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Komatsu PC4000-6 Hydraulic Mining Shovel Shop Manual SN 8155 – PDF DOWNLOAD
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Komatsu PC4000-6 Hydraulic Mining Shovel Shop Manual
SERIAL NUMBERS : PC4000-6 8155
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Description
Komatsu PC4000-6 Hydraulic Mining Shovel Shop Manual
FILE DETAILS:
Komatsu PC4000-6 Hydraulic Mining Shovel Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Mining Shovel
Manuals Type: Shop Manual
Machine Model: PC4000-6
Serial Number: 8155
Language: English
Pages: 950
File Format: Portable Document Format (PDF)
KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL SHOP MANUAL SN 8155 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC4000-6 Hydraulic Mining Shovel Shop Manual
FOREWORD:
GENERAL:
With this SERVICE MANUAL KOMATSU provides you with the
description of the construction and the function of the major systems of the Hydraulic Excavator PC5500-E.
We describe for you all functions and how to carry out the inspections and
adjustments.
How do you find “your” desired information?
In the table of CONTENT all the functions and components are shown in their sequence of the description.
GENERAL PRECAUTIONS:
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
TABLE OF CONTENTS:
Komatsu PC4000-6 Hydraulic Mining Shovel Shop Manual
Main Menu................................................................................................................................. 0 Cover..................................................................................................................................... 2 Contents.................................................................................................................................. 3 TABLE OF CONTENTS..................................................................................................................... 3 SAFETY - FOREWORD................................................................................................................. 4 SAFETY NOTICE................................................................................................................. 4 GENERAL PRECAUTIONS........................................................................................................... 4 PREPARATIONS FOR WORK......................................................................................................... 5 PRECAUTIONS DURING WORK....................................................................................................... 5 FOREWORD...................................................................................................................... 7 HOISTING INSTRUCTIONS..................................................................................................... 8 HOISTING.............................................................................................................. 8 WIRE ROPES............................................................................................................ 8 STANDARD TIGHTENING TORQUE................................................................................................ 10 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS.......................................................................... 10 CONVERSION TABLE.......................................................................................................... 11 METHOD OF USING THE CONVERSION TABLE.................................................................................. 11 TEMPERATURE........................................................................................................... 17 Section 1.0 - Main Assembly Groups........................................................................................................ 18 Table of contents Section 1.0 - Main assembly groups.................................................................................. 18 1.0 - Main Assembly Groups - General lay out...................................................................................... 20 1.1 Superstructure................................................................................................................ 22 1.1.1 Machine house........................................................................................................... 24 1.1.2 Hydraulic Oil Reservoir................................................................................................. 26 1.1.3 Hydraulic Oil Cooler.................................................................................................... 28 1.1.4 Fuel tank (Fuel reservoir).............................................................................................. 30 1.1.5 Counter weight.......................................................................................................... 32 1.1.6 Cab support............................................................................................................. 34 1.1.7 Operators cab........................................................................................................... 36 1.1.8 Control blocks.......................................................................................................... 38 1.1.9 Swing gears............................................................................................................. 40 1.2 Under carriage................................................................................................................ 42 1.3 Attachment.................................................................................................................... 44 1.3.1 Backhoe attachment (BHA)................................................................................................ 44 1.3.2 Front Shovel Attachment (FSA)........................................................................................... 46 Section 2.0 - Drive....................................................................................................................... 47 Table of contents Section 2.0 - Drive................................................................................................. 47 2.0 Prime Drive Assembly - General Lay Out........................................................................................ 49 2.1 Engine and PTO mounts......................................................................................................... 51 2.2 Coupling...................................................................................................................... 55 2.3 Air Filter.................................................................................................................... 57 2.4 Fan drive and radiator assembly............................................................................................... 59 2.5 Radiator fan drive speed adjustment........................................................................................... 63 2.6 Pump distributor gearbox (PTO)................................................................................................ 67 2.7 Pump-spline lubrication....................................................................................................... 69 2.8 PTO Lubrication and cooling................................................................................................... 71 2.9 Hydraulic pumps – location, drive speed and flow rates........................................................................ 75 Section 3.0 - Hydraulic Oil Reservoir..................................................................................................... 76 Table of contents Section 3.0 - Hydraulic Oil Reservoir............................................................................... 76 3.0 Hydraulic Oil Reservoir - General Lay Out..................................................................................... 78 3.1 Main oil tank, location of switches, sensors etc.............................................................................. 80 3.2 Suction oil tank with strainers............................................................................................... 82 3.3 Return oil collector tube with strainer....................................................................................... 84 3.4 Back pressure valve........................................................................................................... 86 3.5 Transfer pump (Optional Equipment)............................................................................................ 88 3.6 Return and Leak Oil Filter.................................................................................................... 90 3.7 Breather filter............................................................................................................... 92 Section 4.0 - Hydraulic Oil Cooling....................................................................................................... 93 Table of contents section 4.0 - Hydraulic Oil Cooling................................................................................. 93 4.1 General....................................................................................................................... 95 4.2 Function of the hydraulic oil cooling circuit................................................................................. 97 4.3 Adjustment of the Back Pressure Valve......................................................................................... 