Komatsu HYDRAULIC MINING SHOVEL PC5500-6 Shop Manual – PDF DOWNLOAD

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Komatsu HYDRAULIC MINING SHOVEL PC5500-6 Shop Manual – PDF DOWNLOAD

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Komatsu HYDRAULIC MINING SHOVEL PC5500-6 Shop Manual – PDF DOWNLOAD

Language : English
Pages :2020
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC MINING SHOVEL PC5500-6 Shop Manual – PDF DOWNLOAD

SERIAL NUMBER 15110 (15100) – up

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.

TABLE OF CONTENTS:

Komatsu HYDRAULIC MINING SHOVEL PC5500-6 Shop Manual – PDF DOWNLOAD

SERIAL NUMBER 15110 (15100) – up

Shop Manual 0
00 Foreword 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
21 SAFETY INFORMATION 10
22 OVERVIEW 11
221 NORMAL OPERATIONS 11
222 REGULAR MAINTENANCE 11
223 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 11
224 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR 11
23 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 12
24 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 13
241 UNDERSTANDING THE MACHINE 13
242 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 13
2421 ENSURING SAFE OPERATION 13
243 PREPARATIONS FOR SAFE OPERATION 13
2431 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 13
2432 INSPECTING THE MACHINE 13
2433 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 14
2434 KEEP MACHINE CLEAN 14
2435 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 14
2436 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 15
2437 IF A PROBLEM IS FOUND 15
244 FIRE PREVENTION 15
2441 PRECAUTIONS TO PREVENT FIRE 15
2442 ACTION IF FIRE OCCURS 16
2443 EMERGENCY EXIT FROM OPERATOR’S CAB 17
245 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 17
2451 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 17
2452 NO JUMPING ON OR OFF THE MACHINE 17
2453 NO PEOPLE ON THE ATTACHMENT 17
2454 WORKING IN HIGH PLACES 17
2455 LEAVING OPERATOR’S SEAT WITH LOCK 18
2456 LEAVING THE MACHINE 18
246 BURN PREVENTION 19
2461 Hot coolant 19
2462 Hot oil 19
247 PRECAUTIONS WHEN CLEANING CAB GLASS 19
248 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 20
2481 UNAUTHORIZED MODIFICATION 20
2482 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 20
249 ELECTROMAGNETIC COMPATIBILITY (EMC) 21
2410 PRECAUTIONS AT JOBSITE 22
24101 VISIBILITY FROM OPERATOR’S SEAT 23
24102 CAMERA SYSTEM WITH MONITORS 23
24103 ENSURE GOOD VISIBILITY 23
24104 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 23
24105 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 24
24106 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 24
24107 WORKING ON LOOSE GROUND 25
24108 GAS, DUST, STEAM AND SMOKE 25
24109 VENTILATION OF ENCLOSED AREAS 26
2411 STARTING motor 27
24111 WARNING TAG 27
24112 CHECKS BEFORE STARTING motor 27
24113 PRECAUTION WHEN STARTING motor 27
24114 PRECAUTION IN COLD AREAS 28
2412 OPERATION 28
24121 CHECKS BEFORE OPERATION 28
24122 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 29
24123 PRECAUTIONS WHEN travelling 30
24124 TRAVELLING ON SLOPES 31
24125 OPERATIONS ON SLOPES 32
24126 PROHIBITED OPERATIONS 32
24127 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 33
24128 PARKING THE MACHINE 33
24129 TRANSPORTATION 33
25 PRECAUTION FOR MAINTENANCE 34
251 GENERAL PRECAUTIONS 34
2511 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 35
2512 STOP motor FOR MAINTENANCE 36
2513 WARNING TAG 37
2514 KEEP WORKPLACE CLEAN AND TIDY 38
2515 APPOINT LEADER WHEN WORKING WITH OTHERS 38
2516 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 39
2517 INSTALLING, REMOVING OR STORING ATTACHMENTS 39
2518 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 40
2519 NOISE 40
25110 WHEN USING A HAMMER 40
25111 PROPER TOOLS 41
25112 ACCUMULATOR 41
25113 PERSONNEL 41
252 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 42
2521 PRECAUTION WHEN WELDING 42
2522 BATTERY HANDLING 42
253 PRECAUTIONS WITH HIGH PRESSURE FLUID 43
2531 PRECAUTIONS WITH HIGH FUEL PRESSURE 43
2532 HANDLING HIGH PRESSURES HOSES OR PIPES 44
2533 REPLACEMENT OF HOSE LINES 44
2534 INSPECTION OF HOSE LINES 44
2535 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 45
2536 PRECAUTIONS FOR HIGH VOLTAGE 45
2537 AIR CONDITIONING MAINTENANCE 45
2538 COMPRESSED AIR 46
2539 WASTE MATERIALS 46
26 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 47
261 INSPECTION OF THE HYDRAULIC SYSTEM 47
262 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 47
263 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 47
27 SPECIAL SAFETY EQUIPMENT 48
271 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 49
272 OBJECT HANDLING 49
273 LIGHTING 49
274 WARNING BEACON 49
275 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 49
2751 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 49
2752 INSTRUCTIONS FOR USE 51
2753 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 53
2754 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1), 53
2755 INSTRUCTIONS FOR USE 55
01 Specification 57
10 Structure & function 67
Table of Contents 69
1 Introduction 81
11 Contents of the binder 82
12 Foreword 82
13 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels 84
14 Explanation of abbreviations 85
15 Diagrams and illustrations in this manual 86
2 SAFETY 87
21 SAFETY INFORMATION 88
22 OVERVIEW 89
221 NORMAL OPERATIONS 89
222 REGULAR MAINTENANCE 89
223 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 89
224 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR 89
23 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 90
24 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 91
241 UNDERSTANDING THE MACHINE 91
242 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 91
2421 ENSURING SAFE OPERATION 91
243 PREPARATIONS FOR SAFE OPERATION 91
2431 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 91
2432 INSPECTING THE MACHINE 91
2433 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 92
2434 KEEP MACHINE CLEAN 92
2435 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 92
2436 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 93
2437 IF A PROBLEM IS FOUND 93
244 FIRE PREVENTION 93
2441 PRECAUTIONS TO PREVENT FIRE 93
2442 ACTION IF FIRE OCCURS 94
2443 EMERGENCY EXIT FROM OPERATOR’S CAB 95
245 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 95
2451 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 95
2452 NO JUMPING ON OR OFF THE MACHINE 95
2453 NO PEOPLE ON THE ATTACHMENT 95
2454 WORKING IN HIGH PLACES 95
2455 LEAVING OPERATOR’S SEAT WITH LOCK 96
2456 LEAVING THE MACHINE 96
246 BURN PREVENTION 97
2461 Hot coolant 97
2462 Hot oil 97
247 PRECAUTIONS WHEN CLEANING CAB GLASS 97
248 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 98
2481 UNAUTHORIZED MODIFICATION 98
2482 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 98
249 ELECTROMAGNETIC COMPATIBILITY (EMC) 99
2410 PRECAUTIONS AT JOBSITE 100
24101 VISIBILITY FROM OPERATOR’S SEAT 101
24102 CAMERA SYSTEM WITH MONITORS 101
24103 ENSURE GOOD VISIBILITY 101
24104 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 101
24105 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 102
24106 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 102
24107 WORKING ON LOOSE GROUND 103
24108 GAS, DUST, STEAM AND SMOKE 103
24109 VENTILATION OF ENCLOSED AREAS 104
2411 STARTING motor 105
24111 WARNING TAG 105
24112 CHECKS BEFORE STARTING motor 105
24113 PRECAUTION WHEN STARTING motor 105
24114 PRECAUTION IN COLD AREAS 106
2412 OPERATION 106
24121 CHECKS BEFORE OPERATION 106
24122 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 107
24123 PRECAUTIONS WHEN travelling 108
24124 TRAVELLING ON SLOPES 109
24125 OPERATIONS ON SLOPES 110
24126 PROHIBITED OPERATIONS 110
24127 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 111
24128 PARKING THE MACHINE 111
24129 TRANSPORTATION 111
25 PRECAUTION FOR MAINTENANCE 112
251 GENERAL PRECAUTIONS 112
2511 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 113
2512 STOP motor FOR MAINTENANCE 114
2513 WARNING TAG 115
2514 KEEP WORKPLACE CLEAN AND TIDY 116
2515 APPOINT LEADER WHEN WORKING WITH OTHERS 116
2516 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 117
2517 INSTALLING, REMOVING OR STORING ATTACHMENTS 117
2518 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 118
2519 NOISE 118
25110 WHEN USING A HAMMER 118
25111 PROPER TOOLS 119
25112 ACCUMULATOR 119
25113 PERSONNEL 119
252 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 120
2521 PRECAUTION WHEN WELDING 120
2522 BATTERY HANDLING 120
