA) 267
83 Distributor manifold – location of restrictor blocks and anti cavitation valves (FSA) 271
84 Distributor manifold – location of restrictor blocks and anti cavitation valves (BHA) 273
85 Single control blocks (floating) for stick and boom (FSA) 275
86 Restrictor block with secondary relief valve 277
87 Anti-cavitation valve (ACV) block 279
88 High-pressure screen 281
89 Control blocks and valves 283
891 Spool types 289
892 MRV, SRV and ACV 291
893 Load holding valve 293
810 Travel brake valve 297
811 4/2 Directional solenoid valves 299
812 4/3 Directional solenoid valves 301
813 Pressure double stage valve 303
814 Hydraulic cylinder with NOK-3 sealing 305
8141 Cylinder data markings 308
815 Auxiliary gear pumps 309
9 Main hydraulic pumps and pump regulation 310
91 General 311
911 Pump locations and pump data 313
92 Main pumps 315
921 Hydraulic pump type HPV375+375 315
9211 Main pump sectional drawings 317
922 Servo valve 319
9221 VC valve  servo piston 320
9222 EPC valve 325
93 Main pump operating principles 327
931 Main pump operating principals 327
94 Electronic pump regulation system 331
941 General 331
942 Signal rectifier modulE (ESR) 333
Function: 334
943 Diagnostics and monitoring 337
944 Temperature control 337
9441 temperature Adjustment (hydraulic oil viscosity) 337
95 Pump controller CR700 339
96 Multimonitor 341
97 Multimonitor software instruction 343
971 Multimonitor main control 343
972 Service menu screen 344
973 Monitoring (menu item 01) 345
974 Abnormality Record (menu item 02) 347
975 Default (menu item 03) 351
9751 Adjustment (menu item 04) 353
976 Description of the Primary P-Factor 355
9761 Adjustment, item 1: Primary P-factor 355
977 Adjustment, items 2328: Sol_adj_min_P1Sol_adj_min_P6 356
978 Adjustment, items 3944: Sol_adj_mAX_P1Sol_adj_mAX_P6 357
979 Display Setup (menu item 05) 358
9710 Table of fault messages and adjustments 360
9711 Controller adjustment table 367
98 Main pump checks and adjustments 368
981 Power check 368
10 Operating hydraulics 372
101 General 373
1011 Floating system (FSA) 375
102 Checks and adjustments of the main relief valve (MRV) 377
103 Hydraulics for the attachment cylinders 381
1031 Checks and adjustments of the secondary relief valves (SRV) 381
10311 Boom cylinders, piston side (BHA & FSA), boom up 381
10312 Boom Cylinder, Piston Rod Side (BHA & FSA), boom down 385
10313 Stick cylinders, piston side (FSA), stick out 389
10314 Stick cylinders, piston side (BHA), stick in 393
10315 Stick cylinders, piston rod side (FSA), stick in 397
10316 Stick cylinders, piston rod side (BHA), stick out 401
10317 Bucket cylinders, piston side (FSA), bucket fill 405
10318 Bucket cylinders, piston side (BHA), bucket fill 409
10319 Bucket cylinders, piston rod side (FSA), bucket dump 413
103110 Bucket cylinders, piston rod side (BHA), bucket dump 417
103111 Clam cylinders, piston rod side (FSA), clam open 421
103112 Clam cylinders, piston side (FSA), clam close 425
1032 Checks and adjustments of the lowering speed 429
10321 Checks and adjustments of the lowering speed – boom (FSA) 429
10322 Checks and adjustments of the lowering speed – boom (BHA) 435
10323 Checks and adjustments of the lowering speed – stick (FSA) 437
10324 Checks and adjustments of the lowering speed – stick (BHA) 443
10325 Checks and adjustments of the lowering speed – bucket (FSA) 445
10326 Checks and adjustments of the lowering speed – bucket (BHA) 447
10327 Checks and adjustments of the lowering speed – clam (FSA) 449
104 Hydraulics for the slew circuit 451
1041 Slew circuit 451
1042 Slew motor 453
1043 Slew gearbox of type 2063 455
1044 Slew gearbox of type 632770 457
1045 Slew parking brake of type 2063 459
1046 Slew parking brake of type 632770 461
1047 Slew brake valve 463
1048 Checks and adjustments for the slew circuit 467
10481 Checks & adjustments, double stage valve 467
10482 checks & adjustments, slew brake pilot pressure 470
10483 Crosscheck of the DSV setting 470
10484 Checks and adjustment of the slew motion detection 471
1049 Function check for the hydraulic slew parking brake 473
105 Hydraulics for the travel circuit 475
1051 Travel circuit 475
1052 Travel motor 477
1053 Rotary joint 479
1054 Travel gearbox 481
1055 Travel parking brake 483
10551 Travel parking brake 483
106 Travel brake valve 485
1061 Checks and adjustments 487
10611 Checks and adjustments for the travel circuit 487