99 4.4 Fan drive (Two stage cooler fan RPM control)..................................................................................101 4.5 Pressure relief valves and solenoid valve.....................................................................................103 4.5 Fixed Displacement Pump, with variable setting................................................................................107 Section 5.0 - Controlling.................................................................................................................108 Table of contents Section 5.0 - Controlling...........................................................................................108 5.0 General Lay Out...............................................................................................................110 5.1 Control and filter panel location of components...............................................................................112 5.2 Pilot Pressure Supply and Adjustments.........................................................................................116 5.3 Remote control valves arrangement.............................................................................................122 5.4 Function principle of the Electro-Hydraulic- Proportional Control.............................................................124 5.5 Potentiometer Control (Lever, Joy Stick)......................................................................................128 5.6 Potentiometer Control (Pedal).................................................................................................130 5.7 Proportional Amplifier Module, Type A.........................................................................................132 5.8 Proportional Amplifier Module, Type B.........................................................................................134 5.9 Ramp Time Module..............................................................................................................136 5.10 Adjustments of Amplifier Modules (General)...................................................................................138 5.11 Adjusting the Amplifiers Type B, illustration (Z 21642)......................................................................140 5.12 Adjusting the Amplifiers Type B, illustration (Z 21643)......................................................................144 5.13 Adjusting the Ramp Time Module...............................................................................................148 Section 6.0 - Components..................................................................................................................153 Table of contents Section 6.0 - Components............................................................................................153 6.0 Components....................................................................................................................153 6.1 Hydraulic.....................................................................................................................153 6.1.1 Main Control Blocks and High Pressure Filter FSA........................................................................155 6.1.2 Main Control Blocks and High Pressure Filter BHA........................................................................157 6.1.3 Distributor Manifold - Location of restrictor blocks and anti cavitation valves FSA.....................................159 6.1.4 Distributor Manifold - Location of restrictor blocks and anti cavitation valves BHA.....................................161 6.1.5 Single Control Blocks (Floating) for Stick and Boom FSA.................................................................163 6.1.6 Restrictor Block with Pressure Relief Valve.............................................................................165 6.1.7 Anti Cavitation Valve Block.............................................................................................167 6.1.8 Remote control valves...................................................................................................169 6.1.9 Directional Solenoid Valves (Three positions / 4-ways)..................................................................171 6.1.10 Proportional Solenoid Valve............................................................................................173 6.1.11 High Pressure Filter...................................................................................................175 6.1.12 Control Blocks and Valves..............................................................................................177 6.1.13 Travel Brake Valve.....................................................................................................189 6.1.14 Pressure Reducing Valve................................................................................................191 6.1.15 Directional Solenoid Valves (Two positions / 4-ways)...................................................................193 6.1.16 Pressure Increasing Valve..............................................................................................195 Section 7.0 - Main Hydraulic Pumps and Pump Regulation System.............................................................................196 Table of contents Section 7.0 - Main Hyraulic Pumps and Pump Regulation System........................................................196 7.0 Main hydraulic pumps and pump regulation system...............................................................................198 7.1 Main Pumps....................................................................................................................206 7.1.1. Location of Pumps......................................................................................................206 7.1.2. Pump bearing flushing / lubrication....................................................................................208 7.1.3 Operating Principles....................................................................................................210 7.1.4 Checks / Adjustments....................................................................................................226 7.2 Electronic Pump Regulation System.............................................................................................236 7.2.1 Electronic load limiting control - general, illustration (Z 21713)......................................................236 7.2.2 Microcontroller MC7, illustration (Z 21716).............................................................................238 7.2.3 Checks and adjustments..................................................................................................240 Method A..................................................................................................................242 X1-pressure with 24V supply to separating terminals at the X2-switch board............................................242 Method B..................................................................................................................244 With the electronic service tool (EST) BB-3 connected to the serial interface X13-1 (located in the operators cab)....244 Language selection....................................................................................................244 Excavator Type selection..............................................................................................248 X1-Pressure (maximum current) Adjustment..............................................................................252 Method C..................................................................................................................256 With a laptop computer and BODEM software connected to the serial interface X13-1 (located in the operators cab)......256 Language selection....................................................................................................260 Excavator Type selection..............................................................................................262 X1-Pressure (maximum current) Adjustment..............................................................................264 7.3 Hydraulic Constant Regulation System..........................................................................................266 7.3.1. General................................................................................................................266 7.3.2. X1-pressure adjustment (constant-pressure) , illustration (Z 22360)....................................................268 7.4 Determination of the Peak point (Engine performance) ,illustration (Z 22360)..................................................270 Section 8.0 - Operating Hydraulic.........................................................................................................271 Table of contents Section 8.0 - Operating Hydraulic...................................................................................271 8.0 General.......................................................................................................................273 8.1 Table of Contents - Hydraulic for the Attachment Cylinders....................................................................276 8.1.1 Electric / Hydraulic flowchart “ Boom raising ” FSA.....................................................................278 8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA....................................................................282 8.1.3 Electric / Hydraulic flowchart “ Stick