253 PRECAUTIONS WITH HIGH PRESSURE FLUID 121
2531 PRECAUTIONS WITH HIGH FUEL PRESSURE 121
2532 HANDLING HIGH PRESSURES HOSES OR PIPES 122
2533 REPLACEMENT OF HOSE LINES 122
2534 INSPECTION OF HOSE LINES 122
2535 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 123
2536 PRECAUTIONS FOR HIGH VOLTAGE 123
2537 AIR CONDITIONING MAINTENANCE 123
2538 COMPRESSED AIR 124
2539 WASTE MATERIALS 124
26 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 125
261 INSPECTION OF THE HYDRAULIC SYSTEM 125
262 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 125
263 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 125
27 SPECIAL SAFETY EQUIPMENT 126
271 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 127
272 OBJECT HANDLING 127
273 LIGHTING 127
274 WARNING BEACON 127
275 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 127
2751 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 127
2752 INSTRUCTIONS FOR USE 129
2753 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 131
2754 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1), 131
2755 INSTRUCTIONS FOR USE 133
3 Specifications 135
31 Lifting Gears 136
32 Safety hints for sling accessory 138
33 Standard Tightening Torque Chart 139
34 Conversion Table 140
35 Blind plugs 146
36 Classification of threads to the nominal width 148
37 Plugs and fittings according to ISO 8434-1 / DIN 2353 149
4 Main assembly groups 151
41 General layout 152
42 Superstructure 154
43 Machine house 156
44 Hydraulic oil tank 158
45 Hydraulic oil cooler 160
46 Fuel tank 162
47 Counterweight 164
48 Cab base 166
49 Operator’s cab 168
410 Control blocks 170
411 Swing machinery 172
4111 Swing machinery L&S 172
4112 Swing machinery SIEBENHAAR 174
412 Undercarriage 176
413 Backhoe attachment (BHA) 178
414 Front shovel attachment (FSA) 180
5 Drive 183
51 Prime drive assembly 184
52 Engine mounts 186
521 Checks and adjustments 187
53 Coupling 188
54 Fan drive and radiator assembly 190
541 Radiator fan drive 192
542 RADIATOR FAN SPEED ADJUSTMENT 196
55 PTO 200
551 PTO lubrication and cooling 202
5511 Checks and adjustments 204
552 Pump spline lubrication 206
553 Hydraulic pumps – arrangement 208
56 Air filter 210
6 Hydraulic oil tank 213
61 General layout 214
62 Hydraulic oil tank, location of the electric equipment 216
63 Suction oil manifold with strainers 218
64 Return oil collector pipe with strainer 220
65 Back pressure valve 222
66 Transfer pump 224
67 Return and leak oil filter 226
68 Breather filter 228
7 Hydraulic oil cooling 231
71 Overall view of the hydraulic oil cooling 232
72 Function of the hydraulic oil cooling circuit 234
73 Adjustment of the back pressure valve 236
74 Two stage cooler fan RPM control 238
741 Pressure relief valves 240
742 Solenoid valves 242
75 Fixed displacement pump with variable setting 244
76 Adjustment of the cooler fan drive speed 246
761 Maximum speed 246
762 Medium speed 248
8 Controlling 251
81 General layout 252
82 Control and filter panels – location of components 254
821 Control and filter panel engine 1 (rear) 254
822 Control and filter panel engine 2 (front) 258
83 Pilot pressure supply and adjustments 262
831 Pilot pressure circuit 263
832 Checks and adjustments of pilot pressure 264
8321 Adjustment 266
833 Remote control valves arrangement 268
84 Function of the electro-hydraulic control system 270
85 Hand lever (joystick) control 274
86 Foot pedal control 276
87 Proportional amplifier module, type A 278
88 Proportional amplifier module, type B 280
89 Ramp time module 282
810 Adjustment of amplifier modules 284
8101 General 285
8102 Adjusting the amplifier module, type A 286
8103 Adjusting the amplifier module, type B 288
811 Adjusting the ramp time module 290
9 Components 295
91 Main control blocks and high pressure filters 296
92 Distributor manifold – location of restrictor blocks and anti-cavitation valves 302
93 Restrictor block with secondary relief valve 306
94 Anti-cavitation valve (ACV) block 308
941 Single ACV block on the manifold 308
942 Double ACV block on the manifold 310
95 Remote control valves 312
96 4/3 Directional solenoid valves 314
97 Proportional solenoid valves 316
98 High-pressure filter (screen) 318
99 Control blocks and valves 320
991 4-spool valve blocks 320
992 Main control block IV (swing) 332
910 Travel brake valve 334
911 Pressure reducing valve 336
912 4/2 Directional valves 338
913 Pressure double stage valve 340
914 Hydraulic cylinder 342
10 Main hydraulic pumps and pump regulation 345
101 General 346
1011 Layout 346
1012 Pump regulation system (“open sensing system”) 349
1013 Pump regulation system — valve function 350
102 Main pumps 352
1021 Pump bearing flushing / lubrication 354
1022 Operating principle 358
1023 Checks / adjustments 374
10231 Adjust the Qmax and Qmin stop bolts 376
103 Electronic pump regulation system 378
1031 Electronic load limiting control – general 379
1032 Micro controller RC4-4 380
104 Hydraulic constant regulation system (emergency mode) 382
1041 General 383
105 ENGINE SPEED SENSOR (PICK-UP) 384
1051 General 385
1052 ENGINE SPEED SENSOR (PICK-UP) ADJUSTMENT 385
106 Checks and adjustments 386
1061 Power Check (ENGINE PERFORMANCE) 386
1062 Electronic load limit regulation, XLR basic adjustment 388
10621 Method “A” with 24 V supply 391
10622 Method “B” with bodas software 392
1063 Electronic load limit regulation RC4, function check 396
1064 Hydraulic Control (emergency mode) 398
1065 Pressure cut-off valve 400
10651 Altering the MRV settings 402
11 Operating hydraulics 403
111 General 404
1111 Spool functionS (FSA), floating function for boom and stick cylinder 406
1112 spool functions (BHA) 408
112 Hydraulics for the attachment cylinders 410
1121 Electric / hydraulic flowchart “Boom UP” (FSA) 410
1122 Electric / hydraulic flowchart “Boom UP” (BHA) 412
1123 Electric / hydraulic flowchart “Boom down” (FSA), Auto-float ON 414
1124 Electric / hydraulic flowchart “Boom down” (FSA), Auto-float OFF 416
1125 Electric / hydraulic flowchart “Boom down” (BHA) 418
1126 Electric / hydraulic flowchart “Stick out” (FSA) 420
1127 Electric / hydraulic flowchart “Stick out” (BHA) 422
1128 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float ON 424
1129 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float OFF 426
11210 Electric / hydraulic flowchart “Stick in” (BHA) 428
11211 Electric / hydraulic flowchart “Bucket fill” (FSA) 430
11212 Electric / hydraulic flowchart “Bucket fill” (BHA) 432
11213 Electric / hydraulic flowchart “Bucket dump” (FSA) 434
11214 Electric / hydraulic flowchart “Bucket dump” (BHA) 436
11215 Electric / hydraulic flowchart “Clam open” (FSA) 438
11216 Electric / hydraulic flowchart “Clam close” (FSA) 440
11217 Checks and adjustments of the main relief valves (MRV) 442
11218 Checks and adjustments of the secondary relief valves (SRV) 444
112181 Boom cylinders, piston side (BHA & FSA), boom up 444
112182 Boom cylinders, piston rod side (BHA & FSA), boom down 448
112183 Stick cylinders, piston side (FSA), stick out 452
112184 Stick cylinders, piston side (BHA), stick in 456
112185 Stick cylinders, piston rod side (FSA), stick in 460
112186 Stick cylinders, piston rod side (BHA), stick out 464
112187 Bucket cylinders, piston side (FSA), bucket fill 468
112188 Bucket cylinders, piston side (BHA), bucket fill 472
112189 Bucket cylinders, piston rod side (FSA), bucket dump 476
1121810 Bucket cylinders, piston rod side (BHA), bucket dump 480
1121811 Clam cylinders, piston rod side (FSA), clam open 484
1121812 Clam cylinders, piston side (FSA), clam close 488
11219 Checks and adjustments of the lowering speed – boom (FSA) 492
11220 Checks and adjustments of the lowering speed – boom (BHA) 496
11221 Checks and adjustments of the lowering speed – stick (FSA) 500
11222 Checks and adjustments of the lowering speed – stick (BHA) 504
11223 Checks and adjustments of the lowering speed – bucket (FSA) 508
11224 Checks and adjustments of the lowering speed – bucket (BHA) 512
11225 Checks and adjustments of the lowering speed – clam (FSA) 516
113 Hydraulics for the swing circuit 518
1131 Swing circuit 518
1132 Swing motor 522
11321 Hydraulic motor control 526
11322 Checks and adjustments in case of troubleshooting 530
1133 Swing gearbox (L&S) 532
1134 Swing gearbox (SIEBENHAAR) 534
1135 Swing parking brake (L&S) 536
1136 Swing parking brake (SIEBENHAAR) 538
1137 Swing brake valve 540
1138 Flushing circuit 544
1139 Electric / hydraulic flowchart “Swing left” (FSA) 546
11310 Electric / hydraulic flowchart “Swing left” (BHA) 548