10612 Function check for the travel parking brake 489
11 Hydraulic track tensioning system 492
111 General 493
112 Functional description 495
113 Double stage valve 497
114 Tensioning cylinder 499
115 Adjustments / checks 501
12 Access ladder, hydraulically operated 504
121 General 505
122 Function of the hydraulically operated access ladder 507
123 Adjustments / checks 511
13 Hints for reading the hydraulic diagram 514
131 General 515
132 Hydraulic symbols 517
1321 Lines, unions 518
1322 Components, valves 520
1323 Sensors 520
1324 Valves, valve components 521
1325 Pump, motor, cylinder 525
14 Hints for reading the electric wiring diagram 530
141 General 531
142 Designation of electrical components 532
143 Electrical symbols 533
144 Symbols 535
1441 Drawing concept 537
1442 Explanation of the drawing concept 539
1443 Reading of the circuit diagrAM 543
15 Electronic Text monitoring system ETM 548
151 General 549
1511 System components 551
1512 Structur and function of the control menu 553
1513 Fault and information message classification 554
15131 Displaying the contents of the record memory 555
1514 Changing the input language 556
1515 Table of messages 557
152 Komtrax plus satellite communication 559
1521 General layout 559
16 Lubrication system 562
161 General overview (SLS & CLS) 563
1611 General description 564
162 Basic function of the lubrication systems 565
163 Lubrication systems (SLS & CLS) 567
1631 Lubrication pump station 567
1632 General information on CLS 569
1633 General information on SLS 569
164 Lubrication cycle 571
1641 Time segments & switch points of a lubrication cycle 572
1642 Automatic lubrication mode CLS 573
16421 Function 574
16422 System monitoring 574
1643 Automatic lubrication mode SLS 575
16431 Function 576
16432 System monitoring 576
1644 Automatic lubrication mode adjustments 577
16441 Pause time adjustment & fault time monitoring adjustment 577
16442 Lube cycle monitoring time adjustment 578
1645 Manual lubrication mode (CLS & SLS) 579
1646 Resetting a faulty lubrication system 579
165 Hydraulically driven lube pump 581
1651 Adjustment of lube pump speed 583
16511 Stroke speed adjustment 584
16512 Working pressure 584
166 Lubricant injectors 585
1661 Tightening torques for fittings at grease injectors 586
1662 Description 586
1663 Adjustment of the lubricant output 587
1664 Operation principle of lubricant injectors 589
16641 Function description 590
1665 Connection of one or more injectors 591
167 Vent valve and grease outlet filter 593
1671 Vent valve description 594
168 End-line switch 595
1681 Description 596
1682 CLS & SLS end-line switch adjustment 597
169 Lubricant level sensors 599
1691 Description 600
16911 Checks 600
1610 Commissioning 601
16101 Commissioning of the CLS lubrication system 601
16102 Fine adjustment 602
16103 Commissioning of the SLS lubrication system 603
17 Deep temperature equipment (option) 606
171 General information 607
1711 Introduction 607
1712 Deep temperature components overview 607
1713 Power supply preconditions for preheating 608
1714 Power requirements for preheating systems 609
172 Preheating procedure 610
1721 Global flow chart of the preheating procedure 610
1722 Starting the preheating procedure 611
1723 Preheating of operator’s cab and Diesel engine [coolant system] 612
1724 Preheating of lubricants and superstructure (Diesel) [electric system] 613
173 Constant heating of travel motors (TTT equipment below-40°C only) 614
174 Component location 615
1741 Electric heating elements for hydraulic & batteries [electric machine] 615
1742 Electric heating elements for hydraulics [Diesel machine] 617
1743 Electric heating elements for engines & batteries [Diesel machine] 619
175 Components of TT equipment 621
1751 Preheating components on a Diesel machine 621
1752 Preheating components on an electric machine 623
1753 Exemplary Wiring Diagrams for preheating systems 624
17531 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3 624
17532 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3 625
17533 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3 626
17534 Wiring diagram “Suction Oil Manifold Preheating” 627
17535 Wiring diagram “PTO Preheating” 628
17536 Wiring diagram “Battery heater pads” 629
18 Cable Guide & Cable Drum 632
181 General layout of the cable guide 633
1811 Safety 634
182 General layout of the cable drum 635
1821 Safety 637
183 Service switch 639
184 Drive system 641
