Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Komatsu PC4000-6 Hydraulic Mining Shovel Shop Manual SM-PC4000-8199 – PDF DOWNLOAD
Original price was: $98.95.$33.95Current price is: $33.95.
Komatsu PC4000-6 Hydraulic Mining Shovel Shop Manual
SERIAL NUMBERS PC4000-6 8199 and up
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Komatsu PC4000-6 Hydraulic Mining Shovel Shop Manual SM-PC4000-8199
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: 8199 and up
Book Code: SM-PC4000-8199
Language: English
Pages: 2445
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC4000-6 Hydraulic Mining Shovel Shop Manual
FOREWORD:
PURPOSE OF THIS THIS MANUAL:
- This manual gives details of the methods of inspection, maintenance and troubleshooting for this machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the inspection, maintenance and troubleshooting of machines. Read, understand and follow all precautions and warnings in this manual and on the machine before performing inspection, maintenance or troubleshooting.
- Failure to do so may result in serious injury or death. Komatsu cannot predict every circumstance that may involve a potential hazard when the machine is used. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If you carry out any inspection, maintenance and troubleshooting under conditions that are not described in this manual, understand that it is your responsibility to take the necessary precautions to ensure safety.
- In no event should you or others engage in prohibited uses or actions described in this manual. Improper inspection, maintenance and troubleshooting of the machine can be hazardous and could result in serious injury or death. If you sell the machine, be sure to give this manual to the new owner together with the machine. This manual uses the international units (SI) for units of measurement. For reference, units that have been used in the past are given in ( ).
- The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of publication. Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual.
- Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If the machine has been purchased in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.
TABLE OF CONTENTS:
Komatsu PC4000-6 Hydraulic Mining Shovel Shop Manual
1 Foreword.............................................................................................................. 3
1.1 Purpose of this THIS MANUAL..................................................................................... 4
1.2 Contents of thE Shop Manual..................................................................................... 5
1.2.1 Contacting the Service.................................................................................... 5
1.2.2 Guarantee................................................................................................. 5
1.3 DIVISION OF THE Shop Manual..................................................................................... 6
00_SAFETY.pdf........................................................................................................... 0
2 SAFETY............................................................................................................ 9
2.1 SAFETY INFORMATION.......................................................................................... 10
2.2 OVERVIEW.................................................................................................... 11
2.2.1 NORMAL OPERATIONS..................................................................................... 11
2.2.2 REGULAR MAINTENANCE................................................................................... 11
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR............................................................... 11
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR....... 11
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB.................................................................. 12
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR.................................................... 13
2.4.1 UNDERSTANDING THE MACHINE............................................................................. 13
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR................................................ 13
2.4.2.1 ENSURING SAFE OPERATION......................................................................... 13
2.4.3 PREPARATIONS FOR SAFE OPERATION....................................................................... 13
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT.................................................. 13
2.4.3.2 INSPECTING THE MACHINE.......................................................................... 13
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT.............................................. 14
2.4.3.4 KEEP MACHINE CLEAN.............................................................................. 14
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT....................................................... 14
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT..................................................... 15
2.4.3.7 IF A PROBLEM IS FOUND........................................................................... 15
2.4.4 FIRE PREVENTION....................................................................................... 15
2.4.4.1 PRECAUTIONS TO PREVENT FIRE..................................................................... 15
2.4.4.2 ACTION IF FIRE OCCURS........................................................................... 16
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB.............................................................. 17
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE........................................................ 17
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE...................................... 17
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE................................................................ 17
2.4.5.3 NO PEOPLE ON THE ATTACHMENT..................................................................... 17
2.4.5.4 WORKING IN HIGH PLACES.......................................................................... 17
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK............................................................... 18
2.4.5.6 LEAVING THE MACHINE............................................................................. 18
2.4.6 BURN PREVENTION....................................................................................... 19
2.4.6.1 Hot coolant..................................................................................... 19
2.4.6.2 Hot oil......................................................................................... 19
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS................................................................... 19
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES.......................................................... 20
2.4.8.1 UNAUTHORIZED MODIFICATION....................................................................... 20
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS.................................................. 20
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)................................................................... 21
2.4.10 PRECAUTIONS AT JOBSITE............................................................................... 22
2.4.10.1 VISIBILITY FROM OPERATOR’S SEAT................................................................ 23
2.4.10.2 CAMERA SYSTEM WITH MONITORS.................................................................... 23
2.4.10.3 ENSURE GOOD VISIBILITY......................................................................... 23
2.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS......................................................... 23
2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS..................................................... 24
2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES......................................................... 24
2.4.10.7 WORKING ON LOOSE GROUND........................................................................ 25
2.4.10.8 GAS, DUST, STEAM AND SMOKE..................................................................... 25
2.4.10.9 VENTILATION OF ENCLOSED AREAS.................................................................. 26
2.4.11 STARTING ENGINE...................................................................................... 27
2.4.11.1 WARNING TAG.................................................................................... 27
2.4.11.2 CHECKS BEFORE STARTING ENGINE.................................................................. 27
2.4.11.3 PRECAUTION WHEN STARTING ENGINE................................................................ 27
2.4.11.4 PRECAUTION IN COLD AREAS....................................................................... 28
2.4.12 OPERATION............................................................................................ 28
2.4.12.1 CHECKS BEFORE OPERATION........................................................................ 28
2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE.............................................. 29
2.4.12.3 PRECAUTIONS WHEN travelling.................................................................... 30
2.4.12.4 TRAVELLING ON SLOPES........................................................................... 31
2.4.12.5 OPERATIONS ON SLOPES........................................................................... 32
2.4.12.6 PROHIBITED OPERATIONS.......................................................................... 32
2.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES.................................................. 33
2.4.12.8 PARKING THE MACHINE............................................................................ 33
2.4.12.9 TRANSPORTATION................................................................................. 33
2.5 PRECAUTION FOR MAINTENANCE.................................................................................. 34
2.5.1 GENERAL PRECAUTIONS................................................................................... 34
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES............................... 35
2.5.1.2 STOP ENGINE FOR MAINTENANCE..................................................................... 36
2.5.1.3 WARNING TAG..................................................................................... 37
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY................................................................... 38
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS......................................................... 38
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING......................................... 39
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS..................................................... 39
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT......................................... 40
2.5.1.9 NOISE........................................................................................... 40
2.5.1.10 WHEN USING A HAMMER............................................................................ 40
2.5.1.11 PROPER TOOLS................................................................................... 41
2.5.1.12 ACCUMULATOR.................................................................................... 41
2.5.1.13 PERSONNEL...................................................................................... 41
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE............................................................ 42
2.5.2.1 PRECAUTION WHEN WELDING......................................................................... 42
2.5.2.2 BATTERY HANDLING................................................................................ 42
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID.................................................................. 43
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE............................................................. 43
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES.......................................................... 44
2.5.3.3 REPLACEMENT OF HOSE LINES....................................................................... 44
2.5.3.4 INSPECTION OF HOSE LINES........................................................................ 44
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................... 45
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE.................................................................... 45
2.5.3.7 AIR CONDITIONING MAINTENANCE.................................................................... 45
2.5.3.8 COMPRESSED AIR.................................................................................. 46
2.5.3.9 WASTE MATERIALS................................................................................. 46
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS........................................... 47
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM.................................................................... 47
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS....................................... 47
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR........................................................ 47
2.7 SPECIAL SAFETY EQUIPMENT.................................................................................... 48
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB............................................. 49
2.7.2 OBJECT HANDLING....................................................................................... 49
2.7.3 LIGHTING.............................................................................................. 49
2.7.4 WARNING BEACON........................................................................................ 49
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD).......................................... 49
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD).................................... 49
2.7.5.2 INSTRUCTIONS FOR USE............................................................................ 51
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL................................................ 53
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1),.... 53
2.7.5.5 INSTRUCTIONS FOR USE............................................................................ 55
START PAGE Safety 00.pdf............................................................................................ 0
00 Safety....................................................................................................... 7
01_SPECIFICATIONS.pdf................................................................................................... 0
START PAGE Specifications 01.pdf.................................................................................... 0
01 SPECIFICATION................................................................................................ 57
10_STRUCTURE, FUNCTION.pdf.............................................................................................. 0
I. INTRODUCTION..................................................................................................... 79
I.I Contents of the Binder...................................................................................... 80
I.II Foreword................................................................................................... 81
SERVICE..................................................................................................... 81
I.III RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE OF HYDRAULIC MINING SHOVELS........ 82
Operation................................................................................................... 82
Maintenance and repair...................................................................................... 82
I.IV Explanation of Abbrevations................................................................................ 83
I.V Diagrams and Illustrations in this manual................................................................... 84
Wiring Diagrams & Hydraulic Diagrams........................................................................ 84
Illustrations & technical drawings.......................................................................... 84
II.