extending ” FSA..................................................................286 8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA.................................................................290 8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” FSA...................................................................294 8.1.6 Electric / Hydraulic flowchart “ Bucket emptying ” FSA..................................................................298 8.1.7 Electric / Hydraulic flowchart “ Clam opening ” FSA.....................................................................302 8.1.8 Electric / Hydraulic flowchart “ Clam closing ” FSA.....................................................................304 8.1.9 Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 21972)..........................................306 8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z21973)..................................310 Boom cylinder “Piston side” FSA + BHA.....................................................................................310 Boom cylinder “Piston rod side” FSA +BHA..................................................................................314 Stick cylinder “Piston side” FSA..........................................................................................318 Stick cylinder “Piston side” BHA..........................................................................................322 Stick cylinder “Piston rod side” FSA......................................................................................326 Stick cylinder “Piston rod side” BHA......................................................................................330 Bucket cylinder “Piston side” FSA.........................................................................................334 Bucket cylinder “Piston side” BHA.........................................................................................338 Bucket cylinder “Piston rod side” FSA.....................................................................................342 Bucket cylinder “Piston rod side” BHA.....................................................................................346 Clam cylinder “Piston rod side” FSA.......................................................................................350 Clam cylinder “Piston side” FSA...........................................................................................352 8.1.11 Checks and adjustments of the lowering speed, illustration (Z 22033)...................................................354 General...................................................................................................................354 Boom cylinder FSA.........................................................................................................356 Boom cylinder BHA.........................................................................................................360 Stick cylinder FSA........................................................................................................362 Stick cylinder BHA........................................................................................................366 Bucket cylinder FSA.......................................................................................................368 Bucket cylinder BHA.......................................................................................................370 Clam cylinder BHA.........................................................................................................372 8.2 Table of Contents - Hydraulic for the Swing Circuit...........................................................................373 8.2.1 Swing Circuit...........................................................................................................375 8.2.2 Swing Motor.............................................................................................................379 8.2.3 Swing Gear Box..........................................................................................................383 8.2.4 Swing Parking Brake (Gear house Brake)..................................................................................385 8.2.5 Swing Brake Valve.......................................................................................................387 8.2.6 Electric / Hydraulic flowchart “Swing Left”.............................................................................391 8.2.7 Electric / Hydraulic flowchart “Swing Right”............................................................................393 8.2.8 Swing Monitoring System, illustration (Z 21947).........................................................................395 8.2.9 Checks and adjustments for the swing circuit............................................................................399 8.2.10 Function check for the swing parking brake.............................................................................405 8.3 Table of Contents - Hydraulic for the Travel Circuit..........................................................................406 8.3.1 Travel Circuit..........................................................................................................408 8.3.2 Travel Motor............................................................................................................412 8.3.3 Rotary Distributor......................................................................................................414 8.3.4 Travel gear.............................................................................................................416 8.3.5 Travel parking brake (Gear house brake).................................................................................418 8.3.6 Travel Brake Valve......................................................................................................420 8.3.7 Electric / Hydraulic flowchart “Traveling forward”......................................................................422 8.3.8 Electric / Hydraulic flowchart “Traveling backward”.....................................................................424 8.3.9 Checks and adjustments for the travel circuit...........................................................................426 8.3.10 Function check for the travel parking brake............................................................................428 Section 9.0 - Hydraulic Track Tensioning System...........................................................................................429 Table of contents Section 9.0 - Hydraulic Track Tensioning System.....................................................................429 9.0 General - Hydraulic Track Tensioning System.......................................................................................431 9.1 Functional description............................................................................................................433 9.2 Pressure Increasing Valve.........................................................................................................437 9.3 Tensioning cylinder...............................................................................................................439 9.4 Adjustments / Checks..............................................................................................................441 9.5 Functional Test...................................................................................................................445 Section 10.0 - Access Ladder Hydraulically Operated.......................................................................................446 Table of contents Section 10.0 - Access Ladder Hydraulic Operated.....................................................................446 10.0 General......................................................................................................................448 10.1 Function of hydraulic operated access ladder illustration (Z 22495)..........................................................450 Section 11.0 - Hydraulic Operated Refilling Arm...........................................................................................453 Table of contents Section 11.0 - Hydraulic Operated Refilling Arm.....................................................................453 11.0 Hydraulic operated refilling arm - General...................................................................................455 11.1 Function of hydraulic operated refilling arm.................................................................................457 Section 12.0 - Hints For Reading The Hydraulic Circuit Diagram............................................................................458 Table of contents Section 12 - Hints For Reading The Hydraulic Circuit Diagram........................................................458 12.0 General - Hints For Reading The Hydraulic Circuit Diagram....................................................................459 12.1 Legend for the circuit diagram...............................................................................................460 12.2 How to read the circuit diagram..............................................................................................468 Hydraulic Plans 897 969 40 - (9 Pages)............................................................................................469 Hydraulic Plan 897 969 40 (Page 1 of 9).......................................................................................469 Hydraulic Plan 897 