1841 Drive motor 643
1842 Connecting the drive motor 645
1843 Drive motor resistor 645
1844 Drive torque regulation 645
1845 Cable strain 646
1846 Chain lubrication & chain tension 647
185 Drum Body 649
1851 Slip ring assembly 650
1852 Carbon graphite brushes 650
1853 Location of dryer and heater units in the drum body 651
1854 Dryer system 652
186 High voltage interlock system 653
187 Switch boxes on the cable drum 655
1871 Install and connect the cable 657
1872 Winding up the cable 659
188 Cable guide drive mechanism 661
1881 Proximity switches on the cable guide drive mechanism 663
1882 Cable deflection & drum full/empty control 665
18821 Monitoring the drum min/max winding status 667
1883 Checks and adjustments 669
189 Travel motion control 671
1891 Overview on switches & control elements on the cable drum 673
1810 Slew angle monitoring & Attention message 675
1811 Commissioning cable drum 677
18111 Cable drum configuration for the MTC (CoDeSys) 678
18112 Lubricate drum drive side bearing with grease 679
18113 Tool set for manual motor rotation 679
18114 Cable drum maintenance 679
1812 Shovel relocation 680
40 Troubleshooting 682
TOC 684
1 Introduction 690
11 Overview 691
111 General advice when using troubleshooting charts 691
12 General Precautions 692
2 General information for troubleshooting 694
21 Preparations for work 695
22 Precautions during work 695
23 Precautions when carrying out any operation 696
231 Precautions when carrying out removal work 696
232 Precautions when carrying out installation work 696
233 Precautions when completing the operation 697
24 Fundamental requirements for troubleshooting 698
241 Technical documentation 698
242 Tools 698
2421 Reference guide for deutsch removal tools 702
243 Personnel 703
25 Points To remember when trouble- shooting 703
26 Sequence Of events In troubleshooting 705
27 Checks before troubleshooting 706
28 Handling Of electric equipment and hydraulic components 707
281 Points to remember when handling electric equipment 707
282 Points To remember when handling hydraulic equipment 710
29 General working procedures 712
291 Air Bleeding of Various Hydraulic Parts 712
292 Air bleeding from the hydraulic pumps 712
293 Air bleeding from hydraulic cylinders 712
210 Cylinder bypass test 713
211 Basics about “How to crimp” (with strain relief) 714
2111 Crimp tool & repair kit 714
2112 General 715
2113 Select the required connector components 715
2114 Stripping a wire 716
2115 Crimping 717
2116 Connector assembly after crimping 718
212 Cable Shielding 719
3 Mounting Locations and Connector Types 720
31 General layout 721
32 Superstructure 723
33 Power house 725
34 Slip ring unit & rotary joint 727
341 Slip ring unit in detail 729
35 location of electrical Capacitor / electric motor 731
36 High Voltage switch cabinet 733
37 Cab base – location of electrical components 735
38 Control and filter plate – location of Components 737
39 PTO and suction oil tank – location of electrical components 739
310 Pilot control frame – location of electrical components 741
311 Main control blocks – location of components 743
312 Lubrication system – location of electrical components 745
3121 location of electrical Parts of the automatic lubrication system 747
313 Hydraulic Oil Tank – Location of Electrical Components 751
314 Hydraulically operated access ladder – location of electrical Components 753
315 Connector Types Overview 755
4 Standard Value Table for Electrical Components 760
5 References for Troubleshooting 770
51 7-segment error code indication 771
52 Relay checks 773
521 Switch contact testing using the Test button 773
522 Measuring of the coil resistance 775
6 Tables for Testing and Troubleshooting 776
61 PT100 temperature charts (PT100) g Centigrade – Ohm 777
62 Test value table for pressure sensors 778
621 Transducers with output voltage range: 0545 Volt 778
622 Transducers with output voltage range: 0595 Volt 778
63 Table of pump-controller-codes (Multitonitor) 779
64 Tables of symptom codes 781
641 Symptoms of the engines and related electrical system 781
642 Symptoms of the electric motor and related electrical system 781
643 Symptoms of the hydraulic system 781
644 Symptoms of the mechanical system 782
645 Symptoms of additional systems 782
65 Cable colour identification 783
7 Troubleshooting by trouble code 784
71 Message -1- Gear lubrication out of function (B17) 785