SAFETY......................................................................................................... 87
CONTENTS........................................................................................................ 88
Overview........................................................................................................ 89
NORMAL OPERATIONS........................................................................................... 89
REGULAR MAINTENANCE......................................................................................... 89
TROUBLESHOOTING, ADJUSTMENTS AND REPAIR..................................................................... 89
ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR............. 89
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR........................................................ 90
PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR...................................................... 90
ENSURING SAFE OPERATION................................................................................. 90
UNDERSTANDING THE MACHINE............................................................................... 90
PREPARATIONS FOR SAFE OPERATION............................................................................. 90
PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT.......................................................... 90
INSPECTING THE MACHINE.................................................................................. 90
WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT...................................................... 91
KEEP MACHINE CLEAN...................................................................................... 91
PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT............................................................... 91
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT............................................................. 92
IF A PROBLEM IS FOUND................................................................................... 92
FIRE PREVENTION............................................................................................. 92
ACTION IF FIRE OCCURS................................................................................... 92
PRECAUTIONS TO PREVENT FIRE............................................................................. 93
PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE.............................................................. 94
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE.............................................. 94
NO JUMPING ON OR OFF THE MACHINE........................................................................ 94
NO PEOPLE ON THE ATTACHMENT............................................................................. 94
LEAVING OPERATOR’S SEAT WITH LOCK....................................................................... 94
LEAVING THE MACHINE..................................................................................... 95
BURN PREVENTION............................................................................................. 95
PRECAUTIONS WHEN CLEANING CAB GLASS......................................................................... 95
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES................................................................ 96
UNAUTHORIZED MODIFICATION............................................................................... 96
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS.......................................................... 96
PRECAUTIONS AT JOBSITE...................................................................................... 97
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS.............................................................. 97
WORKING ON LOOSE GROUND................................................................................. 97
DO NOT GO CLOSE TO HIGH VOLTAGE CABLES.................................................................. 98
Camera System with Monitors............................................................................. 101
CHECKING SIGNS AND SIGNALMAN’S SIGNALS.................................................................. 101
GAS, DUST, STEAM AND SMOKE.............................................................................. 102
VENTILATION OF ENCLOSED AREAS........................................................................... 102
EMERGENCY EXIT FROM OPERATOR’S CAB...................................................................... 102
STARTING ENGINE............................................................................................. 103
WARNING TAG............................................................................................. 103
PRECAUTION WHEN STARTING ENGINE......................................................................... 104
PRECAUTION IN COLD AREAS................................................................................ 104
OPERATION................................................................................................... 104
CHECKS BEFORE OPERATION................................................................................. 104
PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE....................................................... 105
PRECAUTIONS WHEN travelling............................................................................. 106
TRAVELLING ON SLOPES.................................................................................... 106
OPERATIONS ON SLOPES.................................................................................... 107
PROHIBITED OPERATIONS................................................................................... 108
TRAVELLING ON FROZEN OR SNOW COVERED SURFACES........................................................... 108
PARKING THE MACHINE..................................................................................... 109
TRANSPORTATION.......................................................................................... 109
PRECAUTION FOR MAINTENANCE...................................................................................... 110
STOP ENGINE FOR MAINTENANCE................................................................................. 111
WARNING TAG................................................................................................. 112
KEEP WORKPLACE CLEAN AND TIDY............................................................................... 113
APPOINT LEADER WHEN WORKING WITH OTHERS..................................................................... 113
TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING..................................................... 113
INSTALLING, REMOVING OR STORING ATTACHMENTS................................................................. 113
PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT..................................................... 114
NOISE....................................................................................................... 114
WHEN USING A HAMMER......................................................................................... 114
PROPER TOOLS................................................................................................ 115
ACCUMULATOR................................................................................................. 115
PERSONNEL................................................................................................... 115
PRECAUTIONS FOR INSPECTION AND MAINTENANCE.................................................................. 116
PRECAUTION WHEN WELDING................................................................................. 116
BATTERY HANDLING........................................................................................ 116
PRECAUTIONS WITH HIGH PRESSURE OIL...................................................................... 117
PRECAUTIONS WITH HIGH FUEL PRESSURE..................................................................... 117
HANDLING HIGH PRESSURES HOSES OR PIPES.................................................................. 117
REPLACEMENT OF HOSE LINES............................................................................... 117
INSPECTION OF HOSE LINES................................................................................ 118
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS........................................................... 118
PRECAUTIONS FOR HIGH VOLTAGE............................................................................ 120
SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES....................................... 120
WASTE MATERIALS......................................................................................... 120
AIR CONDITIONING MAINTENANCE............................................................................ 121
COMPRESSED AIR.......................................................................................... 121
ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS............................................... 122
INSPECTION OF THE HYDRAULIC SYSTEM.......................................................................... 122
TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS............................................. 122
AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR.............................................................. 123
SPECIAL SAFETY EQUIPMENT........................................................................................ 124
FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB................................................... 125
OBJECT HANDLING............................................................................................. 125
LIGHTING.................................................................................................... 125
WARNING BEACON.............................................................................................. 125
SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)................................................ 125
SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)................................................ 126
INSTRUCTIONS FOR USE........................................................................................ 129
PRIOR TO USING THE HARNESS (1), THE WEARER SHALL............................................................ 131
RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1),................. 131
INSTRUCTIONS FOR USE........................................................................................ 133
III. SPECIFICATIONS................................................................................................. 135
III.I Lifting Gears............................................................................................. 136
III.II Safety hints for sling accessory......................................................................... 138
III.III Standard Tightening Torque Chart........................................................................ 139
III.IV Conversion Table......................................................................................... 140
III.V Blind plugs............................................................................................... 147
III.VI Classification of threads to the nominal width........................................................... 149
III.VII Plugs and fittings according to ISO 8434-1 / DIN 2353................................................... 150
1. MAIN ASSEMBLY GROUPS............................................................................................. 153
1.1 General Layout.............................................................................................. 154
1.2 Superstructure.............................................................................................. 156
1.3 Machine House............................................................................................... 158
1.4 Hydraulic Oil tank.......................................................................................... 160
1.5 Hydraulic Oil Cooler........................................................................................ 162
1.6 Fuel Tank................................................................................................... 164
1.7 Counterweight............................................................................................... 166
1.8 Cab Support................................................................................................. 168
1.9 Operator’s Cab.............................................................................................. 170
1.10 Control Blocks............................................................................................. 172
1.11 Swing machinery............................................................................................ 174
1.11.1 Swing Machinery L&S.................................................................................. 174
1.11.2 Swing Machinery SIEBENHAAR........................................................................... 176
1.12 Undercarriage.............................................................................................. 178
1.13 Backhoe Attachment (BHA)................................................................................... 180
1.14 Front Shovel Attachment (FSA).............................................................................. 182
2. DRIVE............................................................................................................ 185
2.1 Prime Drive Assembly........................................................................................ 186
2.2 Engine and PTO Mounts....................................................................................... 188
2.2.1 engine Mounts......................................................................................... 189
2.2.2 Torque Support........................................................................................ 190
2.3 Geislinger Coupling......................................................................................... 192
2.4 Fan Drive and Radiator Assembly............................................................................. 194
2.4.1 Radiator Fan Drive Speed Adjustment................................................................... 198
2.5 Pump Distributor Gearbox (PTO).............................................................................. 202
2.5.1 Pump Drive Shaft Housing.............................................................................. 204