969 40 (Page 2 of 9).......................................................................................470 Hydraulic Plan 897 969 40 (Page 3 of 9).......................................................................................471 Hydraulic Plan 897 969 40 (Page 4 of 9).......................................................................................472 Hydraulic Plan 897 969 40 (Page 5 of 9).......................................................................................473 Hydraulic Plan 897 969 40 (Page 6 of 9).......................................................................................474 Hydraulic Plan 897 969 40 (Page 7 of 9).......................................................................................475 Hydraulic Plan 897 969 40 (Page 8 of 9).......................................................................................476 Hydraulic Plan 897 969 40 (Page 9 of 9).......................................................................................477 Section 13.0 - Hints For Reading The Electric Circuit Diagram.............................................................................478 Table of contents Section 13.0 - Hints For Reading The Electric Circuit Diagram.......................................................478 13.0 Hints For Reading The Electric Circuit Diagram...............................................................................478 13.1 Designation of electrical devices............................................................................................479 13.2 Symbols......................................................................................................................481 13.3 General information..........................................................................................................485 13.4 Reading a Circuit Diagram....................................................................................................489 13.5 Component list...............................................................................................................493 Electrical Plans 897 844 40 (64 Pages)............................................................................................546 Electrical Plans 897 844 40 (1 of 64 Pages)...................................................................................546 Electrical Plans 897 844 40 (2 of 64 Pages)...................................................................................547 Electrical Plans 897 844 40 (3 of 64 Pages)...................................................................................548 Electrical Plans 897 844 40 (4 of 64 Pages)...................................................................................549 Electrical Plans 897 844 40 (5 of 64 Pages)...................................................................................550 Electrical Plans 897 844 40 (6 of 64 Pages)...................................................................................551 Electrical Plans 897 844 40 (7 of 64 Pages)...................................................................................552 Electrical Plans 897 844 40 (8 of 64 Pages)...................................................................................553 Electrical Plans 897 844 40 (9 of 64 Pages)...................................................................................554 Electrical Plans 897 844 40 (10 of 64 Pages)..................................................................................555 Electrical Plans 897 844 40 (11 of 64 Pages)..................................................................................556 Electrical Plans 897 844 40 (12 of 64 Pages)..................................................................................557 Electrical Plans 897 844 40 (13 of 64 Pages)..................................................................................558 Electrical Plans 897 844 40 (14 of 64 Pages)..................................................................................559 Electrical Plans 897 844 40 (15 of 64 Pages)..................................................................................560 Electrical Plans 897 844 40 (16 of 64 Pages)..................................................................................561 Electrical Plans 897 844 40 (17 of 64 Pages)..................................................................................562 Electrical Plans 897 844 40 (18 of 64 Pages)..................................................................................563 Electrical Plans 897 844 40 (19 of 64 Pages)..................................................................................564 Electrical Plans 897 844 40 (20 of 64 Pages)..................................................................................565 Electrical Plans 897 844 40 (21 of 64 Pages)..................................................................................566 Electrical Plans 897 844 40 (22 of 64 Pages)..................................................................................567 Electrical Plans 897 844 40 (23 of 64 Pages)..................................................................................568 Electrical Plans 897 844 40 (24 of 64 Pages)..................................................................................569 Electrical Plans 897 844 40 (25 of 64 Pages)..................................................................................570 Electrical Plans 897 844 40 (26 of 64 Pages)..................................................................................571 Electrical Plans 897 844 40 (27 of 64 Pages)..................................................................................572 Electrical Plans 897 844 40 (28 of 64 Pages)..................................................................................573 Electrical Plans 897 844 40 (29 of 64 Pages)..................................................................................574 Electrical Plans 897 844 40 (30 of 64 Pages)..................................................................................575 Electrical Plans 897 844 40 (31 of 64 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Pages)..................................................................................590 Electrical Plans 897 844 40 (46 of 64 Pages)..................................................................................591 Electrical Plans 897 844 40 (47 of 64 Pages)..................................................................................592 Electrical Plans 897 844 40 (48 of 64 Pages)..................................................................................593 Electrical Plans 897 844 40 (49 of 64 Pages)..................................................................................594 Electrical Plans 897 844 40 (50 of 64 Pages)..................................................................................595 Electrical Plans 897 844 40 (51 of 64 Pages)..................................................................................596 Electrical Plans 897 844 40 (52 of 64 Pages)..................................................................................597 Electrical Plans 897 844 40 (53 of 64 Pages)..................................................................................598 Electrical Plans 897 844 40 (54 of 64 Pages)..................................................................................599 Electrical Plans 897 844 40 (55 of 64 Pages)..................................................................................600 Electrical Plans 897 844 40 (56 of 64 Pages)..................................................................................601 Electrical Plans 897 844 40 (57 of 64 Pages)..................................................................................602 Electrical Plans 897 844 40 (58 of 64 Pages)..................................................................................603 Electrical Plans 897 844 40 (59 of 64 Pages)..................................................................................604 Electrical Plans 897 844 40 (60 of 64 Pages)..................................................................................605 Electrical Plans 897 844 40 (61 of 64 Pages)..................................................................................606 Electrical Plans 897 844 40 (62 of 64 Pages)..................................................................................607 Electrical Plans 897 844 40 (63 of 64 Pages)..................................................................................608 Electrical Plans 897 844 40 (64 of 64 Pages)..................................................................................609 Section 14.0 - VHMS / ECS-T / ETM.........................................................................................................610 Table of contents Section 14.0 - Vehicle Health Monitoring System.....................................................................610 14.0 General - VHMS...................................................................................................................612 14.1 Colored Graphic Console (CGC) for PC4000 - Specifications for Operators..........................................................613 Table of contents section 14.1 - Colored Graphic Console (CGC) for PC4000.........................................................613 14.1.1 Graphic Flow Chart.........................................................................................................615 14.1.2 