72 Message -2- Motor shutdown: Fire suppression system actuated 788
73 Message -3- Oil filter for control oil restricted (B22) 792
74 Message -4- Oil tank breather filter restricted (B24) 795
75 Message -5- Return oil filter restricted (B26) 798
76 Message -6- Leak oil filter restricted (B25) 801
77 Message -7- Hydraulic oil temperature too high (B15) 804
78 Message -8- (Not used) 810
79 Message -9- Main transformer temperature too high (1K4) 810
710 Message -10- Low voltage monitoring actuated 814
711 Message -11- (Not used) 818
712 Message -12- (Not used) 818
713 Message -13- (Not used) 818
714 Message -14- Motor-shutdown: Too low hydraulic oil level! (B4) 818
715 Message -15- Caution, slew gear house brake ON 823
716 Message -16- Caution, travel gear house brake ON 828
717 Message -17- No clearance for starting, wrong direction of motor rotation 833
718 Message -18- Central lubrication system fault 836
719 Message -19- Slew ring gear lubrication system fault 844
720 Message -20- Motor shutdown: Motor protection relay released (1K2) 852
721 Message -21- Central lubrication system, empty grease barrel 856
722 Message -22- Slew ring gear lubrication system, empty grease barrel 856
723 Message -23- Motor shutdown: Motor bearing temperature too high (1K14) 862
724 Message -24- Caution, Insulation monitoring actuated (1K10) 867
725 Message -25- No clearance for starting by motor protection relay (1K3) 871
726 Message -26- Attention! Overheating protection of cab heating has triggered 874
727 Message -27- (Not used) 878
728 Message -28- (Not used) 878
729 Message -29- (Not used) 878
730 Message -30- (Not used) 878
731 Message -31- (Not used) 878
732 Message -32- PTO-gear lubrication filter restricted (B27) 878
733 Message -33- Cooler fan drive filter restricted (B28) 881
734 Message -34- (Not used) 884
735 Message -35- (Not used) 884
736 Message -36- (Not used) 884
737 Message -37- (Not used) 884
738 Message -38- (Not used) 884
739 Message -39- Motor-shutdown: Shut-Off (gate) valve S31 closed 885
740 Message -40- Caution, switch-cabinet temperature too high (6B1, 6B2) 889
741 Message -41- Motor shutdown: Engine temperature too high (1K6) 893
742 Message -42- (Not used) 898
743 Message -43- Motor-shutdown: Emergency stop switch actuated 898
Message -44- Motor-shutdown: Safety switch actuated (1K58) 902
Message -45- Motor-shutdown: Capacitor failed (1K12) 906
744 Message -46- (Not used) 910
745 Message -47- (Not used) 910
746 Message -48- Too high PTO-gear oil temperature (B49) 910
747 Message -50- Caution, pull switch from ground man actuated 913
748 Message -51- Motor shutdown: pull switch from ground man actuated 914
749 Message -52- Load limiting clam defective 916
750 Message -53- Pressure switch of the central lubrication system actuated (B43) 919
751 Message -54- Pressure switch of the slew ring gear lubrication system actuated (B46) 919
752 Message -55- Refill hydraulic oil 920
753 Message -56- Pilot control cut out 924
754 Message -57- Pump regulation faulty 928
755 Message -58- Strainer oil cooler restricted (B165) 928
756 Message -59- Central lubrication system, refill grease barrel 930
757 Message -60- Slew ring gear lubrication system, refill grease barrel 930
8 Troubleshooting by Symptoms 936
81 Symptoms of the engine and related electrical system 937
811 SEM001 – Motor does not start 937
8111 Wiring diagram for trouble code SEM001 938
8112 Wiring Diagram 2 for trouble code SEM001 939
8113 Wiring Diagram 3 for trouble code SEM001 940
812 SEM002 – Motor does not stop 941
8121 Wiring Diagram for trouble code SEM002 942
813 SEM003 – Excessive motor vibration 943
814 SEM004 – Abnormal noise from motor 944
815 SEM005 – Motor lacks output (low power) 945
816 SEM006 – Air to Air cooling system not sufficient 946
817 SEM007 – Motor shuts down during start 947
8171 Wiring Diagram for trouble code SEM007 948
818 SEM008 – Sub Station main circuit breaker trips 949
8181 Related information for trouble code SEM008 949
8182 Related information for trouble code SEM008 950
82 Symptoms of the hydraulic system 951
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function) 951
821 SHY002 – No work equipment, travel or swing movement 953
822 SHY003 – Work equipment has too much hydraulic drift 954
8221 SHY003 – Work equipment has too much hydraulic drift 955
823 SHY004 – Work equipment has big time lag 956
824 SHY005 – Machine deviates during travel movement 957