2.5.2 PTO Lubrication and Cooling........................................................................... 206
2.5.3 Hydraulic Pumps – Location, Drive Speed and Flow Rates................................................ 210
2.6 Air Filter.................................................................................................. 212
3. HYDRAULIC OIL TANK............................................................................................... 215
3.1 General Layout.............................................................................................. 216
3.2 Hydraulic Oil Tank, Location of the Electric Equipment...................................................... 218
3.3 Suction Oil Tank with Strainers............................................................................. 220
3.4 Return Oil Collector Pipe with Strainer..................................................................... 222
3.5 Back Pressure Valve......................................................................................... 224
3.6 Transfer Pump for hydraulic oil............................................................................. 226
3.7 Return and Leak Oil Filter.................................................................................. 228
3.8 Breather Filter............................................................................................. 230
4. HYDRAULIC OIL COOLING............................................................................................ 233
4.1 Overall view of the hydraulic oil cooling................................................................... 234
4.2 Function of the Hydraulic Oil Cooling Circuit............................................................... 236
4.3 Adjustment of the Back Pressure Valve....................................................................... 238
4.4 Fan Drive (Two Stage Cooler Fan RPM Control)................................................................ 240
4.4.1 Fixed Displacement Pump, with Variable Setting........................................................ 242
4.4.2 Pressure Relief Valve................................................................................. 244
4.4.3 Solenoid Valve........................................................................................ 246
4.5 Adjustment of the Cooler Fan Drive Speed.................................................................... 248
4.5.1 Maximum speed......................................................................................... 248
4.5.2 Medium speed.......................................................................................... 251
4.5.3 Function Check of Fan Speed Control................................................................... 252
5. CONTROLLING...................................................................................................... 255
5.1 General layout.............................................................................................. 256
5.2 Valve cartridge block....................................................................................... 258
5.3 Pilot pressure supply and adjustments....................................................................... 264
5.3.1 Pilot pressure control (PPC) circuit.................................................................. 265
5.3.2 Checks and adjustment of pilot pressure............................................................... 268
5.3.3 Remote control valves arrangement..................................................................... 270
5.4 Function of the electro hydraulic control system............................................................ 272
5.5 Hand lever (joystick) control............................................................................... 276
5.6 Foot pedal control.......................................................................................... 278
5.7 Proportional amplifier module, type A....................................................................... 280
5.8 Proportional amplifier module, type B....................................................................... 282
5.9 Ramp time module............................................................................................ 284
5.10 Adjustments of amplifier modules........................................................................... 286
5.10.1 General.............................................................................................. 287
5.10.2 Adjusting the amplifiers type A...................................................................... 288
5.10.3 Adjusting the amplifiers type B...................................................................... 290
5.11 Adjusting the ramp time modul.............................................................................. 292
6. COMPONENTS....................................................................................................... 297
6.1 Main control blocks and high pressure filter (FSA).......................................................... 298
6.2 Main control blocks and high pressure filter (BHA).......................................................... 300
6.3 Distributor manifold - location of restrictor blocks and anti cavitation valves (FSA)....................... 302
6.4 Distributor manifold - location of restrictor blocks and anti cavitation valves (BHA)....................... 304
6.5 Single control blocks (floating) for stick and boom (FSA)................................................... 306
6.6 Restrictor block with pressure relief valve................................................................. 308
6.7 Anti cavitation valve block................................................................................. 310
6.8 Remote control valves....................................................................................... 312
6.9 4/3 Directional solenoid valves............................................................................. 314
6.10 Proportional solenoid valves............................................................................... 316
6.11 High pressure filter....................................................................................... 318
6.12 Control blocks and valves.................................................................................. 320
6.13 Travel brake valve......................................................................................... 332
6.14 Pressure reducing valve.................................................................................... 334
6.15 4/2 Directional solenoid valves............................................................................ 336
6.16 Pressure double stage valve................................................................................ 338
6.17 Hydraulic cylinder......................................................................................... 340
6.18 Slew ring.................................................................................................. 344
7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION......................................................................... 347
7.1 General..................................................................................................... 348
7.2 Main pumps.................................................................................................. 356
7.2.1 Location of pumps..................................................................................... 357
7.2.2 Pump bearing flushing / lubrication................................................................... 358
7.2.3 Operating principle................................................................................... 360
7.2.4 Checks / adjustments.................................................................................. 376
7.3 Electronic Pump Regulation System........................................................................... 384
7.3.1 Electronic Load Limiting Control - General............................................................ 385
7.3.2 Microcontroller RC4-4................................................................................. 387
7.3.3 Checks and adjustments................................................................................ 389
7.4 Hydraulic Constant Regulation System........................................................................ 396
7.4.1 General............................................................................................... 397
7.4.2 X1 Pressure adjustment (constant pressure)............................................................ 398
7.5 Determination of the peak point (engine performance)........................................................ 400
7.6 Engine speed sensor (pick-up)............................................................................... 402
7.6.1 General............................................................................................... 403
7.6.2 Engine speed sensor (pick-up) adjustment.............................................................. 403
7.7 Energy Efficiency........................................................................................... 404
7.7.1 General............................................................................................... 405
7.7.2 Checks and adjustments................................................................................ 406
8. OPERATING HYDRAULICS............................................................................................. 411
8.1 General..................................................................................................... 412
8.1.1 Floating system....................................................................................... 414
8.2 Hydraulics for the attachment cylinder FSA and BHA.......................................................... 416
8.2.1 Electric / hydraulic flowchart "boom raise" FSA....................................................... 416
8.2.2 Electric / hydraulic flowchart "boom raise" BHA....................................................... 418
8.2.3 Electric / hydraulic flowchart "boom lowering" FSA.................................................... 420
8.2.4 Electric / hydraulic flowchart "boom lowering" BHA.................................................... 422
8.2.5 Electric / hydraulic flowchart "stick extend" FSA..................................................... 424
8.2.6 Electric / hydraulic flowchart "stick extend" BHA..................................................... 426
8.2.7 Electric / hydraulic flowchart "stick retract" FSA.................................................... 428
8.2.8 Electric / hydraulic flowchart "stick retract" BHA.................................................... 430
8.2.9 Electric / hydraulic flowchart "bucket curl" FSA...................................................... 432
8.2.10 Electric / hydraulic flowchart "bucket curl" BHA..................................................... 434
8.2.11 Electric / hydraulic flowchart "bucket dump" FSA..................................................... 436
8.2.12 Electric / hydraulic flowchart "bucket dump" BHA..................................................... 438
8.2.13 Electric / hydraulic flowchart "clam Open" FSA....................................................... 440
8.2.14 Electric / hydraulic flowchart "clam close" FSA...................................................... 442
8.2.15 Checks and adjustments of the main relief valves (FSA)............................................... 444
8.2.16 Checks and adjustments of the main relief valves (BHA)............................................... 446
8.2.17 Checks and adjustments of the secondary relief valves (SRV).......................................... 448
8.2.17.1 Boom cylinder "Piston Side" FSA + BHA.......................................................... 449
8.2.17.2 Boom Cylinder "Piston Rod Side" FSA +BHA....................................................... 453
8.2.17.3 Stick Cylinder "Piston Side" FSA............................................................... 457
8.2.17.4 Stick Cylinder "Piston Side" BHA............................................................... 461
8.2.18 Stick cylinder "piston rod side" FSA................................................................. 465
8.2.18.1 Stick Cylinder "Piston Rod Side" BHA........................................................... 469
8.2.18.2 Bucket Cylinder "Piston Side" FSA.............................................................. 473
8.2.18.3 Bucket Cylinder "Piston Side" BHA.............................................................. 477
8.2.18.4 Bucket Cylinder "Piston Rod Side" FSA.......................................................... 481
8.2.18.5 Bucket Cylinder "Piston Rod Side" BHA.......................................................... 485
8.2.18.6 Clam Cylinder "Piston Rod Side" FSA............................................................ 489
8.2.18.7 Clam Cylinder "Piston Side" FSA................................................................ 491
8.2.18.8 Checks and Adjustments of the Lowering Speed................................................... 493
8.3 Hydraulics for the swing circuit............................................................................ 512
8.3.1 Swing circuit......................................................................................... 512
8.3.2 Swing motor........................................................................................... 516
8.3.3 Swing gearbox (L & S)................................................................................. 518
8.3.4 Swing gearbox (Siebenhaar)............................................................................ 520
8.3.5 Slew parking brake (L & S)............................................................................ 522
8.3.6 Slew parking brake (Siebenhaar)....................................................................... 524
8.3.7 Swing brake valve..................................................................................... 526
8.3.8 Electric / hydraulic flowchart "swing left"........................................................... 528
8.3.9 Electric / hydraulic flowchart "swing right".......................................................... 530
8.3.10 Checks and adjustments for the swing circuit......................................................... 532
8.3.11 Function check for the hydraulic swing brake......................................................... 538
8.3.12 Function check for the slew parking brake............................................................ 540
8.4 Hydraulics for the travel circuit........................................................................... 542