11311 Electric / hydraulic flowchart “Swing right” (FSA) 550
11312 Electric / hydraulic flowchart “Swing right” (BHA) 552
11313 Swing sensing & monitoring system, Version A 554
113131 Checks and adjustments 556
11314 Swing sensing & monitoring system, Version B 558
113141 Checks and adjustments 559
11315 Checks and adjustments for the swing circuit 560
113151 Pressure checks & adjustments, double stage valve 561
113152 Checks & adjustments, brake pilot pressure 563
11316 Function check for hydraulic swing brake 564
11317 Function check for the swing parking brake 566
114 Hydraulics for the travel circuit 568
1141 Travel circuit 568
1142 Travel motor 572
1143 Rotary joint 574
1144 Travel gearbox 576
11441 Travel gearbox (L&S) 576
11442 Travel gearbox (Zollern) 578
1145 Travel parking brake 580
11451 Travel parking brake (L&S) 580
11452 Travel parking brake (Zollern) 581
1146 Electric / hydraulic flowchart “Travel forward” 582
1147 Electric / hydraulic flowchart “Travel backwards” 584
1148 Checks and adjustments 586
11481 Checks and adjustments for the travel circuit 586
11482 Function check for the travel parking brake 589
12 Hydraulic track tensioning system 591
121 General 592
122 Functional description 594
123 Double-stage valve 596
124 Tensioning cylinder 598
125 Adjustments / checks 600
13 Access ladder, hydraulically operated 603
131 General 604
132 Function of the hydraulically operated access ladder 606
133 Adjustments / checks 612
14 Central refilling system (Service arm) 613
141 General 614
142 Function 616
15 Hints for reading the hydraulic diagram 619
151 General 620
152 Hydraulic symbols 622
1521 Lines, unions 623
1522 Components, valves 625
1523 Sensors 625
1524 Valves, valve components 626
1525 Pump, motor, cylinder 630
16 Hints for reading the electric wiring diagram 635
161 General 636
162 Reference code of the electrical components 637
1621 Area code 637
1622 Component identifying letter 639
163 Graphical symbols 640
164 Drawing concept 644
165 Cable marking 654
17 KOMTRAX Plus 655
171 General 656
172 Specifications for Operators 658
1721 Sequence of Displays 659
1722 Opening Screen 659
1723 Main Gauge Screens 1 to 4 660
1724 Fuel Consumption Screen 664
1725 Failure message History for the Operator 666
1726 Main Gauge Screens – Changing of Time / SMR / Date 668
1727 Maintenance Monitor 669
1728 Settings for Operators 672
17281 USER ID Screen 674
17282 Reset Truck Counter 1 & 2 675
17283 Screen Adjustment 676
17284 Date and Time Adjustment 678
17285 Language selection 679
1729 Automatic Messages 680
173 Tables of all Provided Messages 683
1731 Table of G-Codes 684
1732 Table of C-Codes – Diesel engines SDA12V159E-2, TIER 2 691
1733 Table of available Instruction Messages 698
174 Flow Charts (1-4) KOMTRAX Plus Main Screens 701
175 KOMTRAX Plus Service Level 705
1751 Explanation of the Button Symbols (Service Level) 707
1752 Service Menu Select Screen 708
1753 Real Time Menu Select Screen 709
17531 Real Time Menu, option: 01 Motor 1 710
17532 Real Time Menu, option: 02 Motor 2 711
17533 Real Time Menu, option: 03 PTO 1 711
17534 Real Time Menu, option: 04 PTO 2 711
17535 Real Time Menu, option: 05 Hydraulic 712
17536 Real Time Menu, option: 06 Slew 713
17537 Real Time Menu, option: 07 electrical Equipment 714
17538 Real Time Menu, option: 08 Emergency Stop 715
17539 Real Time Menu, option: 09 Manual Switch 716
175310 Real Time Menu, option: 10 Central lUBE System 1 717
175311 Real Time Menu, option: 11 Slew Ring Gear Lube System 718
175312 Real Time Menu, option: 12 Central Lube System 2 719
175313 Real Time Menu, option: 13 Windscreen Wiper 720
175314 Real Time Menu, option: 14 Ladder 721
175315 Real Time Menu, option: 15 Service Arm 722
175316 Real Time Menu, option: 16 Pilot Control 723
175317 Real Time Menu, option: 19 Other Items 724
175318 Real Time Menu, option: 18 Output Signals 725
175319 Output Signals with deactivated MTC-Evaluation 728
1754 PM-Clinic 730
17541 General 730
17542 Power Check 731
1755 Serial/GCC No Setting 733
1756 Memory Clear 734
17561 Input Memory Clear ID 734
17562 Memory Clear Screen 735
1757 Failure History 736
1758 Maintenance Monitor 737
1759 Snapshot 738
17510 Settings 740
175101 Central Lubrication System (CLS 1), screen 1/10 740
175102 Swing Lubrication System (SLS), screen 2/10 741
175103 Central Lubrication System (CLS 2), screen 3/10 742
175104 Qmin – Qmax – Setting, screen 4/10 743
175105 Other Settings 1/2, screen 5/10 743
175106 Other Settings 2/2, screen 6/10 745
175107 Shutdown Bypass ON/OFF 748
176 Interface-Connection KOMTRAX Plus Controller 752
1761 KOMTRAX Plus Controller 753
177 Wiring of the KOMTRAX Plus controller 754
178 Global Layout of the MTC Control System 758
1781 MTC (Master Turbo Controller) 760
17811 MTC-Flowchart 760
17812 MTC Features 760
17813 MTC-Firmware and Software 761
17814 View onto the MTC unit and its Connectors 762
179 Global Layout of the Internal CAN bus 764
1791 General Information about a CAN bus System 764
17911 General CAN bus description 765
17912 CAN bus troubleshooting 765
17913 Can bus wiring 766
17914 CAN bus End Resistor 768
1710 The Nodes in the CAN bus System 770
17101 Global Layout 770
17102 Introduction 771
171021 ICN-V Features 772
171022 ICN-D Features 773
17103 Node DIP-Switches 774
17104 Node Box 775
17105 Node Locations on the Machine 778
171051 Node & Location Chart 779
171052 Exemplary View onto Location 11 (Cab base) 780
18 Lubrication system 781
181 General overview (SLS & CLS 1 / 2) 782
1811 General description 783
182 Basic function of the lubrication systems 784
183 Central lubrication system (CLS 1 & 2) 786
1831 General information on the CLS (CLS 1 / 2) 787
18311 Manual lube activation 788
184 Swing circle lubrication system (SLS) 790
1841 General information on the SLS 792
18411 Manual lube activation 792
185 Lubrication cycle 793
1851 Operation and control 793
1852 Lubrication cycle – components 794
1853 Lubrication cycle – processing 796
1854 Time segments & switch points of a lubrication cycle 797
1855 Lubrication modes 798
18551 Automatic lubrication mode 798
18552 Manual lubrication mode 798
18553 Komtrax Plus service mode 798
186 Hydraulically driven lube pump 800
1861 Adjustment of lube pump speed & working pressure 802
18611 Stroke speed adjustment 803
18612 Working pressure adjustment 804
187 Lubricant injectors 806
1871 Tightening torques for fittings at grease injectors 807
1872 Description 807
1873 Adjustment of the lubricant output 808
1874 Operation principle of lubricant injectors 810
18741 Function description 811
1875 Connection of one or more injectors 812
188 Vent valve 814
1881 Description 815
189 End-line switch 816
1891 Description 817
1892 CLS end-line switch adjustment 818
1893 SLS end-line switch adjustment 820
1810 In-line filter 822
18101 Description 823
18102 Maintenance procedure 823
1811 Lubricant level sensor 824
18111 Sonar type lubricant level sensor 824
18112 Description 825
181121 LEDs at the sonar sensor 826
18113 Binary type lubricant level sensor 828
18114 Description 829
181141 Adjustment 829
1812 Commissioning 830
18121 Commissioning of the CLS 1 & CLS 2 lubrication systems 830
18122 Fine adjustment 831
18123 Commissioning of the SLS lubrication system 832
19 Deep temperature equipment (option) 835
191 General information 836
1911 Introduction 836
1912 Deep temperature components overview 836
1913 Power supply preconditions for preheating 837
1914 Power requirements for preheating systems 838
192 Preheating procedure 839
1921 Global flow chart of the preheating procedure 839
1922 Starting the preheating procedure 840
1923 Preheating of operator’s cab and Diesel engine [coolant system] 841
1924 Preheating of lubricants and superstructure (Diesel) [electric system] 842
193 Constant heating of travel motors (TTT equipment below-40°C only) 843
194 Component location 844
1941 Electric heating elements for hydraulic & batteries [electric machine] 844
1942 Electric heating elements for hydraulics [Diesel machine] 846
1943 Electric heating elements for engines & batteries [Diesel machine] 848
195 Components of TT equipment 850
1951 Preheating components on a Diesel machine 850
1952 Preheating components on an electric machine 852
1953 Exemplary Wiring Diagrams for preheating systems 853
19531 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3 853
19532 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3 854
19533 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3 855
19534 Wiring diagram “Suction Oil Manifold Preheating” 856