825 SHY006 – Machine does not swing 958
826 SHY007 – Swing acceleration is poor 959
8261 SHY007 – Swing acceleration is poor 960
827 SHY008 – Excessive overrun when stopping swing 961
8271 SHY008 – Excessive overrun when stopping swing 962
828 SHY009 – Floating system without function 963
829 SHY010 – Abnormal noise coming from SRV or MRV 964
8210 SHY011 – Track tensioning system without function 965
8211 SHY012 – Ladder does not move, or slow movement 966
82111 SHY012 – Ladder does not move, or slow movement 967
8212 SHY013 – The hydraulic driven grease pump does not move 968
8213 SHY014 – Abnormal track chain movement during digging 970
8214 SHY015 – Swing parking brake without function 971
8215 SHY016 – Travel parking Brake without function 972
83 Symptoms of the mechanical system 973
831 SME001 – Abnormal noise around the PTO / hydraulic pumps 973
8311 SME001 – Abnormal noise around the PTO / hydraulic pumps 974
832 SME002 – There is a big shock when stopping swing 975
833 SME003 – There is a big abnormal noise when moving/ stopping swing 976
8331 SME003 – There is a big abnormal noise when moving/stopping swing 977
834 SME004 – Abnormal noise coming from a travel gearbox 978
8341 SME004 – Abnormal noise coming from a travel gearbox 979
835 SME005 – Abnormal noise coming from the work equipment (lack of grease) 980
8351 SME005 – Abnormal noise coming from the work equipment (lack of grease) 981
836 SME006 – Abnormal idler movement 982
837 SME007 – Leak at the PTO shaft seal 983
8371 SME007 – Leak at the PTO shaft seal 984
84 Symptoms of Additional Systems 985
SAD001 – Air conditioner for the cabin does not work 985
View onto the A/C unit (SAD001) 986
SAD002 – Air conditioner compressor clutch is burnt 987
View onto the A/C compressor and its mounting (SAD002) 988
SAD003 – Air conditioning system defective (pipes and hoses full of moisture) 989
View onto an A/C filling and service station 990
50 Disassembly & Assembly 992
TOC 994
1 SAFETY1004
11 SAFETY INFORMATION1005
12 OVERVIEW1006
121 NORMAL OPERATIONS1006
122 REGULAR MAINTENANCE1006
123 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR1006
124 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR1006
13 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB1007
14 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR1008
141 UNDERSTANDING THE MACHINE1008
142 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR1008
1421 ENSURING SAFE OPERATION1008
143 PREPARATIONS FOR SAFE OPERATION1008
1431 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT1008
1432 INSPECTING THE MACHINE1008
1433 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT1009
1434 KEEP MACHINE CLEAN1009
1435 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT1009
1436 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT1010
1437 IF A PROBLEM IS FOUND1010
144 FIRE PREVENTION1010
1441 PRECAUTIONS TO PREVENT FIRE1010
1442 ACTION IF FIRE OCCURS1011
1443 EMERGENCY EXIT FROM OPERATOR’S CAB1012
145 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE1012
1451 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE1012
1452 NO JUMPING ON OR OFF THE MACHINE1012
1453 NO PEOPLE ON THE ATTACHMENT1012
1454 WORKING IN HIGH PLACES1012
1455 LEAVING OPERATOR’S SEAT WITH LOCK1013
1456 LEAVING THE MACHINE1013
146 BURN PREVENTION1014
1461 Hot coolant1014
1462 Hot oil1014
147 PRECAUTIONS WHEN CLEANING CAB GLASS1014
148 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES1015
1481 UNAUTHORIZED MODIFICATION1015
1482 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS1015
149 PRECAUTIONS AT JOBSITE1016
1491 VISIBILITY FROM OPERATOR’S SEAT1017
1492 CAMERA SYSTEM WITH MONITORS1017
1493 ENSURE GOOD VISIBILITY1017
1494 CHECKING SIGNS AND SIGNALMAN’S SIGNALS1017
1495 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS1018
1496 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES1018
1497 WORKING ON LOOSE GROUND1019
1498 GAS, DUST, STEAM AND SMOKE1019
1499 VENTILATION OF ENCLOSED AREAS1020
1410 STARTING ENGINE1021
14101 WARNING TAG1021
14102 CHECKS BEFORE STARTING ENGINE1021
14103 PRECAUTION WHEN STARTING ENGINE1021
14104 PRECAUTION IN COLD AREAS1022
1411 OPERATION1022
14111 CHECKS BEFORE OPERATION1022
14112 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE1023
14113 PRECAUTIONS WHEN travelling1024
14114 TRAVELLING ON SLOPES1025
14115 OPERATIONS ON SLOPES1026
14116 PROHIBITED OPERATIONS1026
14117 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES1027