8.4.1 Travel circuit........................................................................................ 542
8.4.2 Travel motor.......................................................................................... 546
8.4.3 Rotary joint.......................................................................................... 548
8.4.4 Travel gearbox (L & S)................................................................................ 550
8.4.5 Travel gearbox (Zollern).............................................................................. 552
8.4.6 Travel parking brake (gear house brake)............................................................... 554
8.4.7 Travel brake valve.................................................................................... 556
8.4.8 Electric / hydraulic flowchart “travel forward”....................................................... 558
8.4.9 Electric / hydraulic flowchart “travel backwards”..................................................... 560
8.4.10 Checks and adjustments for the travel circuit........................................................ 562
8.4.11 Function check for the travel parking brake.......................................................... 564
9. HYDRAULIC TRACK TENSIONING SYSTEM................................................................................ 567
9.1 General..................................................................................................... 568
9.2 Functional description...................................................................................... 570
9.3 Pressure double stage valve................................................................................. 572
9.4 Tensioning cylinder......................................................................................... 574
9.5 Adjustments / checks........................................................................................ 576
10. ACCESS LADDER, HYDRAULICALLY OPERATED........................................................................... 579
10.1 General.................................................................................................... 580
10.2 Function of Hydraulically Operated Access Ladder........................................................... 582
10.3 Adjustments / Checks....................................................................................... 586
11. CENTRAL REFILLING SYSTEM (SERVICE ARM).......................................................................... 589
11.1 General.................................................................................................... 590
11.2 Function................................................................................................... 592
12. HINTS FOR READING THE HYDRAULIC DIAGRAM......................................................................... 595
12.1 General.................................................................................................... 596
12.2 Hydraulic symbols.......................................................................................... 598
12.2.1 Lines, unions........................................................................................ 599
12.2.2 Components, valves................................................................................... 601
12.2.3 Sensors.............................................................................................. 601
12.2.4 Valves, valve components............................................................................. 602
12.2.5 Pump, motor, cylinder................................................................................ 606
13. HINTS FOR READING THE ELECTRIC WIRING DIAGRAM................................................................... 611
13.1 General.................................................................................................... 612
13.2 Reference designation of the electrical components......................................................... 613
13.2.1 Area code............................................................................................ 613
13.2.2 Component identifying letter......................................................................... 615
13.3 Graphical symbols.......................................................................................... 616
13.4 Drawing concept............................................................................................ 620
13.5 Cable marking.............................................................................................. 630
13.6 Table of new and old component designations................................................................ 631
14. VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM.................................................... 667
14.1 General.................................................................................................... 668
14.2 Specifications for Operators............................................................................... 670
14.2.1 Sequence of Displays................................................................................. 671
14.2.2 Opening Screen....................................................................................... 671
14.2.3 Main Gauge Screens 1 to 3............................................................................ 672
14.2.4 Fuel Consumption Screen.............................................................................. 677
14.2.5 Failure message Screen for the Operator.............................................................. 679
14.2.6 Main Gauge Screens - Changing of Time / SMR / Date................................................... 681
14.2.7 Maintenance Monitor.................................................................................. 682
14.2.8 Settings for Operators............................................................................... 684
14.2.9 Automatic Messages................................................................................... 692
14.2.10 Tables of all Messages provided by the System....................................................... 695
14.2.10.1 Table of G-Codes.............................................................................. 696
14.2.10.2 Table of C-Codes - Diesel engines with emission standard TIER 2............................... 705
14.2.10.3 Table of C-Codes - Diesel engines with emission standard TIER 1............................... 712
14.2.10.4 Table of available Instruction Messages....................................................... 718
14.3 Flow Charts (1-4) VHMS Main Screens........................................................................ 721
14.4 VHMS Service Level......................................................................................... 725
14.4.1 Explanation of the Button Symbols (Service Level).................................................... 726
14.4.2 Service Menu Select Screen........................................................................... 727
14.4.3 Real Time Menu Select Screen......................................................................... 728
14.4.3.1 Real Time Menu, option: 01 Engine 1............................................................ 728
14.4.3.2 Real Time Menu, option: 02 PTO 1............................................................... 729
14.4.3.3 Real Time Menu, option: 03 Hydraulic........................................................... 730
14.4.3.4 Real Time Menu, option: 04 Slew................................................................ 731
14.4.3.5 Real Time Menu, option: 05 Electrical Equipment................................................ 731
14.4.3.6 Real Time Menu, option: 06 Emergency Stop...................................................... 731
14.4.3.7 Real Time Menu, option: 07 Manual Switch....................................................... 732
14.4.3.8 Real Time Menu, option: 08 Central lUBE System 1............................................... 733
14.4.3.9 Real Time Menu, option: 09 Slew Ring Gear Lube System.......................................... 733
14.4.3.10 Real Time Menu, option: 10 Windscreen Wiper................................................... 734
14.4.3.11 Real Time Menu, option: 11 lADDER............................................................. 734
14.4.3.12 Real Time Menu, option: 12 Service Arm........................................................ 735
14.4.3.13 Real Time Menu, option: 13 Pilot Control...................................................... 736
14.4.3.14 Real Time Menu, option: 14 oTHER ITEMS........................................................ 737
14.4.3.15 Real Time Menu, option: 15 Output Signals..................................................... 738
14.4.3.16 Output Signals with deactivated MTC- Evaluation............................................... 743
14.4.4 PM-Clinic............................................................................................ 744
14.4.4.1 General........................................................................................ 744
14.4.4.2 Power Check.................................................................................... 745
14.4.5 Serial/GCC No. Setting............................................................................... 746
14.4.6 Memory Clear......................................................................................... 747
14.4.6.1 Input Memory Clear ID.......................................................................... 747
14.4.6.2 Memory Clear Screen............................................................................ 748
14.4.7 Failure History...................................................................................... 749
14.4.8 Maintenance Monitor.................................................................................. 750
14.4.9 Snapshot............................................................................................. 751
14.4.10 Settings............................................................................................ 752
14.4.10.1 Central Lubrication System (CLS 1), screen 1/8................................................ 752
14.4.10.2 Swing Lubrication System (SLS), screen 2/8.................................................... 753
14.4.10.3 Qmin - Qmax - Setting, screen 3/8............................................................. 754
14.4.10.4 Other Settings 1/2, screen 4/8................................................................ 754
14.4.10.5 Other Settings 2/2, screen 5/8................................................................ 756
14.4.10.6 Shutdown Bypass ON/OFF........................................................................ 758
14.5 Interface-Connection VHMS-Controller....................................................................... 760
14.5.1 VHMS-Controller...................................................................................... 761
14.6 Wiring of the VHMS-Controller.............................................................................. 762
14.7 Global Layout of the MTC Control System.................................................................... 766
14.7.1 MTC (Master Turbo Controller)........................................................................ 768
14.7.1.1 MTC-Flowchart.................................................................................. 768
14.7.1.2 MTC Features................................................................................... 768
14.7.1.3 MTC-Firmware and Software...................................................................... 769
14.7.1.4 View onto the MTC unit and its Connectors...................................................... 770
14.8 Global Layout of the Internal CAN bus...................................................................... 772
14.8.1 General Information about a CAN bus System........................................................... 772
14.8.1.1 General CAN bus description.................................................................... 773
14.8.1.2 CAN bus troubleshooting........................................................................ 773
14.8.1.3 Can bus wiring................................................................................. 774
14.8.1.4 CAN bus End Resistor........................................................................... 776
14.9 The Nodes in the CAN bus System............................................................................ 778
14.9.1 Global Layout........................................................................................ 778
14.9.2 Introduction......................................................................................... 779
14.9.2.1 ICN-V Features................................................................................. 780
14.9.2.2 ICN-D Features................................................................................. 781
14.9.3 Node DIP-Switches.................................................................................... 782
14.9.4 Node Box............................................................................................. 783
14.9.5 Node Locations on the Machine........................................................................ 784
14.9.5.1 Node & Location Chart.......................................................................... 785
14.9.5.2 Exemplary View onto Location 11 (Cab base)..................................................... 786
15. AUTOMATIC LUBRICATION SYSTEMS................................................................................... 789
15.1 General Overview CLS & SLS................................................................................. 790
15.1.1 General Description.................................................................................. 791
15.2 Basic Function of the Lubrication Systems.................................................................. 792
15.3 Central Lubrication System (CLS)........................................................................... 794
15.3.1 General Information on CLS........................................................................... 796
15.4 Lubrication Pump Station (SLS)............................................................................. 798
15.4.1 General Information on SLS........................................................................... 800
15.5 Lubrication Cycle.......................................................................................... 801
15.5.1 Operation and Control................................................................................ 801