Initialization Screen (No. 0.0)............................................................................................617 14.1.3 Operator Information Screen (No. 1.1)......................................................................................617 14.1.4 Monitoring Screens.........................................................................................................619 Standard Monitor 1 (No. 1.2)..................................................................................................619 Expansion monitor 2 (No. 1.3).................................................................................................619 Expansion monitor 3 (No. 1.4).................................................................................................619 14.1.5 Brightness and Contrast Setting Screen (No. 1.2.1).........................................................................621 14.1.6 Fuel Consumption Screen (No. 1.2.2)........................................................................................623 14.1.7 Settings for Operator, Screen (No. 1.2.3)..................................................................................625 Entry of the Operator identification number...................................................................................625 Resetting the Truck Counter...................................................................................................625 14.1.8 Maintenance Monitor (No. 1.2.4)............................................................................................627 14.1.9 Failure Message (No. 1.2.5)................................................................................................631 Failure history for Operator..................................................................................................631 14.1.10 Automatic Messages........................................................................................................633 14.2 Colored Graphic Console (CGC) for PC4000 - Specifications for Servicemen.........................................................634 Table of contents Section 14.2 - Colored Graphic Console (CGC) for PC4000.........................................................634 14.2.1 Graphic Flow Chart.....................................................................................................636 14.2.2 Service ID Setup Screen (No. 2.0)......................................................................................638 14.2.3 Service Menu Select Screen (No. 3.1)...................................................................................640 14.2.4 Real Time Menu Select Screen (No. 4.1.1)...............................................................................642 Engine (No. 5.1.1 - No. 5.1.4)............................................................................................642 Engine (No. 5.2.1)........................................................................................................644 Hydraulic (No. 5.3.1 - No. 5.3.7).........................................................................................646 Electrical Equipment (No. 5.4.1 - 5.4.2)..................................................................................648 Emergency Stop (No. 5.5.1 - No. 5.5.2)....................................................................................650 Manual Switch (No. 5.6.1 - No. 5.6.3).....................................................................................652 Central Lubrication System (No. 5.7.1 - No. 5.7.2)........................................................................654 Swing Lubrication System (No. 5.8.1 - No. 5.8.2)..........................................................................656 Other Items (No. 5.9.1 - No. 5.9.3).......................................................................................658 Output Signals (No. 5.10.1 - No. 5.10.6).................................................................................660 14.2.5 PM-Clinic (No. 4.2.1 + 4.2.2) General..................................................................................662 (No. 4.2.1 + 4.2.2) General...............................................................................................662 (No. 4.2.3 – 4.2.5) Power Check...........................................................................................664 14.2.6 Serial No. Setting (No. 4.3.1) Machine.................................................................................666 (No. 4.3.1) Machine.......................................................................................................666 (No. 4.3.2) Engine........................................................................................................668 14.2.7 Memory Clear (No. 4.3.2) Input Memory Clear ID.........................................................................670 Entry of the identification number........................................................................................670 Memory Clear (No. 4.4.1) Memory Clear Screen..............................................................................672 14.2.8 Maintenance Monitor (No. 4.5 – 4.5.1) Maintenance Acknowledgement......................................................674 14.2.9 Failure History for Service (No. 4.6)..................................................................................676 14.2.10 Snapshot Trigger (No. 4.7)............................................................................................678 14.2.11 Settings (No. 4.8.1 – No. 4.8.10).....................................................................................680 Central Lubrication System CLS No. 4.8.1).................................................................................680 Swing Lubrication System SLS No. 4.8.2)...................................................................................682 Other Settings 1/2 (No. 4.8.3)............................................................................................684 Language selector button..............................................................................................684 Operating Hours.......................................................................................................684 Date Settings.........................................................................................................684 Time Settings.........................................................................................................686 GMT Ref...............................................................................................................686 Other Settings 2/2 (No. 4.8.4)............................................................................................688 Oil Viscosity Hydraulic...............................................................................................688 Oil Viscosity Gear....................................................................................................688 Messages ON/OFF.......................................................................................................690 PLC-autom. ON/OFF.....................................................................................................690 Shut Down ON / OFF (No. 4.8.5 - No. 4.8.10)...............................................................................692 14.4 Wiring of the Main Components....................................................................................................693 Table of contents section 14.4 - Wiring of the Main Components....................................................................693 14.4 Wiring of the main components............................................................................................695 14.4.1 Wiring of the engine...............................................................................................697 14.4.2 Wiring of the VHMS Controller......................................................................................699 14.4.3 Wiring of the CGC Monitor..........................................................................................703 14.4.4 Wiring of the PLC..................................................................................................705 Section 15.0 - Lubrication Systems........................................................................................................706 Introduction..........................................................................................................................706 General Contents......................................................................................................................708 Table of Contents Chapter 1 - Hydraulically Driven Lube Pump......................................................................709 Function - Hydraulically Driven Lube Pump Power Master III....................................................................711 Oscillation Cylinder and Control Block, illustration Z 21174..................................................................715 Adjustments (illustration Z21175).............................................................................................717 Table of Contents Chapter 2 - One Line System With Hydraulically Driven "Power Master III" Pump...................................718 Function Central Lubrication System...........................................................................................720 Electrical Function...........................................................................................................724 