19535 Wiring diagram “PTO Preheating” 857
19536 Wiring diagram “Battery heater pads” 858
40 Troubleshooting 859
Table of Contents 861
1 SAFETY 879
11 SAFETY INFORMATION 880
12 OVERVIEW 881
121 NORMAL OPERATIONS 881
122 REGULAR MAINTENANCE 881
123 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 881
124 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR 881
13 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 882
14 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 883
141 UNDERSTANDING THE MACHINE 883
142 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 883
1421 ENSURING SAFE OPERATION 883
143 PREPARATIONS FOR SAFE OPERATION 883
1431 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 883
1432 INSPECTING THE MACHINE 883
1433 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 884
1434 KEEP MACHINE CLEAN 884
1435 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 884
1436 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 885
1437 IF A PROBLEM IS FOUND 885
144 FIRE PREVENTION 885
1441 PRECAUTIONS TO PREVENT FIRE 885
1442 ACTION IF FIRE OCCURS 886
1443 EMERGENCY EXIT FROM OPERATOR’S CAB 887
145 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 887
1451 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 887
1452 NO JUMPING ON OR OFF THE MACHINE 887
1453 NO PEOPLE ON THE ATTACHMENT 887
1454 WORKING IN HIGH PLACES 887
1455 LEAVING OPERATOR’S SEAT WITH LOCK 888
1456 LEAVING THE MACHINE 888
146 BURN PREVENTION 889
1461 Hot coolant 889
1462 Hot oil 889
147 PRECAUTIONS WHEN CLEANING CAB GLASS 889
148 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 890
1481 UNAUTHORIZED MODIFICATION 890
1482 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 890
149 ELECTROMAGNETIC COMPATIBILITY (EMC) 891
1410 PRECAUTIONS AT JOBSITE 892
14101 VISIBILITY FROM OPERATOR’S SEAT 893
14102 CAMERA SYSTEM WITH MONITORS 893
14103 ENSURE GOOD VISIBILITY 893
14104 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 893
14105 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 894
14106 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 894
14107 WORKING ON LOOSE GROUND 895
14108 GAS, DUST, STEAM AND SMOKE 895
14109 VENTILATION OF ENCLOSED AREAS 896
1411 STARTING motor 897
14111 WARNING TAG 897
14112 CHECKS BEFORE STARTING motor 897
14113 PRECAUTION WHEN STARTING motor 897
14114 PRECAUTION IN COLD AREAS 898
1412 OPERATION 898
14121 CHECKS BEFORE OPERATION 898
14122 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 899
14123 PRECAUTIONS WHEN travelling 900
14124 TRAVELLING ON SLOPES 901
14125 OPERATIONS ON SLOPES 902
14126 PROHIBITED OPERATIONS 902
14127 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 903
14128 PARKING THE MACHINE 903
14129 TRANSPORTATION 903
15 PRECAUTION FOR MAINTENANCE 904
151 GENERAL PRECAUTIONS 904
1511 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES 905
1512 STOP motor FOR MAINTENANCE 906
1513 WARNING TAG 907
1514 KEEP WORKPLACE CLEAN AND TIDY 908
1515 APPOINT LEADER WHEN WORKING WITH OTHERS 908
1516 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 909
1517 INSTALLING, REMOVING OR STORING ATTACHMENTS 909
1518 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 910
1519 NOISE 910
15110 WHEN USING A HAMMER 910
15111 PROPER TOOLS 911
15112 ACCUMULATOR 911
15113 PERSONNEL 911
152 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 912
1521 PRECAUTION WHEN WELDING 912
1522 BATTERY HANDLING 912
153 PRECAUTIONS WITH HIGH PRESSURE FLUID 913
1531 PRECAUTIONS WITH HIGH FUEL PRESSURE 913
1532 HANDLING HIGH PRESSURES HOSES OR PIPES 914
1533 REPLACEMENT OF HOSE LINES 914
1534 INSPECTION OF HOSE LINES 914
1535 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 915
1536 PRECAUTIONS FOR HIGH VOLTAGE 915
1537 AIR CONDITIONING MAINTENANCE 915
1538 COMPRESSED AIR 916
1539 WASTE MATERIALS 916
16 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 917
161 INSPECTION OF THE HYDRAULIC SYSTEM 917
162 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 917
163 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 917
17 SPECIAL SAFETY EQUIPMENT 918
171 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 919
172 OBJECT HANDLING 919
173 LIGHTING 919
174 WARNING BEACON 919
175 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 919
1751 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 919
1752 INSTRUCTIONS FOR USE 921
1753 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 923
1754 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1), 923
1755 INSTRUCTIONS FOR USE 925
2 Introduction & general information for troubleshooting 927
21 Overview 928
211 General advice when using troubleshooting charts 928
22 General precautions 929
23 Preparations for work 930
24 Precautions during work 930
25 Precautions when carrying out any operation 931
251 precautions when carrying out removal work 931
252 Precautions when carrying out installation work 931
253 Precautions when completing the operation 932
26 Fundamental requirements for troubleshooting 933
261 Technical documentation 933
262 Tools 933
2621 Reference guide for deutsch removal tools 936
263 Personnel 937
27 Points to remember when trouble- shooting 937
28 Sequence of events in troubleshooting 939
29 Checks before troubleshooting 940
210 Handling of electric equipment and hydraulic components 941
2101 Points to remember when handling electric equipment 941
2102 Points to remember when handling hydraulic equipment 944
211 General working procedures 946
2111 Air bleeding of various yydraulic parts 946
2112 Air bleeding from the hydraulic pumps 946
2113 Air bleeding from the hydraulic cylinders 946
212 Cylinder bypass test 947
213 Information about MTC & nodes 948
2131 Outline of the MTC and its connector locations 948
21311 View onto the MTC connectors* LH & RH 948
21312 General description of the MTC 948
21313 Information about the LED indications at the MTC 949
2132 Information about the ICN-D node 949
21321 View onto an ICN-D node without wiring 950
21322 View onto the status LEDs at the ICN-D node 951
21323 General information on the LED control 951
2133 Information about the ICN-V node 953
21331 View onto an ICN-V node 953
21332 View onto an open ICN-V node and its DIP-switches 954
2134 DIP switches at the ICN-D and ICN-V nodes 955
214 Basics about “how to crimp” 956
2141 Stripping a wire for use with the HDT 48 crimp tool 956
2142 View onto the Deutsch crimp tool HDT 48 956
2143 Adjustment of the wire size at the Deutsch crimp tool HDT 48 957
21431 Wire cross section units in mm2 and AWG 957
2144 Crimping instructions (for Deutsch crimp tool HDT 48) 958
215 Cable shielding 959
3 Mounting locations and connector types 961
31 Component location 962
311 View onto the superstructure 962
312 Machine house 964
313 Location of the electrical parts on the engines 966
314 Location of engine remote oil tank sensors 968
315 Suction oil manifold with strainers 970
316 Control and filter panels – location of components 972
317 Location of the remote control valves 976
318 Hydraulic oil tank – location of electrical components 978
319 CLS1/2 & SLS lubrication station and the lubrication cycle components 980
3110 Electrical components in the cab base 982
3111 Emergency shutdown switches & safety switch for maintenance 986
3112 Hydraulically operated access ladder 988
3113 Service arm 990
32 Connector types overview 992
4 Standard value table for electrical components 997
5 References for Troubleshooting (CAN Bus & Node Outputs)1009
51 CAN-Bus trouble or Node Output Trouble1010
511 Trouble CAN-BUS or CAN-Hardware (G00308)1011
512 Trouble output short-circuit (G00043)1012
52 Sequence of the CAN nodes at the CAN bus1014
53 Troubleshooting for Relay Monitored Node Outputs1015
531 Relay Check1015
5311 G00107 – Trouble slew parking brake control 56K250a G00109 – Trouble slew parking brake control 56K250b1016
532 Output Check1020
5321 G00108 – Trouble slew parking brake control Output to 56K250a G00110 – Trouble slew parking brake control Output to 56K250b1021
6 Tables for testing and troubleshooting1025
61 Test value table for temperature sensors (PT100) g Centigrade – Volt1026
62 Test Value Table for Temperature Sensors (PT100) g Centigrade – Ohm1027
63 Table of trouble codes (G-Codes)1028
64 Table of instruction messages1035
65 Table of binary codes1038
651 Table of Add-On binary codes for G003081040
66 Binary Output Signals on the KOMTRAX Plus Monitor1041
67 Tables of Symptom Codes1044
671 Symptoms of the Engines and Related Electrical Systems1044