14118 PARKING THE MACHINE1027
14119 TRANSPORTATION1027
15 PRECAUTION FOR MAINTENANCE1028
151 GENERAL PRECAUTIONS1028
1511 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES1029
1512 STOP ENGINE FOR MAINTENANCE1030
1513 WARNING TAG1031
1514 KEEP WORKPLACE CLEAN AND TIDY1032
1515 APPOINT LEADER WHEN WORKING WITH OTHERS1032
1516 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING1033
1517 INSTALLING, REMOVING OR STORING ATTACHMENTS1033
1518 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT1034
1519 NOISE1034
15110 WHEN USING A HAMMER1034
15111 PROPER TOOLS1035
15112 ACCUMULATOR1035
15113 PERSONNEL1035
152 PRECAUTIONS FOR INSPECTION AND MAINTENANCE1036
1521 PRECAUTION WHEN WELDING1036
1522 BATTERY HANDLING1036
153 PRECAUTIONS WITH HIGH PRESSURE Fluid1037
1531 PRECAUTIONS WITH HIGH FUEL PRESSURE1037
1532 HANDLING HIGH PRESSURES HOSES OR PIPES1038
1533 REPLACEMENT OF HOSE LINES1038
1534 INSPECTION OF HOSE LINES1038
1535 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS1039
1536 PRECAUTIONS FOR HIGH VOLTAGE1039
1537 AIR CONDITIONING MAINTENANCE1039
1538 COMPRESSED AIR1040
1539 WASTE MATERIALS1040
16 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS1041
161 INSPECTION OF THE HYDRAULIC SYSTEM1041
162 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS1041
163 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR1041
17 SPECIAL SAFETY EQUIPMENT1042
171 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB1043
172 OBJECT HANDLING1043
173 LIGHTING1043
174 WARNING BEACON1043
175 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)1043
1751 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)1043
1752 INSTRUCTIONS FOR USE1045
1753 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL1047
1754 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1),1047
1755 INSTRUCTIONS FOR USE1049
2 Superstructure1050
21 Superstructure overview1051
22 Electric motors1053
221 Removal of the electric motor1053
222 Replacement of the electric motor1058
223 Final alignment of the electric motors1061
224 Capacitor assembly1065
2241 Removal of the capacitor assembly1065
2242 Replacement of the capacitor assembly1067
23 Batteries1068
231 Removal of the batteries1068
232 Replacement of the batteries1070
24 Torsion Coupling1071
241 Reich coupling1071
2411 Removal of the Reich coupling1072
2412 Replacement of the Reich coupling1075
25 PTO1077
251 Main pumps1077
2511 Preparatory works for main pump removal1078
2512 Removal of main pump 11082
2513 Replacement of main pump 11084
2514 Removal of main pump 21085
2515 Replacement of main pump 21088
2516 Removal of main pump 31089
2517 Replacement of main pump 31092
252 PTO oil circulation pump (auxiliary pump)1093
2521 Removal of the PTO oil circulation pump1093
2522 Replacement of the PTO oil circulation pump1094
253 Pump distributor gear box (PTO)1095
2531 Preparatory work for PTO removal1095
2532 Removal of the pump distributor gear box (PTO)1096
2533 Replacement of the pump distributor gear box (PTO)1098
26 Hydraulics1099
261 Hydraulic cooler fan drive pump1099
2611 Removal of hydraulic cooler fan drive pump1099
2612 Replacement of hydraulic cooler fan drive pump1102
262 Hydraulic oil cooler assembly1103
2621 Removal of the hydraulic cooler fan assembly1106
2622 Replacement of the hydraulic cooler fan assembly1108
2623 Removal of hydraulic cooler fan and motor1109
2624 Replacement of hydraulic cooler fan and motor1111
2625 Removal of the hydraulic oil coolers1114
2626 Replacement of the hydraulic oil coolers1117
2627 Removal of the hydraulic oil cooler Assembly1120
2628 Replacement of the hydraulic oil cooler Assembly1125
263 Pilot oil pump (Gear pump)1126
2631 Removal of the pilot oil pump1127
2632 Replacement of the pilot oil pump1129
264 Main gate valve1130
2641 Removal of the main gate valve1130
2642 Replacement of the main gate valve1132
265 Hydraulic oil reservoir1133
2651 Removal of the hydraulic oil reservoir1134
2652 Replacement of the hydraulic oil reservoir1140
266 Main control valve blocks1141
2661 General information1141
2662 Removal of the main control valve blocks1151
2663 Replacement of the main control valve blocks1156
267 Main relief valves (MRV)1157
2671 Removal of the MRV at the main control valve blocks1157
2672 Replacement of the MRV at the main control valve blocks1158
268 Service line relief valves (SRV)1159
2681 Removal of SRV on the main control valve blocks1159