Sonar Sensor For Grease Level.................................................................................................728 Adjustments...................................................................................................................730 End Line Pressure Switch..................................................................................................730 Injectors.................................................................................................................732 Table of Contents Chapter 3 - Pinion Type System With Hydr. Driven "Power Master III" Pump........................................733 Function Pinion type (dummy wheel) system.....................................................................................735 Electrical Function (dummy wheel) system......................................................................................739 Lubricant Level Monitoring....................................................................................................743 Adjustments...................................................................................................................745 End-Of-Line Switch Setting................................................................................................745 Injectors.................................................................................................................747 Table of Contents Chapter 4 - Components..........................................................................................748 Hydraulically Drive Lube Pump.................................................................................................750 Lubricant Injectors...........................................................................................................754 End-Of-Line Switch............................................................................................................760 Filter........................................................................................................................762 Vent valve (Solenoid valve)...................................................................................................764 Magnetventile Solenoid Valves - Owner's Manual............................................................................765 Table of Content......................................................................................................766 Safety Instructions...............................................................................................766 Application.......................................................................................................767 Examples of Application...........................................................................................767 Erection and Installation.........................................................................................767 Operating Instructions............................................................................................767 Type Identification...............................................................................................768 Troubleshooting...................................................................................................769 Technical Data....................................................................................................769 Electrical Data...................................................................................................769 Dimensions........................................................................................................770 Troubleshooting Elektro Plan 897 888 40 (68 Pages)........................................................................................773 Elektroplan 897 888 40 (Page 1 of 68).................................................................................................773 Elektroplan 897 888 40 (Page 2 of 68).................................................................................................774 Elektroplan 897 888 40 (Page 3 of 68).................................................................................................775 Elektroplan 897 888 40 (Page 4 of 68).................................................................................................776 Elektroplan 897 888 40 (Page 5 of 68).................................................................................................777 Elektroplan 897 888 40 (Page 6 of 68).................................................................................................778 Elektroplan 897 888 40 (Page 7 of 68).................................................................................................779 Elektroplan 897 888 40 (Page 8 of 68).................................................................................................780 Elektroplan 897 888 40 (Page 9 of 68).................................................................................................781 Elektroplan 897 888 40 (Page 10 of 68)................................................................................................782 Elektroplan 897 888 40 (Page 11 of 68)................................................................................................783 Elektroplan 897 888 40 (Page 12 of 68)................................................................................................784 Elektroplan 897 888 40 (Page 13 of 68)................................................................................................785 Elektroplan 897 888 40 (Page 14 of 68)................................................................................................786 Elektroplan 897 888 40 (Page 15 of 68)................................................................................................787 Elektroplan 897 888 40 (Page 16 of 68)................................................................................................788 Elektroplan 897 888 40 (Page 17 of 68)................................................................................................789 Elektroplan 897 888 40 (Page 18 of 68)................................................................................................790 Elektroplan 897 888 40 (Page 19 of 68)................................................................................................791 Elektroplan 897 888 40 (Page 20 of 68)................................................................................................792 Elektroplan 897 888 40 (Page 21 of 68)................................................................................................793 Elektroplan 897 888 40 (Page 22 of 68)................................................................................................794 Elektroplan 897 888 40 (Page 23 of 68)................................................................................................795 Elektroplan 897 888 40 (Page 24 of 68)................................................................................................796 Elektroplan 897 888 40 (Page 25 of 68)................................................................................................797 Elektroplan 897 888 40 (Page 26 of 68)................................................................................................798 Elektroplan 897 888 40 (Page 27 of 68)................................................................................................799 Elektroplan 897 888 40 (Page 28 of 68)................................................................................................800 Elektroplan 897 888 40 (Page 29 of 68)................................................................................................801 Elektroplan 897 888 40 (Page 30 of 68)................................................................................................802 Elektroplan 897 888 40 (Page 31 of 68)................................................................................................803 Elektroplan 897 888 40 (Page 32 of 68)................................................................................................804 Elektroplan 897 888 40 (Page 33 of 68)................................................................................................805 Elektroplan 897 888 40 (Page 34 of 68)................................................................................................806 Elektroplan 897 888 40 (Page 35 of 68)................................................................................................807 Elektroplan 897 888 40 (Page 36 of 68)................................................................................................808 Elektroplan 897 888 40 (Page 37 of 68)................................................................................................809 Elektroplan 897 888 40 (Page 38 of 68)................................................................................................810 Elektroplan 897 888 40 (Page 39 of 68)................................................................................................811 Elektroplan 897 888 40 (Page 40 of 68)................................................................................................812 Elektroplan 897 888 40 (Page 41 of 68)................................................................................................813 Elektroplan 897 888 40 (Page 42 of 68)................................................................................................814 Elektroplan 897 888 