672 Symptoms of the Hydraulic System1044
673 Symptoms of the Mechanical System1045
674 SYMPTOMS OF ADDITIONAL SYSTEMS1045
68 Power Supply1046
69 Cable colour identification1046
7 Troubleshooting by trouble code1047
G00001 – Trouble Shut-Off (gate) valve1048
View onto the gap of proximity switch 40B0311050
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR1051
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor1051
Wiring diagram (40B031) for trouble code G00001 (Trouble Shut-Off (gate) valve)1052
G00002 – Test speed 1800 1/min engine 11053
Wiring diagram (11S041-1 & 11S041-2) for trouble codes G00002 & G000061054
G00003 – Trouble pump controller1055
G00005 – Low hydraulic oil level1061
Wiring diagram, oil level label, and defined position of the attachment (G00005)1063
G00006 – Test speed 1800 1/min engine 21064
G00007 – Trouble hydraulic oil level1064
Wiring diagram (40B004) and the defined position of the attachment (G00007)1065
G00012 – Central lubrication system grease level too low1066
G00013 – Slew ring gear lubr system grease level too low1066
Troubleshooting for sonar type grease level sensors1066
Troubleshooting for binary type grease level sensors1070
Wiring diagram (sonar type sensors) for trouble codesG00012 / G00013 / G002021073
Wiring diagram (sonar sensor junction box) for trouble codes G00012 / G00013 / G002021074
Wiring diagram (binary type sensors) for trouble codesG00012 / G00013 / G002021075
Wiring diagram (binary sensor junction box) for trouble codes G00012 / G00013 / G002021076
G00020 – Trouble Shut-Off (gate) valve (Start blocked)1077
View onto the gap of proximity switch 40B031 (G00020)1079
Wiring diagram (40B031) for trouble code G00020 (Main gate valve closed)1080
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR1081
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor1081
G00031 – Set engine to low idle1082
Wiring diagram (20S030) for trouble code G000311083
Input signal of the engine speed switch 20S030 on the REAL TIME MONITOR1083
G00032 – Trouble starter1084
Wiring diagram (Cold Start Signal Engine 1 & 2) for trouble code G000321085
Wiring diagram (“Engine running” signals) for trouble code G000321086
G00033 – Trouble KOMTRAX Plus controller1087
G00034 – Trouble KOMTRAX Plus display1088
G00035 – Trouble totally loss gear oil (PTO 1)1089
G00036 – Trouble totally loss gear oil (PTO 2)1089
View onto the location of sensor 57B175-1/-2 at the PTO1/2 (G00035)1091
Input signal (analog) of the gear oil sensors 57B175-1/-2 on the REAL TIME MONITOR1092
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor1092
Wiring diagram (57B175-1/-2) for trouble codes G00035 & G000361093
G00037 – Trouble monitoring, engine 2 speed too low1094
G00038 – Trouble monitoring, engine 2 speed too high1094
G00039 – Actuate engine speed selector switch1094
G00043 – Trouble output short-circuit1095
G00048 – Trouble emergency safety circuit1096
Wiring diagram (11K044a) for trouble code G000481097
G00053 – Reset emergency safety circuit1098
G00054 – Monitoring idle position cut off1099
Wiring diagram (11K032) for trouble code G000541100
Input signal (analog) of relay 11K032 on the REAL TIME MONITOR (G00054)1101
Exemplary view onto the KOMTRAX Plus Failure History (G00054)1101
G00060 – Fire in the power house1102
Wiring diagram (fire alarm) for trouble code G000601104
Wiring diagram (10B350 in the safety circuit) for G000601105
G00061 – Trouble monitoring, engine 1 speed too low1106
Input signal (analog) of 51K003b-1 & 51K003b-2 on the REAL TIME MONITOR1108
Wrong signal of the engine 2 speed converter on the REAL TIME MONITOR1108
Wiring diagram (engine speed) for trouble codes G00061 & G000371109
G00062 – Trouble monitoring, engine 1 speed too high1110
Wiring diagram (engine speed) for trouble codes G00062 & G000381111
G00063 – Trouble monitoring hydraulic oil temp1112
Wiring diagram (59B015) for trouble code G000631113
G00064 – Trouble monitoring hydraulic oil level1114
Wiring diagram (40B004) for trouble code G000641116
G00065 – Very low hydraulic oil level1117
View onto the hydraulic oil level label1117
G00066 – Trouble hydraulic oil temperature1118
Hydraulic oil temperature table1119
Wiring diagram (57K506a-1/57K506b-1 & 57K506a-2/57K506b-2) and location for G000661120
G00067 – Trouble battery voltage too high1121
Wiring diagram (11T080) and component location for G000671122
Input signal of 11T080 on the REAL TIME MONITOR for G000671123
G00068 – Trouble gear lubrication (PTO 2)1124
G00069 – Trouble monitoring oil temperature gear (PTO 1)1125
Input of 57B049-1 on the REAL TIME MONITOR (G00069)1126
Gear oil temperature (PTO 1 & PTO 2) on the Main Gauge Screen1126
Wiring diagram (57B049-1 & 57B049-2) and component location (G00069 & G00083)1127
G00070 – Trouble oil temperature gear (PTO 1)1128
PTO gear oil settings (oil type and viscosity)1130
Location of the PTO gear oil level dipstick & temperature sensors 57B049-1/57B049-21131
G00071 – Trouble gear lubrication (PTO 1)1132
Wiring diagram (57B017-1 & 57B017-2) for trouble codes G00071 & G000681133
G00081 – Trouble lubrication system1134
Wiring diagram (11K050) for trouble code G000811135
Operation cycles of the lubrication systems1136
G00083 – Trouble monitoring oil temperature gear (PTO 2)1137
G00084 – Trouble oil temperature gear (PTO 2)1137
G00086 – SHUTDOWN1137
G00087 – Stop all movements for low idle1138
G00090 – Trouble power supply1139
Wiring diagram (stabilized power supply) for G00090 & G000991140
G00091 – Pilot control cut out1141
View onto the lock lever and the cover of 20S105 (G00091)1142
G00092 – Emergency shut-down at access ladder1143
G00093 – Emergency shut-down at valve block1143
G00094 – Emergency shut-down at hydraulic control panel1143
G00095 – Emergency shut-down in cabin1143
Wiring diagram (emergency switches) for G00092~G00095 & G000971145
G00096 – Pilot control cut out1146
Wiring diagram (20S094) for trouble code G000961147
G00097 – Emergency shut-down at counterweight1148
G00099 – Trouble power supply1148
G00100 – Maintenance Safety Switch1148
Wiring diagram (50S058) for trouble code G001001149
G00103 – Faulty switch 20M0041150
Wiring diagram 1 (windscreen wiper) for trouble code G001031152
Wiring diagram 2 (windscreen wiper) for trouble code G001031153
G00104 – Trouble battery current1154
Wiring diagram (battery current) for trouble code G001041156
G00105 – Trouble battery charging current too low1157
Wiring diagram (11T080) for trouble code G001051158
G00107 – Trouble slew parking brake control 56K250a1159
View onto the CoDeSys HMI Visualization screen for trouble code G001071161
Wiring diagram (56K250a & 56K250b) for trouble code G001071162
G00108 – Trouble slew parking brake control Output to 56K250a1163
View onto the CoDeSys HMI Visualization screen for trouble code G001081165
Wiring diagram (56K250a & 56K250b) for trouble code G001081166
G00109 – Trouble slew parking brake control 56K250b1167
G00110 – Trouble slew parking brake control Output to 56K250b1167
G00111 – Trouble travel parking brake control 56K251a1167
56K251a & 56K251b (relay check) on the REAL TIME MONITOR (G00111 & G00113)1167
G00112 – Trouble travel parking brake control Output to 56K251a1168
56K251a & 56K251b (output check) on the REAL TIME MONITOR (G00112 & G00114)1168
G00113 – Trouble travel parking brake control 56K251b1169
G00114 – Trouble travel parking brake control Output to 56K251b1169
G00115 – Trouble slew hydraulic brake control 56K252a1169
56K252a & 56K252b (relay check) on the REAL TIME MONITOR (G00115 & G00117)1169
G00116 – Trouble slew hydraulic brake control Output to 56K252a1170
56K252a & 56K252b (output check) on the REAL TIME MONITOR (G00116 & G00118)1170
G00117 – Trouble slew hydraulic brake control 56K252b1171
G00118 – Trouble slew hydraulic brake control Output to 56K252b1171
G00139 – Trouble monitoring X1-2 pressure1171
G00140 – Trouble monitoring X1-1 pressure1171
Wiring diagram (57B085-1 & 57B085-2) for trouble codes G00140 & G001391173
G00141 – Trouble monitoring X2 pressure1174
Wiring diagram (57B086) for trouble code G001411176
G00142 – Trouble monitoring pump support pressure X4-11177
Input signal of 57B097-1 & 57B097-2 on the REAL TIME MONITOR for G00142 & G001961179
Wiring Diagram (57B097-1 & 57B097-2) for G00142 & G001961180
G00147 – Trouble monitoring gear lubrication (PTO 1)1181
Wiring diagram (57B017-1 & 57B017-2) for trouble codes G00147 & G001501184
G00148 – Trouble monitoring fuel level1185
Wiring diagram (31B063) for G001481187