2682 Replacement of SRV on the main control valve blocks1161
269 Anti-cavitation valves (ACV)1162
2691 Removal of ACV on manifold1163
2692 Replacement of ACV on manifold1165
2693 Removal of ACV on main control valve blocks1166
2694 Replacement of ACV on main control valve blocks1168
2610 Throttle check valves1169
26101 Removal of throttle check valves1170
26102 Replacement of throttle check valves1173
26103 Removal of the diffuser on the manifold (FSA only)1174
26104 Replacement of the diffuser on the manifolD (FSA Only)1176
2611 Manifold1177
26111 Layout1177
26112 Removal of the manifold1179
26113 Replacement of the manifold1181
27 Slew drive1182
271 Slew gear box1183
2711 Removal of the slew gear box1184
2712 Replacement of the slew gear box1187
272 Swing motor1189
2721 Removal of the swing motor1190
2722 Replacement of the swing motor1193
273 Slew parking brake1195
2731 Removal/disassembly of the slew parking brake of type 20631196
2732 Replacement/assembly of the slew parking brake of type 20631199
2733 Removal of the slew parking brake of type 6327701202
2734 Replacement of the slew parking brake of type 6327701205
274 Dynamic slew brake1209
2741 Removal of the slew service brake valve1212
2742 Replacement of the slew service brake valve1214
275 Swing circle lubrication pinion1215
2751 Removal of the lubrication pinion assembly1216
2752 Replacement of the lubrication pinion assembly1218
276 Swing circle1219
2761 Removal of the swing circle1220
2762 Replacement of the swing circle1223
28 Lubrication pumps1227
281 Removal of the lubrication pump1227
282 Replacement of the lubricating pump1228
29 Operator’s cab1229
291 Removal of the operator’s cab1230
292 Replacement of the operator’s cab1235
293 Cab mounts1235
2931 Removal of the cab mounts1235
2932 Replacement of the cab mounts1237
294 Front window1237
2941 Removal of the front window1237
2942 Replacement of the front window1238
295 Operator’s seat1239
2951 Removal of the operator’s seat1239
2952 Replacement of the operator’s seat1240
296 ETM1241
2961 Removal of the ETM1241
2962 Replacement of the ETM1241
210 Cab base (MEDIUM VOLTAGE SWITCH CABINET)1242
2101 Removal of the cab base1242
2102 Replacement of the cab base1244
2103 Pump controller1246
21031 Removal of the pump controller CR7001246
21032 Replacement of the pump controller CR7001247
211 Access Ladder1248
2111 Removal of access ladder1248
2112 Replacement of access ladder1251
2113 Removal of access ladder cylinder1252
2114 Replacement of access ladder cylinder1254
212 Counterweight1255
2121 Removal of the counterweight1258
2122 Replacement of the counterweight1260
213 Superstructure lifting1261
2131 Remove the superstructure from the undercarriage1261
2132 Install the superstructure onto the undercarriage1264
214 High voltage switch cabinet1266
2141 Removal of the High voltage switch cabinet1267
2142 Replacement of the high voltage switch cabinet1270
215 Slip ring unit1271
2151 Removal of the slip ring unit1272
2152 Replacement of the slip ring unit1274
3 Undercarriage1276
31 Undercarriage overview1277
32 Travel System1279
321 Track group1279
3211 changing the track group1279
322 Sprocket1284
3221 Removal of the sprocket1284
3222 Replacement of the sprocket1287
323 Guide wheels (Idlers)1289
3231 Removal of the guide wheel assembly1289
3232 Replacement of the guide wheel assembly1291
324 Track tensioning accumulators1293
3241 Removal of the low pressure accumulators1293
3242 Replacement of the low pressure accumulators1295
3243 Removal of the high pressure accumulators1296
3244 Replacement of the high pressure accumulators1297
325 Track tension valve block1298
3251 Removal of the track tensioning valve block1298
3252 Replacement of the track tensioning valve block1300
326 Track tensioning cylinders1301
3261 Removal of the track tensioning cylinders1301
3262 Replacement of the track tensioning cylinders1303
327 Substitute the Hydraulic hoses of the track tensioning system1304
3271 Precursory work1304
3272 Substitute the hydraulic hoses inside the car body1306
3273 Substitute the hydraulic hose between car body and crawler frame1306
3274 Substitute the hydraulic hoses inside the crawler frame1308
3275 Subsequent work1309
328 Travel brake valve block (overspeed valve)1310
3281 Removal of the travel brake valve block1313
3282 Replacement of the travel brake valve block1314
329 Travel motor1315
3291 Removal of the travel motors1315