15.5.2 Lubrication Cycle - Components....................................................................... 802
15.5.3 Lubrication Cycle - Processing....................................................................... 804
15.5.4 Time Segments & Switch Points of a Lubrication Cycle................................................. 805
15.5.5 Lubrication Modes.................................................................................... 806
15.5.5.1 Automatic Lubrication Mode..................................................................... 806
15.5.5.2 Manual Lubrication Mode........................................................................ 806
15.5.5.3 VHMS Service Mode.............................................................................. 806
15.6 Hydraulically Driven Lube Pump............................................................................. 808
15.6.1 Adjustment of Lube Pump Speed & Working Pressure..................................................... 810
15.6.1.1 Stroke Speed Adjustment........................................................................ 811
15.6.1.2 Working Pressure Adjustment.................................................................... 811
15.7 Lubricant Injectors........................................................................................ 812
15.7.1 Tightening torque for fittings at the grease incetors................................................ 813
15.7.2 Description.......................................................................................... 813
15.7.3 Adjustment of the Lubricant Output................................................................... 813
15.7.4 Operation Principle of Lubricant Injectors........................................................... 814
15.7.4.1 Function Description........................................................................... 816
15.7.5 Connection of one or more Injectors.................................................................. 817
15.8 Vent Valve................................................................................................. 818
15.8.1 Description.......................................................................................... 819
15.9 End-Line Switch............................................................................................ 820
15.9.1 Description.......................................................................................... 821
15.9.2 CLS End-Line Switch Adjustment....................................................................... 822
15.9.3 SLS End-Line Switch Adjustment....................................................................... 824
15.10 In-Line Filter............................................................................................ 826
15.10.1 Description......................................................................................... 827
15.10.2 Maintenance procedure............................................................................... 827
15.11 Lubricant Level Sensor.................................................................................... 828
15.11.1 Description......................................................................................... 829
15.11.1.1 LEDs at the sonar sensor...................................................................... 829
15.12 Lubrication Pinion (SLS).................................................................................. 832
15.12.1 Description......................................................................................... 833
15.13 Commissioning............................................................................................. 834
15.13.1 COMMISSIONING OF THE CLS Lubrication SYSTEM......................................................... 834
15.13.2 Fine Adjustment..................................................................................... 835
15.13.3 COMMISSIONING OF THE SLS Lubrication SYSTEM......................................................... 836
START PAGE Structure_Function 10.pdf................................................................................ 0
10 STRUCTURE, FUNCTION.......................................................................................... 67
40_TROUBLESHOOTING.pdf.................................................................................................. 0
1 SAFETY............................................................................................................ 855
1.1 SAFETY INFORMATION.......................................................................................... 856
1.2 OVERVIEW.................................................................................................... 857
1.2.1 NORMAL OPERATIONS..................................................................................... 857
1.2.2 REGULAR MAINTENANCE................................................................................... 857
1.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR............................................................... 857
1.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR....... 857
1.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB.................................................................. 858
1.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR.................................................... 859
1.4.1 UNDERSTANDING THE MACHINE............................................................................. 859
1.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR................................................ 859
1.4.2.1 ENSURING SAFE OPERATION......................................................................... 859
1.4.3 PREPARATIONS FOR SAFE OPERATION....................................................................... 859
1.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT.................................................. 859
1.4.3.2 INSPECTING THE MACHINE.......................................................................... 859
1.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT.............................................. 860
1.4.3.4 KEEP MACHINE CLEAN.............................................................................. 860
1.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT....................................................... 860
1.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT..................................................... 861
1.4.3.7 IF A PROBLEM IS FOUND........................................................................... 861
1.4.4 FIRE PREVENTION....................................................................................... 861
1.4.4.1 PRECAUTIONS TO PREVENT FIRE..................................................................... 861
1.4.4.2 ACTION IF FIRE OCCURS........................................................................... 862
1.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB.............................................................. 863
1.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE........................................................ 863
1.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE...................................... 863
1.4.5.2 NO JUMPING ON OR OFF THE MACHINE................................................................ 863
1.4.5.3 NO PEOPLE ON THE ATTACHMENT..................................................................... 863
1.4.5.4 WORKING IN HIGH PLACES.......................................................................... 863
1.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK............................................................... 864
1.4.5.6 LEAVING THE MACHINE............................................................................. 864
1.4.6 BURN PREVENTION....................................................................................... 865
1.4.6.1 Hot coolant..................................................................................... 865
1.4.6.2 Hot oil......................................................................................... 865
1.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS................................................................... 865
1.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES.......................................................... 866
1.4.8.1 UNAUTHORIZED MODIFICATION....................................................................... 866
1.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS.................................................. 866
1.4.9 PRECAUTIONS AT JOBSITE................................................................................ 867
1.4.9.1 VISIBILITY FROM OPERATOR’S SEAT................................................................. 868
1.4.9.2 CAMERA SYSTEM WITH MONITORS..................................................................... 868
1.4.9.3 ENSURE GOOD VISIBILITY.......................................................................... 868
1.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS.......................................................... 868
1.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS...................................................... 869
1.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES.......................................................... 869
1.4.9.7 WORKING ON LOOSE GROUND......................................................................... 870
1.4.9.8 GAS, DUST, STEAM AND SMOKE...................................................................... 870
1.4.9.9 VENTILATION OF ENCLOSED AREAS................................................................... 871
1.4.10 STARTING ENGINE...................................................................................... 872
1.4.10.1 WARNING TAG.................................................................................... 872
1.4.10.2 CHECKS BEFORE STARTING ENGINE.................................................................. 872
1.4.10.3 PRECAUTION WHEN STARTING ENGINE................................................................ 872
1.4.10.4 PRECAUTION IN COLD AREAS....................................................................... 873
1.4.11 OPERATION............................................................................................ 873
1.4.11.1 CHECKS BEFORE OPERATION........................................................................ 873
1.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE.............................................. 874
1.4.11.3 PRECAUTIONS WHEN travelling.................................................................... 875
1.4.11.4 TRAVELLING ON SLOPES........................................................................... 876
1.4.11.5 OPERATIONS ON SLOPES........................................................................... 877
1.4.11.6 PROHIBITED OPERATIONS.......................................................................... 877
1.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES.................................................. 878
1.4.11.8 PARKING THE MACHINE............................................................................ 878
1.4.11.9 TRANSPORTATION................................................................................. 878
1.5 PRECAUTION FOR MAINTENANCE.................................................................................. 879
1.5.1 GENERAL PRECAUTIONS................................................................................... 879
1.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES............................... 880
1.5.1.2 STOP ENGINE FOR MAINTENANCE..................................................................... 881
1.5.1.3 WARNING TAG..................................................................................... 882
1.5.1.4 KEEP WORKPLACE CLEAN AND TIDY................................................................... 883
1.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS......................................................... 883
1.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING......................................... 884
1.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS..................................................... 884
1.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT......................................... 885
1.5.1.9 NOISE........................................................................................... 885
1.5.1.10 WHEN USING A HAMMER............................................................................ 885
1.5.1.11 PROPER TOOLS................................................................................... 886
1.5.1.12 ACCUMULATOR.................................................................................... 886
1.5.1.13 PERSONNEL...................................................................................... 886
1.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE............................................................ 887
1.5.2.1 PRECAUTION WHEN WELDING......................................................................... 887
1.5.2.2 BATTERY HANDLING................................................................................ 887
1.5.3 PRECAUTIONS WITH HIGH PRESSURE Fluid.................................................................. 888
1.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE............................................................. 888
1.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES.......................................................... 889
1.5.3.3 REPLACEMENT OF HOSE LINES....................................................................... 889
1.5.3.4 INSPECTION OF HOSE LINES........................................................................ 889
1.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................... 890
1.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE.................................................................... 890
1.5.3.7 AIR CONDITIONING MAINTENANCE.................................................................... 890
1.5.3.8 COMPRESSED AIR.................................................................................. 891
1.5.3.9 WASTE MATERIALS................................................................................. 891
1.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS........................................... 892
1.6.1 INSPECTION OF THE HYDRAULIC SYSTEM.................................................................... 892
1.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS....................................... 892
1.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR........................................................ 892