G00150 – Trouble monitoring gear lubrication (PTO 2)1188
G00151 – Trouble monitoring gear (PTO) oil filter 11188
Wiring diagram (57B027-1/-2) and component location for G00151 & G001931191
G00154 – Trouble monitoring return oil filter1192
Wiring diagram (40B163) for trouble code G001541194
G00155 – Trouble monitoring leak oil filter1195
Wiring diagram (40B164) for trouble code G001551197
G00159 – Trouble monitoring breather filter1198
Wiring diagram (40B024) for trouble code G001591200
G00160 – Trouble monitoring engine air cleaner 11201
Wiring diagram (52B018-1/-2 & 52B019-1/-2) for trouble codes G00160 & G001971203
G00161 – Trouble monitoring battery voltage1204
Wiring diagram (11T080) for trouble code G001611206
G00162 – Trouble monitoring charging-/discharging current1207
Wiring diagram (battery charging current) for trouble code G001621209
G00164 – Trouble air cleaner 11210
View onto the engine air cleaners (G00164 & G00198)1211
G00165 – Trouble breather filter hydraulic oil tank1212
Sight glass, hydraulic oil temperature information, and defined positions (G00165)1213
G00166 – Trouble oil filter gear (PTO 1)1214
View onto the pressure sensors 57B027-1 & 57B027-2 (G00166/G00191)1215
G00169 – Trouble return oil filter hydraulic oil tank1216
G00170 – Trouble leak oil filter hydraulic oil tank1217
G00176 – Trouble battery voltage too low1218
Wiring diagram (batteries) for trouble code G001761220
G00177 – Trouble battery charging circuit1221
Wiring diagram (measuring points 1-4) for trouble code G001771222
G00178 – Trouble battery charging current too high1223
Wiring diagram (51T017) for trouble code G001781224
G00179 – Trouble control pressure X1-11225
The adjustment of the X1-pressure with two different methods (G00179 & G00182)1226
G00180 – Trouble pilot pressure X2 too low1227
Rear control & filter panel with X2 pressure sensor 57B086 & M31228
G00181 – Trouble pilot pressure X2 too high1229
Rear control & filter panel with X2 pressure sensor 57B086 & M31230
G00182 – Trouble control pressure X1-21231
G00183 – Trouble pump support pressure X4-11231
Wiring Diagram (57B097-1 & 57B097-2) for G00183 & G001951232
Input signals of 57K602-1 & 57K602-2 on the REAL TIME MONITOR for G00183 & G001951232
Wiring Diagram (57K602-1 & 57K602-2) for G00183 & G001951233
Locations 57B097-1 / 57B097-2 & 57K602-1 / 57K602-2 for G00183 & G001951234
G00184 – Central lubrication system empty1235
Grease level (CLS 1 & SLS & CLS 2) on the REAL TIME MONITOR1237
G00185 – Trouble central lubrication system1238
Allocation of vent valves and end-of-line switches1239
Action chart for lube cycles1240
View onto the vent valve (62Q507a – 62Q509a – 62Q642a)1241
Wiring diagram (60B043/62B046/80B043) for trouble codes G00185/G00188/G002031242
G00186 – Trouble central lubrication system1243
Action chart for lube cycles1244
View onto the vent valve (62Q507a – 62Q509a – 62Q642a)1245
G00187 – Slew ring gear lubrication system empty1246
G00188 – Trouble slew ring gear lubrication system1246
G00189 – Trouble slew ring gear lubrication system1246
G00191 – Trouble oil filter gear (PTO 2)1246
G00193 – Trouble monitoring gear (PTO) oil filter 21246
G00195 – Trouble pump support pressure X4-21246
G00196 – Trouble monitoring pump support pressure X4-21246
G00197 – Trouble monitoring engine air cleaner 21246
G00198 – Trouble air cleaner 21246
G00201 – Attachment lubrication system empty1246
G00202 – Attachment lubrication system grease level too low1246
G00203 – Trouble attachment lubrication system1246
G00204 – Trouble attachment lubrication system1247
G00207 – Engine remote oil tank 1 empty1247
G00208 – Engine remote oil tank 2 empty1247
G00216 – Trouble software not compatible1248
G00218 – Switch off all motors for running transfer pump1250
G00220 – Trouble transfer pump motor overheated1251
Wiring diagram (transfer pump) for trouble code G002201252
G00221 – Trouble slew direction module defect1253
Slew direction module 11B142 for trouble code G002211254
G00223 – Trouble starter control 51K001a-11255
51K001a-1/-2 & 51K001b-1/-2 (relay check) on the REAL TIME MONITOR1255
G00224 – Trouble starter control Output to 51K001a-11256
51K001a-1/-2 & 51K001b-1/-2 (output check) on the REAL TIME MONITOR1256
G00225 – Trouble starter control 51K001b-11257
G00226 – Trouble starter control Output to 51K001b-11257
G00227 – Trouble starter control 51K001a-21257
G00228 – Trouble starter control Output to 51K001a-21257
G00229 – Trouble starter control 51K001b-21257
G00230 – Trouble starter control Output to 51K001b-21257
G00231 – Trouble pilot control lever 20S0191258
G00232 – Trouble pilot control lever 20S0201258
Wiring diagram (20S019) for trouble code G002311259
Wiring diagram (20S020) for trouble code G002321260
G00233 – Trouble pilot control 11Q0451261
Wiring diagram (11Q045) for trouble code G002331262
G00234 – Trouble pilot control 11K111a1263
11K111a & 11K111b (relay check) on the REAL TIME MONITOR (G00234 & G00236)1263
G00235 – Trouble pilot control Output to 11K111a1264
11K111a & 11K111b (output check) on the REAL TIME MONITOR (G00235 & G00237)1264
G00236 – Trouble pilot control 11K111b1265
G00237 – Trouble pilot control Output to 11K111b1265
G00238 – Trouble supply by key switch 11Q0441266
Input signal of 11Q044 on the REAL TIME MONITOR (G00238)1266
Wiring diagram (11Q044) for trouble code G002381267
G00240 – Trouble hydraulic oil temperature1268
G00242 – Engine 1 already running1269
G00243 – Fill up fuel tank1270
G00245 – Engine shutdown from ground1271
Input signal of 54S007/51 & 54S008/52 on the REAL TIME MONITOR (G00245)1272
G00246 – Hydraulic oil temperature1273
G00248 – Engine 2 already running1273
G00252 – Emergency shut-down at access ladder1274
G00253 – Emergency shut-down at valve block1274
G00254 – Emergency shut-down at hydraulic control panel1274
G00255 – Emergency shut-down in cabin1274
Wiring diagram (emergency switches) for trouble codes G00252~G00255 & G002581276
G00256 – Operator warning system1277
G00257 – Hydraulic oil temperature1278
G00258 – Emergency shut-down at counterweight1279
G00261 – Maintenance Safety Switch1279
Wiring diagram (50S058) for trouble code G002611280
G00262 – Trouble screen at hydr cooler entry clogged1281
40B166 and 40B165 on the REAL TIME MONITOR (05 Hydraulic)1281
Location of 40B166 and 40B165 at the hydraulic oil tank (G00262)1282
Wiring diagram (40B166 & 40B165) for trouble code G002621283
G00308 – Trouble CAN-Bus or CAN-Hardware1284
G00309 – Trouble ladder up 56K253a1288
56K253a & 56K253b (relay check) on the REAL TIME MONITOR (G00309 & G00311)1288
G00310 – Trouble ladder up Output to 56K253a1289
56K253a & 56K253b (output check) on the REAL TIME MONITOR (G00310 & G00312)1289
G00311 – Trouble ladder up redundant 56K253b1290
G00312 – Trouble ladder up redundant Output to 56K253b1290
G00313 – Trouble ladder down 56K254a1290
56K254a & 56K254b (relay check) on the REAL TIME MONITOR (G00313 & G00315)1290
G00314 – Trouble ladder down Output to 56K254a1291
56K254a & 56K254b (output check) on the REAL TIME MONITOR (G00314 & G00316)1291
G00315 – Trouble ladder down redundant 56K254b1292
G00316 – Trouble ladder down redundant Output to 56K254b1292
G00317 – Trouble service arm up 56K255a1292
56K255a & 56K255b (relay check) on the REAL TIME MONITOR (G00317 & G00319)1292
G00318 – Trouble service arm up Output to 56K255a1293
56K255a & 56K255b (output check) on the REAL TIME MONITOR (G00318 & G00320)1293
G00319 – Trouble service arm up redundant 56K255b1294
G00320 – Trouble service arm up redundant Output to 56K255b1294
G00321 – Trouble service arm down 56K256a1294
56K256a & 56K256b (relay check) on the REAL TIME MONITOR (G00321 & G00323)1294
G00322 – Trouble service arm down Output to 56K256a1295
56K256a & 56K256b (output check) on the REAL TIME MONITOR (G00322 & G00324)1295
G00323 – Trouble service arm down redundant 56K256b1296
G00324 – Trouble service arm down redundant Output to 56K256b1296
G00325 – Trouble service arm Input1297
G00326 – Trouble ladder Input1297
G00327 – Trouble parking brake Input1297
G00328 – Trouble start Input1297
G00330 – Trouble pilot control 11Q1111300
Wiring diagram (11Q111/11K126) for trouble code G003301302
G00331 – Automatic after_running engine 11303
G00332 – Automatic after_running engine 21303
G00333 – Trouble battery charger relay1304
Wiring diagram (11Q122) for trouble code G003331305
G00336 – Trouble monitoring slew speed1306
Slew speed module 11B143 for trouble code G003361307
G00349 – Engine 2 running1308
G00350 – Engine 2 standstill1308
G00351 – Engine 1 running1308