40 (Page 43 of 68)................................................................................................815 Elektroplan 897 888 40 (Page 44 of 68)................................................................................................816 Elektroplan 897 888 40 (Page 45 of 68)................................................................................................817 Elektroplan 897 888 40 (Page 46 of 68)................................................................................................818 Elektroplan 897 888 40 (Page 47 of 68)................................................................................................819 Elektroplan 897 888 40 (Page 48 of 68)................................................................................................820 Elektroplan 897 888 40 (Page 49 of 68)................................................................................................821 Elektroplan 897 888 40 (Page 50 of 68)................................................................................................822 Elektroplan 897 888 40 (Page 51 of 68)................................................................................................823 Elektroplan 897 888 40 (Page 52 of 68)................................................................................................824 Elektroplan 897 888 40 (Page 53 of 68)................................................................................................825 Elektroplan 897 888 40 (Page 54 of 68)................................................................................................826 Elektroplan 897 888 40 (Page 55 of 68)................................................................................................827 Elektroplan 897 888 40 (Page 56 of 68)................................................................................................828 Elektroplan 897 888 40 (Page 57 of 68)................................................................................................829 Elektroplan 897 888 40 (Page 58 of 68)................................................................................................830 Elektroplan 897 888 40 (Page 59 of 68)................................................................................................831 Elektroplan 897 888 40 (Page 60 of 68)................................................................................................832 Elektroplan 897 888 40 (Page 61 of 68)................................................................................................833 Elektroplan 897 888 40 (Page 62 of 68)................................................................................................834 Elektroplan 897 888 40 (Page 63 of 68)................................................................................................835 Elektroplan 897 888 40 (Page 64 of 68)................................................................................................836 Elektroplan 897 888 40 (Page 65 of 68)................................................................................................837 Elektroplan 897 888 40 (Page 66 of 68)................................................................................................838 Elektroplan 897 888 40 (Page 67 of 68)................................................................................................839 Elektroplan 897 888 40 (Page 68 of 68)................................................................................................840 Troubleshooting Hydraulic Plan 897 893 40 (9 Pages).......................................................................................841 Hydraulikplan 897 893 40 (Page 1 of 9)................................................................................................841 Hydraulikplan 897 893 40 (Page 2 of 9)................................................................................................842 Hydraulikplan 897 893 40 (Page 3 of 9)................................................................................................843 Hydraulikplan 897 893 40 (Page 4 of 9)................................................................................................844 Hydraulikplan 897 893 40 (Page 5 of 9)................................................................................................845 Hydraulikplan 897 893 40 (Page 6 of 9)................................................................................................846 Hydraulikplan 897 893 40 (Page 7 of 9)................................................................................................847 Hydraulikplan 897 893 40 (Page 8 of 9)................................................................................................848 Hydraulikplan 897 893 40 (Page 9 of 9)................................................................................................849 Troubleshooting Flowchart 897 894 40 (51 Pages)...........................................................................................850 Ablaufdiagramm Flowchart 897 894 40 (Page 1 of 51)....................................................................................850 Ablaufdiagramm Flowchart 897 894 40 (Page 2 of 51)....................................................................................851 Ablaufdiagramm Flowchart 897 894 40 (Page 3 of 51)....................................................................................852 Ablaufdiagramm Flowchart 897 894 40 (Page 4 of 51)....................................................................................853 Ablaufdiagramm Flowchart 897 894 40 (Page 5 of 51)....................................................................................854 Ablaufdiagramm Flowchart 897 894 40 (Page 6 of 51)....................................................................................855 Ablaufdiagramm Flowchart 897 894 40 (Page 7 of 51)....................................................................................856 Ablaufdiagramm Flowchart 897 894 40 (Page 8 of 51)....................................................................................857 Ablaufdiagramm Flowchart 897 894 40 (Page 9 of 51)....................................................................................858 Ablaufdiagramm Flowchart 897 894 40 (Page 10 of 51)...................................................................................859 Ablaufdiagramm Flowchart 897 894 40 (Page 11 of 51)...................................................................................860 Ablaufdiagramm Flowchart 897 894 40 (Page 12 of 51)...................................................................................861 Ablaufdiagramm Flowchart 897 894 40 (Page 13 of 51)...................................................................................862 Ablaufdiagramm Flowchart 897 894 40 (Page 14 of 51)...................................................................................863 Ablaufdiagramm Flowchart 897 894 40 (Page 15 of 51)...................................................................................864 Ablaufdiagramm Flowchart 897 894 40 (Page 16 of 51)...................................................................................865 Ablaufdiagramm Flowchart 897 894 40 (Page 17 of 51)...................................................................................866 Ablaufdiagramm Flowchart 897 894 40 (Page 18 of 51)...................................................................................867 Ablaufdiagramm Flowchart 897 894 40 (Page 19 of 51)...................................................................................868 Ablaufdiagramm Flowchart 897 894 40 (Page 20 of 51)...................................................................................869 Ablaufdiagramm Flowchart 897 894 40 (Page 21 of 51)...................................................................................870 Ablaufdiagramm Flowchart 897 894 40 (Page 22 of 51)...................................................................................871 Ablaufdiagramm Flowchart 897 894 40 (Page 23 of 51)...................................................................................872 Ablaufdiagramm Flowchart 897 894 40 (Page 24 of 51)...................................................................................873 Ablaufdiagramm Flowchart 897 894 40 (Page 25 of 51)...................................................................................874 Ablaufdiagramm Flowchart 897 894 40 (Page 26 of 51)...................................................................................875 Ablaufdiagramm Flowchart 897 894 40 (Page 27 of 51)...................................................................................876 Ablaufdiagramm Flowchart 897 894 40 (Page 28 of 51)...................................................................................877 Ablaufdiagramm Flowchart 897 894 40 (Page 29 of 51)...................................................................................878 Ablaufdiagramm Flowchart 897 894 40 (Page 30 of 51)...................................................................................879 Ablaufdiagramm Flowchart 897 894 40 (Page 31 of 51)...................................................................................880 Ablaufdiagramm Flowchart 897 894 40 (Page 32 of 51)...................................................................................881 Ablaufdiagramm Flowchart 897 894 40 (Page 33 of 51)...................................................................................882 