1.7 SPECIAL SAFETY EQUIPMENT.................................................................................... 893
1.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB............................................. 894
1.7.2 OBJECT HANDLING....................................................................................... 894
1.7.3 LIGHTING.............................................................................................. 894
1.7.4 WARNING BEACON........................................................................................ 894
1.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD).......................................... 894
1.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD).................................... 894
1.7.5.2 INSTRUCTIONS FOR USE............................................................................ 896
1.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL................................................ 898
1.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1)...... 898
1.7.5.5 INSTRUCTIONS FOR USE............................................................................ 900
2 Introduction & General Information for Troubleshooting............................................................ 901
2.1 Overview.................................................................................................... 902
2.1.1 General advice when using troubleshooting charts...................................................... 902
2.2 General Precautions......................................................................................... 903
2.3 Preparations For Work....................................................................................... 904
2.4 Precautions During Work..................................................................................... 904
2.5 Precautions When Carrying Out Any Operation................................................................. 905
2.5.1 Precautions when carrying out removal work............................................................ 905
2.5.2 Precautions when carrying out installation work....................................................... 905
2.5.3 Precautions when completing the operation............................................................. 906
2.6 Fundamental Requirements for Troubleshooting................................................................ 907
2.6.1 Technical documentation............................................................................... 907
2.6.2 Tools................................................................................................. 907
2.6.2.1 Reference Guide for Deutsch Removal Tools....................................................... 910
2.6.3 Personnel............................................................................................. 911
2.7 Points To Remember When Troubleshooting..................................................................... 911
2.8 Sequence Of Events In Troubleshooting....................................................................... 913
2.9 Checks Before Troubleshooting............................................................................... 914
2.10 Handling Of Electric Equipment And Hydraulic Components.................................................... 915
2.10.1 Points to remember when handling electric equipment.................................................. 915
2.10.2 Points To Remember When Handling Hydraulic Equipment................................................. 917
2.11 General working procedures................................................................................. 920
2.11.1 Air Bleeding of Various Hydraulic Parts.............................................................. 920
2.11.2 Air bleeding from the hydraulic pumps................................................................ 920
2.11.3 Air bleeding from hydraulic cylinders................................................................ 920
2.12 Cylinder bypass test....................................................................................... 921
2.13 Information about MTC & Nodes.............................................................................. 922
2.13.1 Outline of the MTC and its connector locations....................................................... 922
2.13.1.1 View onto the MTC connectors* LH & RH.......................................................... 922
2.13.1.2 General description of the MTC................................................................. 922
2.13.1.3 Information about the LED indications at the MTC............................................... 923
2.13.2 Information about the ICN-D node..................................................................... 923
2.13.2.1 View onto an ICN-D node without wiring......................................................... 924
2.13.2.2 View onto the Status LEDs at the ICN-D node.................................................... 925
2.13.2.3 General information on the LED control......................................................... 925
2.13.3 Information about the ICN-V node..................................................................... 927
2.13.3.1 View onto an ICN-V node........................................................................ 927
2.13.3.2 View onto an open ICN-V node and its DIP-switches.............................................. 928
2.13.4 DIP switches at the ICN-D and ICN-V nodes............................................................ 929
2.14 Basics about "How to crimp"................................................................................ 930
2.14.1 Stripping a wire for use with the HDT 48 crimp tool.................................................. 930
2.14.2 View onto the Deutsch crimp tool HDT 48.............................................................. 930
2.14.3 Adjustment of the wire size at the Deutsch crimp tool HDT 48......................................... 931
2.14.3.1 Wire cross section units in mm2 and AWG........................................................ 931
2.14.4 Crimping instructions (for Deutsch crimp tool HDT 48)................................................ 932
2.15 Cable Shielding............................................................................................ 933
3 Mounting Locations and Connector Types............................................................................ 935
3.1 Component location.......................................................................................... 936
3.1.1 View onto the Superstructure.......................................................................... 936
3.1.2 Location of Engine Electrical Parts (1)............................................................... 938
3.1.3 Location of Engine Electrical Parts (2)............................................................... 940
3.1.4 Location of Hydraulic Components (1).................................................................. 941
3.1.5 Location of Hydraulic Components (2).................................................................. 943
3.1.6 Location of the Remote Control Valves................................................................. 944
3.1.7 Location of the High Pressure Sensors................................................................. 946
3.1.8 View onto the SLS and CLS Grease Barrel and the Lubrication Cycle Components.......................... 947
3.1.9 View onto the Electrical Components in the Cab Base................................................... 949
3.1.10 Hydraulic Oil Tank - Location of Electrical Components............................................... 951
3.1.11 Hydraulically Operated Access Ladder................................................................. 953
3.2 Connector Types Overview.................................................................................... 955
4 Standard Value Table for Electrical Components.................................................................... 961
5 References for Troubleshooting (CAN Bus & Node Outputs)........................................................... 973
5.1 CAN-Bus trouble or Node Output Trouble...................................................................... 974
5.1.1 Trouble CAN-BUS or CAN-Hardware (G00308).............................................................. 975
5.1.2 Trouble output short-circuit (G00043)................................................................. 976
5.2 Sequence of the CAN nodes at the CAN bus.................................................................... 978
5.3 Troubleshooting for Relay Monitored Node Outputs............................................................ 979
5.3.1 Relay Check........................................................................................... 979
G00107 - Trouble slew parking brake control 56K250a............................................................. 980
G00109 - Trouble slew parking brake control 56K250b............................................................. 980
View onto the CoDeSys HMI Visualization screen for trouble code G00107...................................... 982
Wiring Diagram (56K250a & 56K250b) for trouble code G00107.................................................. 983
5.3.2 Output Check.......................................................................................... 984
G00108 - Trouble slew parking brake control Output to 56K250a................................................... 985
G00110 - Trouble slew parking brake control Output to 56K250b................................................... 985
View onto the CoDeSys HMI Visualization screen for trouble code G00108...................................... 987
Wiring Diagram (56K250a & 56K250b) for trouble code G00108.................................................. 988
6 Tables for Testing and Troubleshooting............................................................................ 991
6.1 Index of Tables in this section............................................................................. 992
6.2 Test Value Table for Temperature Sensors (PT100) g Centigrade - Volt........................................ 993
6.3 Test Value Table for Temperature Sensors (PT100) g Centigrade - Ohm......................................... 994
6.4 Table of Trouble Codes (G-Codes)............................................................................ 995
6.5 Table of Instruction Messages...............................................................................1001
6.6 Table of Binary Codes.......................................................................................1004
6.6.1 Table of Add-On Binary Codes for G00308...............................................................1006
6.7 Binary Output Signals on the VHMS Monitor...................................................................1007
6.8 Power Supply................................................................................................1009
6.9 Cable colour identification.................................................................................1010
7 Troubleshooting by Trouble Code...................................................................................1011
G00001 - Trouble Shut-Off (gate) valve..........................................................................1012
View onto the gap of proximity switch 40B031................................................................1014
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR...............................1015
View onto the setting for SHUTDOWN BYPASS on the VHMS monitor...............................................1015
Wiring Diagram (40B031) for trouble code G00001 (Main gate valve open)......................................1016
G00002 - Test speed 1800 1/min engine 1.........................................................................1017
Wiring Diagram (11S041-1) for trouble code G00002...........................................................1018
G00003 - Trouble pump controller................................................................................1019
G00005 - Low hydraulic oil level................................................................................1023
Wiring Diagram, oil level label, and defined position of the attachment (G00005)............................1025
G00007 - Trouble hydraulic oil level............................................................................1026
Wiring Diagram (40B004) and the defined position of the attachment (G00007).................................1027
G00012 - Central lubrication system grease level too low........................................................1028
G00013 - Slew ring gear lubr. system grease level too low.......................................................1028
Wiring Diagram (62B108 & 62B109) for trouble codes G00012 & G00013..........................................1032
Wiring Diagram (junction box) for trouble codes G00012 & G00013.............................................1033
G00020 - Trouble Shut-Off (gate) valve (Start blocked)..........................................................1034
View onto the gap of proximity switch 40B031 (G00020).......................................................1036
Wiring Diagram (40B031) for trouble code G00020 (Main gate valve closed)....................................1037
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR...............................1038
View onto the setting for SHUTDOWN BYPASS on the VHMS monitor...............................................1038
G00031 - Set engine to low idle.................................................................................1039
Wiring Diagram (20S030) for trouble code G00031.............................................................1040
Input signal of the engine speed switch 20S030 on the REAL TIME MONITOR.....................................1040
G00032 - Trouble starter........................................................................................1041
Wiring Diagram (Cold Start Signal) for trouble code G00032..................................................1042
Wiring Diagram ("Engine running" signal) for trouble code G00032............................................1043
G00033 - Trouble VHMS-Controller................................................................................1044
G00034 - Trouble VHMS-Display...................................................................................1045
G00035 - Trouble totally loss gear oil (PTO 1)..................................................................1046
View onto the location of sensor 57B175-1 at the PTO (G00035)...............................................1048