G00352 – Engine 1 standstill1308
G00417 – Communication failure PLC [MTC] <=> KOMTRAX Plus controller1309
G00420 – Connector sel error1311
G00421 – Farm sys error1312
G00422 – Can-net sys (J1939)1313
G00423 – Application sys error1314
G00425 – Settings impossible to take over into the PLC [MTC]1315
Wiring diagram overview for G00425: KOMTRAX Plus monitor → KOMTRAX Plus controller → MTC1316
G00491 – Communication failure MH800 <=> KOMTRAX Plus controller1317
Wiring diagram overview for G00491: MH800 <=> KOMTRAX Plus controller1318
8 Troubleshooting by symptoms1319
81 Symptoms of the engines and related electrical systems1320
SEL001 – Engine does not start (engine does not rotate)1320
Wiring diagram 1 (starter batteries) for trouble code SEL0011322
Wiring diagram 2 (engine 1 start) for trouble code SEL0011324
Wiring diagram 3 (engine 2 start) for trouble code SEL0011326
Wiring diagram 4 (engine start & stop buttons) for trouble code SEL0011328
Wiring diagram 5 (engine start relays) for trouble code SEL0011330
SEL002 – Engine stops while in operation1332
View onto the water separators and fuel filters (SEL002)1334
Sectional view onto fuel filters, shut-off solenoid valves, and fuel piping (SEL002)1336
SEL003 – Engine speed is hunting during boom-up movement1338
SEL004 – Engine does not stop1339
SEL005 – Engine lacks output (no power)1340
Judgment Table for SEL0051341
SEL006 – Exhaust smoke is black1342
Judgment Table for SEL0061343
SEL007 – Oil consumption is excessive1344
Judgment Table for SEL0071345
SEL008 – Oil becomes contaminated quickly1346
Judgment Table for SEL0081347
SEL009 – Fuel consumption is excessive1348
Judgment Table for SEL0091349
SEL010 – Oil is in engine coolant1350
Judgment Table for SEL0101351
SEL011 – Oil level rises1352
Judgment Table for SEL0111353
SEL012 – Coolant temperature becomes too high (overheating)1354
Judgment Table for SEL0121355
82 Symptoms of the hydraulic system1356
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function)1356
SHY002 – No work equipment, travel or swing movement1358
SHY003 – Work equipment has too much hydraulic drift1359
SHY004 – Work equipment has big time lag1361
SHY005 – Machine deviates during travel movement1362
SHY006 – Machine does not swing1363
SHY007 – Swing acceleration is poor1364
SHY008 – Excessive overrun when stopping swing1367
SHY009 – Floating system without function1369
SHY010 – Abnormal noise coming from SRV or MRV1370
SHY011 – Track tensioning system without function1371
SHY012 – Ladder does not move, or slow movement1372
SHY013 – Refilling arm does not move, or slow movement1374
SHY014 – The hydraulic driven grease pump does not move1376
SHY015 – Trouble pump bearing lubrication1378
SHY016 – Abnormal track chain movement during digging1379
SHY017 – Swing parking brake without function1380
SHY018 – Travel parking brake without function1381
83 Symptoms of the Mechanical System1384
SME001 – Abnormal noise is made1384
Judgment Table for SME0011385
SME002 – Abnormal noise around the PTOs / hydraulic pumps1386
SME003 – Vibration is excessive (engine mountings)1388
Judgment Table for SME0031389
SME004 – Vibration is excessive (engine torsion)1390
SME005 – There is a big shock when stopping swing1391
SME006 – There is a big abnormal noise when moving/stopping swing1392
SME007 – Abnormal noise coming from a travel gearbox1394
SME008 – Abnormal noise coming from the work equipment (lack of grease)1396
SME009 – Abnormal idler movement1398
SME010 – Leak at the PTO shaft seal1399
84 Symptoms of Additional Systems1401
SAD001 – Air conditioner does not work1401
View onto the A/C unit (SAD001)1402
SAD002 – Air conditioner compressor clutch is burnt1403
View onto the A/C compressor and its mounting (SAD002)1404
SAD003 – Air conditioning system defective (pipes and hoses full of moisture)1405
SAD004 – Travel alarm does not sound1406
Wiring diagram (60P140) for trouble code SAD0041407
50 Disassembly & assembly 1409
Table of contents1413
1 Introduction1423
11 Contents of the binder1424
12 Foreword1425
121 Service1426
2 Safety and Standards1427
21 Safety Instructions1428
211 Method of using this manual1428
212 General precautions1430
213 Preparations for work1431
214 Precautions during work1432
215 Warning of special dangers1434
2151 Electrical energy1434
2152 Gas, dust, steam and smoke1435
2153 Hydraulic, air conditioning and pneumatic equipment1436
2154 Noise1436
2155 Heat1437
2156 Oil, grease and other chemical substances1437
2157 Height1437
216 Special safety equipment1439
2161 Safety harness in conformity with EN 361 (european standard)1439
2162 Instructions for use1441
2163 Recommendations for use of the holding hooks and hold-back hooks of the safety harness1443
2164 Instaructions for using the fall absorber1445
217 Safety hints for hydraulic hose installation1446
218 Safety hints for lifting heavy parts1449
219 Safety hints for wire ropes1449
2110 Safety hints for sling accessory1451
2111 Weight tables1452
21111 Superstructure1452
21112 Undercarriage1455
21113 Backhoe attachment (BHA)1457
21114 Face shovel attachment (FSA)1458
22 Torque charts according to DIN1459
221 Metric standard thread1459
222 Metric fine thread1460
223 Cummins motor torques – metric1461
224 Cummins motor torques – US customary1461
225 SAE flange connections1462
23 Blind plugs1463
231 Dummy plates for SAE-flanges1463
232 Classification of threads to the nominal width1465
233 Plugs and fittings according to DIN 23531466
24 Conversion table1467
241 Method of using the conversion table1467
242 Millimeter – Inch & Kilogram – Pound1468
243 Liter – US Gallon & Liter – UK Gallon1469
244 Nm – ftlb1470
245 Bar – PSI / PSI – Bar1471
246 Basic values in Ohm according to DIN 43 761472
247 Temperature1473
25 Tools1474
251 Standard tool case1474
26 Explanation of abbreviations1476
3 Superstructure1477
31 Diesel engine1478
311 Removal of the diesel engines1478
3111 Preparatory work for diesel engines removal1478
3112 Removal of the front diesel engine (engine 2)1483
3113 Replacement of the front diesel engine (engine 2)1487
3114 Removal of the rear diesel engine (engine 1)1490
3115 Replacement of the rear diesel engine (engine 1)1490
312 Engine torque support and engine/PTO mounts1492
3121 Flexible mounts1493
3122 Torque support1495
313 Alternator1496
3131 Removal of the alternator1496
3132 Replacement of the alternator1497
314 Batteries1498
3141 Removal of the batteries1498
3142 Replacement of the batteries1500
315 Radiator fan1502
3151 Removal of the radiator fan assembly1503
3152 Replacement of the radiator fan assembly1507
3153 Removal of the radiator fan1509
3154 Replacement of the radiator fan1509
3155 Removal of the radiator fan drive pump1510
3156 Replacement of the radiator fan drive pump1512
316 Radiators1514
3161 Removal of the radiator assembly1514
3162 Replacement of the radiator assembly1517
317 Starter system1518
3171 Removal of the starter motor1518
3172 Replacement of the starter motor1519
318 Torsion type coupling (GEISLINGER)1520
3181 Removal of the Geislinger coupling1521
3182 Replacement of the Geislinger coupling1525
32 PTO1526
321 Main pumps1526
3211 Preparatory works for main pump removal1527
3212 Removal of main pumps1530
3213 Replacement of main pumps1532
322 PTO oil pump (auxiliary pump)1534
3221 Removal of PTO oil pump (auxiliary pump)1534
3222 Replacement of the PTO oil pump (auxiliary pump)1536
323 Oil Circulation pump (auxiliary pump)1537
3231 Removal of oil circulation pump (auxiliary pump)1537
3232 Replacement of the oil circulation pump (auxiliary pump)1539
324 Pump distributor gearbox (PTO)1540
3241 Removal of the pump distributor gearbox (PTO)1542
3242 Replacement of the pump distributor gearbox (PTO)1546
33 Hydraulics1547
331 Hydraulic cooler fan drive pump1547
3311 Removal of the hydraulic cooler fan drive pump1548
3312 Replacement of the hydraulic cooler fan drive pump1551
332 Hydraulic cooler fan assembly1552
3321 Removal of hydraulic cooler fan assembly1553
3322 Replacement of hydraulic cooler fan assembly1556
3323 Removal of hydraulic cooler fan and motor1558
3324 Replacement of hydraulic cooler fan and motor1560
333 Hydraulic oil coolers1562
3331 Removal of the hydraulic oil coolers1564
3332 Replacement of the hydraulic oil coolers1568
3333 Removal of the hydraulic oil cooler frame1570
3334 Replacement of the hydraulic oil cooler frame1574
334 Main relief valves (MRV)1575
3341 Removal of the MRV1575
3342 Replacement of the MRV1576
335 Pilot oil pump (gear pump)1577