Ablaufdiagramm Flowchart 897 894 40 (Page 34 of 51)...................................................................................883 Ablaufdiagramm Flowchart 897 894 40 (Page 35 of 51)...................................................................................884 Ablaufdiagramm Flowchart 897 894 40 (Page 36 of 51)...................................................................................885 Ablaufdiagramm Flowchart 897 894 40 (Page 37 of 51)...................................................................................886 Ablaufdiagramm Flowchart 897 894 40 (Page 38 of 51)...................................................................................887 Ablaufdiagramm Flowchart 897 894 40 (Page 39 of 51)...................................................................................888 Ablaufdiagramm Flowchart 897 894 40 (Page 40 of 51)...................................................................................889 Ablaufdiagramm Flowchart 897 894 40 (Page 41 of 51)...................................................................................890 Ablaufdiagramm Flowchart 897 894 40 (Page 42 of 51)...................................................................................891 Ablaufdiagramm Flowchart 897 894 40 (Page 43 of 51)...................................................................................892 Ablaufdiagramm Flowchart 897 894 40 (Page 44 of 51)...................................................................................893 Ablaufdiagramm Flowchart 897 894 40 (Page 45 of 51)...................................................................................894 Ablaufdiagramm Flowchart 897 894 40 (Page 46 of 51)...................................................................................895 Ablaufdiagramm Flowchart 897 894 40 (Page 47 of 51)...................................................................................896 Ablaufdiagramm Flowchart 897 894 40 (Page 48 of 51)...................................................................................897 Ablaufdiagramm Flowchart 897 894 40 (Page 49 of 51)...................................................................................898 Ablaufdiagramm Flowchart 897 894 40 (Page 50 of 51)...................................................................................899 Ablaufdiagramm Flowchart 897 894 40 (Page 51 of 51)...................................................................................900 Troubleshooting Flowcharts 898 688 40 (50 Pages)..........................................................................................901 Flowcharts 898 688 40 (Page 1 of 50)..................................................................................................901 Flowcharts 898 688 40 (Page 2 of 50)..................................................................................................902 Flowcharts 898 688 40 (Page 3 of 50)..................................................................................................903 Flowcharts 898 688 40 (Page 4 of 50)..................................................................................................904 Flowcharts 898 688 40 (Page 5 of 50)..................................................................................................905 Flowcharts 898 688 40 (Page 6 of 50)..................................................................................................906 Flowcharts 898 688 40 (Page 7 of 50)..................................................................................................907 Flowcharts 898 688 40 (Page 8 of 50)..................................................................................................908 Flowcharts 898 688 40 (Page 9 of 50)..................................................................................................909 Flowcharts 898 688 40 (Page 10 of 50).................................................................................................910 Flowcharts 898 688 40 (Page 11 of 50).................................................................................................911 Flowcharts 898 688 40 (Page 12 of 50).................................................................................................912 Flowcharts 898 688 40 (Page 13 of 50).................................................................................................913 Flowcharts 898 688 40 (Page 14 of 50).................................................................................................914 Flowcharts 898 688 40 (Page 15 of 50).................................................................................................915 Flowcharts 898 688 40 (Page 16 of 50).................................................................................................916 Flowcharts 898 688 40 (Page 17 of 50).................................................................................................917 Flowcharts 898 688 40 (Page 18 of 50).................................................................................................918 Flowcharts 898 688 40 (Page 19 of 50).................................................................................................919 Flowcharts 898 688 40 (Page 20 of 50).................................................................................................920 Flowcharts 898 688 40 (Page 21 of 50).................................................................................................921 Flowcharts 898 688 40 (Page 22 of 50).................................................................................................922 Flowcharts 898 688 40 (Page 23 of 50).................................................................................................923 Flowcharts 898 688 40 (Page 24 of 50).................................................................................................924 Flowcharts 898 688 40 (Page 25 of 50).................................................................................................925 Flowcharts 898 688 40 (Page 26 of 50).................................................................................................926 Flowcharts 898 688 40 (Page 27 of 50).................................................................................................927 Flowcharts 898 688 40 (Page 28 of 50).................................................................................................928 Flowcharts 898 688 40 (Page 29 of 50).................................................................................................929 Flowcharts 898 688 40 (Page 30 of 50).................................................................................................930 Flowcharts 898 688 40 (Page 31 of 50).................................................................................................931 Flowcharts 898 688 40 (Page 32 of 50).................................................................................................932 Flowcharts 898 688 40 (Page 33 of 50).................................................................................................933 Flowcharts 898 688 40 (Page 34 of 50).................................................................................................934 Flowcharts 898 688 40 (Page 35 of 50).................................................................................................935 Flowcharts 898 688 40 (Page 36 of 50).................................................................................................936 Flowcharts 898 688 40 (Page 37 of 50).................................................................................................937 Flowcharts 898 688 40 (Page 38 of 50).................................................................................................938 Flowcharts 898 688 40 (Page 39 of 50).................................................................................................939 Flowcharts 898 688 40 (Page 40 of 50).................................................................................................940 Flowcharts 898 688 40 (Page 41 of 50).................................................................................................941 Flowcharts 898 688 40 (Page 42 of 50).................................................................................................942 Flowcharts 898 688 40 (Page 43 of 50).................................................................................................943 Flowcharts 898 688 40 (Page 44 of 50).................................................................................................944 Flowcharts 898 688 40 (Page 45 of 50).................................................................................................945 Flowcharts 898 688 40 (Page 46 of 50).................................................................................................946 Flowcharts 898 688 40 (Page 47 of 50).................................................................................................947 Flowcharts 898 688 40 (Page 48 of 50).................................................................................................948 Flowcharts 898 688 40 (Page 49 of 50).................................................................................................949 Flowcharts 898 688 40 (Page 50 of 50).................................................................................................950
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Casen Marcus –
Good so far