Input signal (analog) of the PTO 1 gear oil sensor 57B175-1 on the REAL TIME MONITOR........................1049
View onto the setting for SHUTDOWN BYPASS on the VHMS monitor...............................................1049
Wiring Diagram (57B175-1) for trouble code G00035...........................................................1050
G00039 - Actuate engine speed selector switch...................................................................1051
G00043 - Trouble output short-circuit...........................................................................1052
G00048 - Trouble emergency safety circuit.......................................................................1053
Wiring Diagram (11K044a) for trouble code G00048............................................................1053
G00053 - Reset emergency safety circuit.........................................................................1054
G00054 - Monitoring idle position cut off.......................................................................1055
Wiring Diagram (11K032) for trouble code G00054.............................................................1056
Input signal (analog) of relay 11K032 on the REAL TIME MONITOR (G00054).....................................1057
Exemplary view onto the VHMS Failure History (G00054).......................................................1057
G00060 - Fire in the power house................................................................................1058
Wiring Diagram (fire alarm) for trouble code G00060.........................................................1060
Wiring Diagram (10B351 in the safety circuit) for G00060....................................................1061
G00061 - Trouble monitoring, engine 1 speed too low.............................................................1062
Input signal (analog) of 51K003b-1 on the REAL TIME MONITOR (G00061)........................................1063
Wrong signal of the engine speed converter on the REAL TIME MONITOR (G00061)................................1064
Wiring Diagram (engine speed) for trouble code G00061.......................................................1064
G00062 - Trouble monitoring, engine 1 speed too high............................................................1065
Wiring Diagram (engine speed) for trouble code G00062.......................................................1066
G00063 - Trouble monitoring hydraulic oil temp..................................................................1067
Wiring Diagram (59B015) for trouble code G00063.............................................................1068
G00064 - Trouble monitoring hydraulic oil level.................................................................1069
Wiring Diagram (40B004) for trouble code G00064.............................................................1071
G00065 - Very low hydraulic oil level...........................................................................1072
View onto the hydraulic oil level label.....................................................................1072
G00066 - Trouble hydraulic oil temperature......................................................................1073
Wiring Diagram (57K506a-1 / 57K506b-1) and location for G00066..............................................1075
Hydraulic oil temperature table.............................................................................1075
G00067 - Trouble battery voltage too high.......................................................................1076
Wiring Diagram (11T080) and component location for G00067...................................................1077
G00067 - Input signal of 11T080 on the REAL TIME MONITOR....................................................1077
G00069 - Trouble monitoring oil temperature gear (PTO 1)........................................................1078
Input of 57B049-1 on the REAL TIME MONITOR (G00069).........................................................1079
Gear oil temperature (PTO 1) on the Main Gauge Screen (G00069)..............................................1079
Wiring Diagram (57B049-1) and component location for G00069.................................................1080
G00070 - Trouble oil temperature gear (PTO 1)...................................................................1081
Location of the PTO 1 gear oil level dipstick and temperature sensor 57B049-1...............................1083
G00071 - Trouble gear lubrication (PTO 1).......................................................................1084
Wiring Diagram (57B017-1) for trouble code G00071...........................................................1085
G00081 - Trouble lubrication system.............................................................................1086
Operation cycles of the lubrication systems.................................................................1088
Wiring Diagram (11K050) for trouble code G00081.............................................................1089
Wiring Diagram (pilot control slew & stick) for trouble code G00081.........................................1090
G00086 - SHUTDOWN...............................................................................................1091
G00087 - Stop all movements for low idle........................................................................1092
G00090 - Trouble power supply...................................................................................1093
G00099 - Trouble power supply...................................................................................1093
Wiring Diagram (stabilized power supply) for G00090 & G00099................................................1094
G00091 - Pilot control cut out..................................................................................1095
View onto the lock lever and the cover of 20S105 (G00091)...................................................1096
G00092 - Emergency shut-down at access ladder...................................................................1097
G00093 - Emergency shut-down at valve block.....................................................................1097
G00094 - Emergency shut-down at hydraulic control panel.........................................................1097
G00095 - Emergency shut-down in cabin...........................................................................1097
Wiring Diagram (emergency switches) for G00092~G00095.......................................................1098
G00096 - Pilot control cut out..................................................................................1099
Wiring Diagram (20S094) for trouble code G00096.............................................................1100
G00100 - Maintenance Safety Switch..............................................................................1101
Wiring Diagram (50S058) for trouble code G00100.............................................................1102
G00102 - Switch off wiper [S/N 08199 only]......................................................................1103
G00103 - Faulty switch 20M004 [S/N 08199 only]..................................................................1104
Wiring Diagram 1 (wiper) for trouble code G00103 [S/N 08199 only]...........................................1106
Wiring Diagram 2 (wiper) for trouble code G00103 [S/N 08199 only]...........................................1107
G00104 - Trouble battery current................................................................................1108
Wiring Diagram (battery current) for trouble code G00104....................................................1110
G00105 - Trouble battery charging current too low...............................................................1111
Wiring Diagram (11T080) for trouble code G00105.............................................................1112
G00107 - Trouble slew parking brake control 56K250a.............................................................1113
G00109 - Trouble slew parking brake control 56K250b.............................................................1113
View onto the CoDeSys HMI Visualization screen for trouble code G00107......................................1115
Wiring Diagram (56K250a & 56K250b) for trouble code G00107..................................................1116
G00108 - Trouble slew parking brake control Output to 56K250a...................................................1117
G00110 - Trouble slew parking brake control Output to 56K250b...................................................1117
View onto the CoDeSys HMI Visualization screen for trouble code G00108......................................1119
Wiring Diagram (56K250a & 56K250b) for trouble code G00108..................................................1120
G00111 - Trouble travel parking brake control 56K251a...........................................................1121
G00113 - Trouble travel parking brake control 56K251b...........................................................1121
G00112 - Trouble travel parking brake control Output to 56K251a.................................................1122
G00114 - Trouble travel parking brake control Output to 56K251b.................................................1122
G00115 - Trouble slew hydraulic brake control 56K252a...........................................................1123
G00117 - Trouble slew hydraulic brake control 56K252b...........................................................1123
G00116 - Trouble slew hydraulic brake control Output to 56K252a.................................................1124
G00118 - Trouble slew hydraulic brake control Output to 56K252b.................................................1124
G00140 - Trouble monitoring X1-1 pressure.......................................................................1125
Wiring Diagram (57B085-1) for trouble code G00140...........................................................1127
G00141 - Trouble monitoring X2 pressure.........................................................................1128
Wiring Diagram (57B086) for trouble code G00141.............................................................1130
G00147 - Trouble monitoring gear lubrication (PTO 1)............................................................1131
Wiring Diagram (57B017-1) for trouble code G00147...........................................................1133
G00148 - Trouble monitoring fuel level..........................................................................1134
Wiring Diagram (31B063) and component location for G00148...................................................1136
G00151 - Trouble monitoring gear (PTO) oil filter 1.............................................................1137
Wiring Diagram (57B027-1) and component location for trouble code G00151....................................1139
G00154 - Trouble monitoring return oil filter...................................................................1140
Wiring Diagram (40B163) for trouble code G00154.............................................................1142
G00155 - Trouble monitoring leak oil filter.....................................................................1143
Wiring Diagram (40B164) for trouble code G00155.............................................................1145
G00159 - Trouble monitoring breather filter.....................................................................1146
Wiring Diagram (40B024) for trouble code G00159.............................................................1148
G00160 - Trouble monitoring engine air cleaner 1................................................................1149
Wiring diagram (52B018-1 & 52B019-1) for trouble code G00160................................................1151
G00161 - Trouble monitoring battery voltage.....................................................................1152
Wiring Diagram (11T080) for trouble code G00161.............................................................1154
G00162 - Trouble monitoring charging-/discharging current.......................................................1155
Wiring Diagram (battery charging current) for trouble code G00162...........................................1157
G00164 - Trouble air cleaner 1..................................................................................1158
View onto the engine air cleaner (G00164)...................................................................1159
G00165 - Trouble breather filter hydraulic oil tank.............................................................1160
Label showing temperature information and defined positions (G00165)........................................1161
G00166 - Trouble oil filter gear (PTO 1)........................................................................1162
View onto the PTO 1 gear oil filter with pressure sensor 57B027-1 (G00166)..................................1163
G00169 - Trouble return oil filter hydraulic oil tank...........................................................1164
G00170 - Trouble leak oil filter hydraulic oil tank.............................................................1165
G00176 - Trouble battery voltage too low........................................................................1166
Wiring Diagram (batteries) for trouble code G00176..........................................................1168
G00177 - Trouble battery charging circuit.......................................................................1169
Wiring Diagram (measuring points 1-4) for trouble code G00177...............................................1170
G00178 - Trouble battery charging current too high..............................................................1171
Wiring Diagram (51T017) for trouble code G00178.............................................................1172
G00179 - Trouble control pressure X1-1..........................................................................1173
View onto the valve cartridge block (G00179)................................................................1174
G00180 - Trouble pilot pressure X2 too low......................................................................1175
Valve cartridge block with X2 pressure sensor 57B086 & M1.2.................................................1176
G00181 - Trouble pilot pressure X2 too high.....................................................................1177
Valve cartridge block with X2 pressure sensor 57B086 & M1.2.................................................1178
G00184 - Central lubrication system empty.......................................................................1179
G00187 - Slew ring gear lubrication system empty................................................................1179
Grease level (CLS & SLS) on the REAL TIME MONITOR...........................................................1180