3351 Removal of the pilot oil pump1577
3352 Replacement of the pilot oil pump1579
336 Main gate valve1580
3361 Removal of the main gate valve1580
3362 Replacement of the main gate valve1581
337 Hydraulic oil reservoir1582
3371 Removal of the hydraulic oil reservoir1584
3372 Replacement of the hydraulic oil reservoir1590
338 Main control valve blocks1593
3381 Removal of the main control valve blocks1602
3382 Replacement of the main control valve blocks1608
339 Service line relief valves (SRV)1609
3391 Removal of SRV on main control valve block1609
3392 Replacement of SRV on main control valve blocks1612
3310 Anti-cavitation valves (ACV)1614
33101 Removal of ACV on manifold1615
33102 Replacement of the ACV on manifold1620
33103 Removal of ACV on main control valve blocks1621
33104 Replacement of ACV on main control valve blocks1624
3311 Throttle check valves1626
33111 Removal of throttle check valves1628
33112 Replacement of throttle check valves1631
3312 Manifold1632
33121 Removal of the manifold1632
33122 Replacement of the manifold1634
34 Slew drive1635
341 Slew gear1636
3411 Removal of the slew gear1637
3412 Replacement of the slew gear1641
342 Swing motor1644
3421 Removal of the swing motor1645
3422 Replacement of the swing motor1648
343 Slew parking brake1650
3431 Removal/disassembly of the slew parking brake (L&S)1653
3432 Replacement/assembly of the slew parking brake (L&S)1656
3433 Removal of the slew parking brake (Siebenhaar)1659
3434 replacement of the slew parking brake (Siebenhaar)1662
344 Dynamic slew brake1666
3441 Removal of the slew brake valve1669
3442 Replacement of the slew brake valve1671
345 Swing circle lubrication pinion (dummy wheel)1672
3451 Removal of the lubrication pinion assembly1674
3452 Replacement of the lubrication pinion assembly1676
346 swing circle1678
3461 Removal of the swing circle1679
3462 Replacement of the swing circle1682
35 Lubrication pumps1688
351 Removal of the lubrication pump1690
352 Replacement of the lubrication pump1692
36 Pump controller MC71693
361 Removal of the pump controller MC71693
362 Replacement of the pump controller MC71693
37 Operator’s cab1694
371 Removal of the operator’s cab1697
372 Replacement of the operator’s cab1702
373 Cab-mounts1704
3731 Removal of the cab-mounts1704
3732 Replacement of the cab-mounts1706
374 Front window (windscreen)1708
3741 Removal of the front window1708
3742 Replacement of the front window1709
375 Operator’s seat1710
3751 Removal of the operator’s seat1710
3752 Replacement of the operator’s seat1711
376 ECS1712
3761 Removal of the ECS text display1712
3762 Replacement of the ECS text display1712
377 Access ladder1714
3771 Removal of the access ladder1717
3772 Replacement of the access ladder1719
3773 Removal of the access ladder cylinder1721
3774 Replacement of the access ladder cylinder1723
378 Removal of the cab base1724
379 Replacement of the cab base1726
38 Counterweight1728
381 Removal of the counterweight1729
382 Replacement of the counterweight1731
39 Superstructure lifting1733
391 Remove the superstructure from the undercarriage1733
392 Install the superstructure onto the undercarriage1737
310 Fuel tank1740
3101 Removal of the fuel tank1741
3102 Replacement of the fuel tank1745
4 Undercarriage1747
41 Travel system1748
411 Track group1748
4111 Changing of the track group1748
412 Sprocket1753
4121 Removal of the sprocket1753
4122 Replacement of the sprocket1758
4123 Removal of the segmented sprocket (only for type with pinned undercarriage up to SN 025)1760
4124 Replacement of the segmented sprocket (only for type with pinned undercarriage up to SN 025)1764
413 Guide wheels1766
4131 Removal of the guide wheel assembly1766
4132 Replacement of the guide wheel assembly1768
414 Track tensioning accumulators1769
4141 Removal of the low pressure accumulators1769
4142 Replacement of the low pressure accumulators1771
4143 Removal of the high pressure accumulators1772
4144 Replacement of the high pressure accumulators1773
415 Track tension valve block1774
4151 Removal of the track tensioning valve block1774
4152 Replacement of the track tensioning valve block1775
416 Hydraulic hoses of the track tensioning system1777
4161 Substitute the hydraulic hoses1777
417 Travel brake valve block (overspeed valve)1780
4171 Removal of the travel brake valve block1781
4172 Replacement of the travel brake valve block1783
418 Track tensioning cylinders1784
4181 Removal of the track tensioning cylinders1784
4182 Replacement of the track tensioning cylinders1785
419 Travel motor1786
4191 Removal of the travel motors1786
4192 Replacement of the travel motors1788
4110 Travel parking brake1790
41101 Removal of the travel parking brake1792
41102 Replacement of the travel parking brake1794
4111 Travel gearbox1796
41111 Removal of the travel gearbox1797
41112 Replacement of the travel gearbox1799
41113 Removal of the travel gearbox (only for type with pinned undercarriage up to SN 025)1801
41114 Replacement of the travel gearbox (only for type with pinned undercarriage up to SN 025)1807
4112 Carrier roller1812
41121 Removal of the carrier roller assembly1812
41122 Replacement of the carrier roller assembly1814
4113 Track roller1815
41131 Removal of the track roller assembly1815
41132 Replacement of the track roller assembly1817
42 Car body1818
421 Removal of the car body and the crawler carriers (type with pinned undercarriage)1818
422 Replacement of the car body and the crawler carriers (type with pinned undercarriage)1822
423 Removal of the car body and the crawler carriers (type with bolted undercarriage)1826
424 Replacement of the car body and the crawler carriers (type with bolted undercarriage)1831
4241 Tightening torque for the crawler carrier mounting bolts1834
425 Rotary joint1838
4251 Removal of the rotary joint1840
4252 Replacement of the rotary joint1842
5 Attachment1843
51 Backhoe1844
511 Boom1846
5111 Removal of the boom1846
5112 Replacement of the boom1850
5113 Removal of boom cylinders1852
5114 Replacement of boom cylinders1858
512 Stick1862
5121 Removal of the stick1862
5122 Replacement of the stick1866
5123 Removal of stick cylinders1868
5124 Replacement of stick cylinders1874
513 Bucket1878
5131 Removal of the bucket1878
5132 Replacement of the bucket1881
5133 Removal of bucket cylinders1882
5134 Replacement of bucket cylinders1888
514 Bucket link rod and steering rods1891
5141 Removal of the bucket link rod1891
5142 Replacement of the bucket link rod1893
5143 Removal of the steering rods1894
5144 Replacement of the steering rods1897
515 Ground engaging tools (GET)1898
5151 Removal and replacement of the GET1899
516 Hydraulic hoses at the backhoe attachment1900
5161 Substitute the boom arc hoses1900
5162 Substitute the boom cylinder hoses1904
5163 Substitute the stick cylinder hoses1908
5164 Substitute the bucket cylinder hoses1912
52 Face shovel1916
521 Using the installation tools for hydraulic cylinders1917
522 Boom1918
5221 Removal of the boom1918
5222 Replacement of the boom1923
5223 Removal of the boom cylinders1928
5224 Replacement of the boom cylinders1933
523 Stick1936
5231 Removal of the stick1936
5232 Replacement of the stick1940
5233 Removal of the stick cylinders1942
5234 Replacement of the stick cylinders1947
524 Bull clam bucket1950
5241 Removal of the bull clam bucket1952
5242 Replacement of the bull clam bucket1956
5243 Removal of the bucket cylinders1958
5244 Replacement of the bucket cylinders1963
5245 Removal of the clam cylinders1966
5246 Replacement of the clam cylinders1971
525 Ground engaging tools (GET)1974
5251 Removal and replacement of the GET1975
526 Hydraulic hoses at the face shovel attachment1976
5261 Substitute the boom arc hoses1976
5262 Substitute the boom cylinder hoses1980
5263 Substitute the stick arc hoses1984
5264 Substitute the stick cylinder hoses1988
5265 Substitute the bucket cylinder hoses1992
5266 Substitute the clam cylinder hoses1996
53 Metering valves (grease injectors) at the attachment2004
531 Removal of the metering valves (grease injectors)2004
532 Replacement of the metering valves (grease injectors)2005
54 Cylinder bypass test2006
6 Service Information2009
61 Fluids and lubricants2010
611 Lubricants for operation in moderate and hot climates2010
612 Lubricants for operation in cold and arctic climates2012
62 Filling capacities2013
63 Work instructions2015
631 Surface coating with INTERZINC 6972015
632 Remove / install the crawler carrier2017
64 Used special tools (overview)2018

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24