3292 Replacement of the travel motors1317
3210 Travel parking brake1319
32101 Removal of the travel parking brake1320
32102 Replacement of the travel parking brake1322
3211 Travel gear box1323
32111 Removal of the travel gear box1324
32112 Replacement of the travel gear box1328
3212 Carrier roller1331
32121 Removal of the carrier roller assembly1331
32122 Replacement of the carrier roller assembly1333
3213 Track roller1334
32131 Removal of the track roller assembly1334
32132 Replacement of the track roller assembly1336
33 Car body1337
331 Removal of the car body and the crawler carriers1337
332 Replacement of the car body and the crawler carriers1343
3321 Tightening torque for the crawler carrier mounting bolts1349
333 Rotary joint1351
3331 Removal of the rotary joint1351
3332 Replacement of the rotary joint1353
34 Cable supply1355
341 Removal of the cable supply1355
342 Replacement of the cable supply assembly1357
4 Attachment1360
41 Backhoe1361
411 Boom1363
4111 Removal of the boom1363
4112 Replacement of the boom1366
4113 Removal of boom cylinders1369
4114 Replacement of boom cylinders1374
412 Stick1379
4121 Removal of the stick1379
4122 Replacement of stick1383
4123 Removal of stick cylinders1385
4124 Replacement of stick cylinders1390
413 Bucket1393
4131 Removal of the bucket1393
4132 Replacement of the bucket1396
4133 Removal of bucket cylinders1397
4134 Replacement of bucket cylinders1403
414 Bucket link rod and steering rods1406
4141 Removal of the bucket link rod1406
4142 Replacement of the bucket link rod1408
4143 Removal of the steering rods1409
4144 Replacement of the steering rod1412
415 Ground engaging tools (GET)1413
4151 Removal and replacement of the GET1413
416 Hydraulic hoses at the backhoe attachment1415
4161 Substitute the boom arc hoses1415
4162 Substitute the boom cylinder hoses1419
4163 Substitute the stick cylinder hoses1423
4164 Substitute the bucket cylinder hoses1427
42 Face shovel1431
421 Using the installation tools for hydraulic cylinders1432
422 Boom1433
4221 Removal of the boom1433
4222 Replacement of the boom1440
4223 Removal of the boom cylinders1445
4224 Replacement of the boom cylinders1449
423 Stick1453
4231 Removal of the stick1453
4232 Replacement of the stick1457
4233 Removal of the stick cylinders1461
4234 Replacement of the stick cylinders1465
424 Bull clam bucket1469
4241 Removal of the bull clam bucket1469
4242 Replacement of the bull clam bucket1475
4243 Removal of the bucket cylinders1477
4244 Replacement of the bucket cylinders1481
4245 Removal of the clam cylinders1485
4246 Replacement of the clam cylinders1489
425 Ground engaging tools (GET)1492
4251 Removal and replacement of the GET1492
426 Hydraulic hoses at the face shovel attachment1493
4261 Substitute the boom arc hoses1493
4262 Substitute the boom cylinder hoses1497
4263 Substitute the stick arc hoses1501
4264 Substitute the stick cylinder hoses1505
4265 Substitute the bucket cylinder hoses1509
4266 Substitute the clam cylinder hoses1513
43 Metering valves (grease injectors) at the attachment1521
431 Operation test of the metering valves (grease injectors)1522
432 Removal of the metering valves (grease injectors)1523
433 Replacement of the metering valves (grease injectors)1525
44 Cylinder bypass test1526
5 Service Information1528
51 Fluids and lubricants1529
52 Filling capacities1530
53 Work instructions1531
531 Surface coating with INTERZINC 6971531
532 Remove / install the crawler carrier1533
54 Weight tables1534
541 Superstructure1534
542 Undercarriage1536
543 Backhoe attachment (BHA)1537
544 Face shovel attachment (FSA)1538
55 Torque charts according to KOMATSU company standard1539
551 Metric standard thread1539
552 Metric fine thread1540
553 Cummins motor torques – metric1541
554 Cummins motor torques – US customary1541
555 Flange connections1542
56 Blind plugs1543
561 Dummy plates for SAE–flanges1543
562 Classification of threads to the nominal width1545
563 Plugs and fittings according to DIN 23531546
57 Conversation table1547
571 Method of using the conversation table1547
572 Millimeter – inch & kilogram – pound1548
573 Liter – US gallon & liter – UK gallon1549
574 Nm- ftlb1550
575 Bar – PSI – kPa – MPa1551
576 Basic values in Ohm according to ISO 43 761552
577 Temperature1553
58 Tools1554
581 Standard tool case1554
582 Used special tools (Overview)1556

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24