G00185 - Trouble central lubrication system.....................................................................1181
G00188 - Trouble slew ring gear lubrication system..............................................................1181
Allocation of vent valves and end-of-line switches..........................................................1182
Action chart for lube cycles................................................................................1183
View onto the vent valve (62Q507a/62Q509a)..................................................................1184
Wiring Diagram (80B043 & 62B046) for trouble codes G00185/G00188............................................1185
G00186 - Trouble central lubrication system.....................................................................1186
G00189 - Trouble slew ring gear lubrication system..............................................................1186
Allocation of vent valves...................................................................................1186
Action chart for lube cycles................................................................................1187
View onto the vent valve (62Q507a/62Q509a)..................................................................1188
G00207 - Engine remote oil tank 1 empty.........................................................................1189
G00216 - Trouble software not compatible........................................................................1190
G00218 - Switch off all motors for running transfer pump........................................................1192
G00220 - Trouble transfer pump motor overheated.................................................................1193
Wiring Diagram (transfer pump) for trouble code G00220......................................................1194
G00223 - Trouble starter control 51K001a-1......................................................................1195
G00225 - Trouble starter control 51K001b-1......................................................................1195
G00224 - Trouble starter control Output to 51K001a-1............................................................1196
G00226 - Trouble starter control Output to 51K001b-1............................................................1196
G00231 - Trouble pilot control lever 20S019.....................................................................1197
Wiring Diagram (20S019) for trouble code G00231.............................................................1198
Wiring Diagram (20S020) for trouble code G00232.............................................................1199
G00233 - Trouble pilot control 11Q045...........................................................................1200
Wiring Diagram (11Q045) for trouble code G00233.............................................................1201
G00234 - Trouble pilot control 11K111a..........................................................................1202
G00236 - Trouble pilot control 11K111b..........................................................................1202
G00235 - Trouble pilot control Output to 11K111a................................................................1203
G00237 - Trouble pilot control Output to 11K111b................................................................1203
G00238 - Trouble supply by key switch 11Q044....................................................................1204
Input signal of 11Q044 on the REAL TIME MONITOR (G00238)....................................................1204
Wiring Diagram (11Q044) for trouble code G00238.............................................................1205
G00240 - Trouble hydraulic oil temperature......................................................................1206
G00242 - Engine 1 already running...............................................................................1207
G00243 - Fill up fuel tank......................................................................................1207
G00245 - Engine shutdown from ground............................................................................1208
Input signal of 54S007 & 54S008 on the REAL TIME MONITOR (G00245)...........................................1209
G00246 - Hydraulic oil temperature..............................................................................1210
G00252 - Emergency shut-down at access ladder...................................................................1211
G00253 - Emergency shut-down at valve block.....................................................................1211
G00254 - Emergency shut-down at hydraulic control panel.........................................................1211
G00255 - Emergency shut-down in cabin...........................................................................1211
Wiring Diagram (emergency switches) for trouble codes G00252~G00255.........................................1212
G00257 - Hydraulic oil temperature..............................................................................1213
G00261 - Maintenance Safety Switch..............................................................................1214
Wiring Diagram (50S058) for trouble code G00261.............................................................1215
G00262 - Trouble screen at hydr. cooler entry clogged...........................................................1216
40B166 and 40B165 on the REAL TIME MONITOR 03 Hydraulic (G00262)............................................1216
Location of 40B166 and 40B165 at the hydraulic oil tank (G00262)............................................1217
Wiring Diagram (40B166 & 40B165) for trouble code G00262....................................................1218
G00308 - Trouble CAN-Bus or CAN-Hardware........................................................................1219
G00309 - Trouble ladder up 56K253a..............................................................................1222
G00311 - Trouble ladder up redundant 56K253b....................................................................1222
G00310 - Trouble ladder up Output to 56K253a....................................................................1223
G00312 - Trouble ladder up redundant Output to 56K253b..........................................................1223
G00313 - Trouble ladder down 56K254a............................................................................1224
G00315 - Trouble ladder down redundant 56K254b..................................................................1224
G00314 - Trouble ladder down Output to 56K254a..................................................................1225
G00316 - Trouble ladder down redundant Output to 56K254b........................................................1225
G00317 - Trouble service arm up 56K255a.........................................................................1226
G00319 - Trouble service arm up redundant 56K255b...............................................................1226
G00318 - Trouble service arm up Output to 56K255a...............................................................1227
G00320 - Trouble service arm up redundant Output to 56K255b.....................................................1227
G00321 - Trouble service arm down 56K256a.......................................................................1228
G00323 - Trouble service arm down redundant 56K256b.............................................................1228
G00322 - Trouble service arm down Output to 56K256a.............................................................1229
G00324 - Trouble service arm down redundant Output to 56K256b...................................................1229
G00325 - Trouble service arm Input..............................................................................1230
G00326 - Trouble ladder Input...................................................................................1230
G00327 - Trouble parking brake Input............................................................................1230
G00328 - Trouble start Input....................................................................................1230
G00330 - Trouble pilot control 11Q111...........................................................................1233
Wiring Diagram (11Q111/11K126) for trouble code G00330......................................................1235
G00331 - Automatic after_running engine 1.......................................................................1236
G00333 - Trouble battery charger relay..........................................................................1237
Wiring Diagram (11Q122) for trouble code G00333.............................................................1238
G00351 - Engine 1 running.......................................................................................1239
G00352 - Engine 1 standstill....................................................................................1239
G00417 - Communication failure PLC [MTC] <=> VHMS-controller....................................................1240
G00420 - Connector sel error....................................................................................1241
G00421 - Farm sys error.........................................................................................1242
G00422 - Can-net sys (J1939)....................................................................................1243
G00423 - Application sys error..................................................................................1244
G00425 - Settings impossible to take over into the PLC..........................................................1245
Wiring Diagram overview for G00425: VHMS monitor → VHMS controller → MTC....................................1246
G00491 - Communication failure MH800 <=> VHMS-Controller........................................................1247
Wiring Diagram overview for G00491: VHMS monitor (MH801) → VHMS controller..................................1248
8 Troubleshooting by Symptoms.......................................................................................1251
8.1 Symptoms of the Engine and Related Electrical System........................................................1252
SEL001 - Engine does not start (engine does not rotate).........................................................1252
Wiring Diagram 1 (engine start) for trouble code SEL001.....................................................1254
Wiring Diagram 2 (engine start) for trouble code SEL001.....................................................1256
SEL002 - Engine stops while in operation........................................................................1257
View onto the fuel system water separator (SEL002)..........................................................1259
SEL003 - Engine speed is hunting during boom-up movement........................................................1260
SEL004 - Engine does not stop...................................................................................1261
SEL005 - Engine lacks output (no power).........................................................................1262
Judgment Table for SEL005...................................................................................1263
SEL006 - Exhaust smoke is black.................................................................................1264
Judgment Table for SEL006...................................................................................1265
SEL007 - Oil consumption is excessive...........................................................................1266
Judgment Table for SEL007...................................................................................1267
SEL008 - Oil becomes contaminated quickly.......................................................................1268
Judgment Table for SEL008...................................................................................1269
SEL009 - Fuel consumption is excessive..........................................................................1270
Judgment Table for SEL009...................................................................................1271
SEL010 - Oil is in engine coolant...............................................................................1272
Judgment Table for SEL010...................................................................................1273
SEL011 - Oil level rises........................................................................................1274
Judgment Table for SEL011...................................................................................1275
SEL012 - Coolant temperature becomes too high (overheating).....................................................1276
Judgment Table for SEL012...................................................................................1277
8.2 Symptoms of the Hydraulic System............................................................................1278
SHY001 - All the work equipment shows lack of power or slow movement (especially the "boom up" function)........1278
SHY002 - Engine speed sharply drops or engine stalls too much...................................................1280
SHY003 - No work equipment, travel or swing movement............................................................1282
SHY004 - Work equipment has too much hydraulic drift............................................................1283
SHY005 - Work equipment has big time lag........................................................................1285
SHY006 - Machine deviates during travel movement................................................................1286
SHY007 - Hydraulic system has lack of power (Energy Efficiency).................................................1287
SHY008 - Machine does not swing.................................................................................1289
SHY009 - Swing acceleration is poor.............................................................................1290
SHY010 - Excessive overrun when stopping swing..................................................................1292
SHY011 - Floating system without function.......................................................................1294
SHY012 - Abnormal noise coming from SRV or MRV..................................................................1295
SHY013 - Track tensioning system without function...............................................................1296
SHY014 - Ladder does not move, or slow movement.................................................................1297
SHY015 - Refilling arm does not move, or slow movement..........................................................1299
SHY016 - The hydraulic driven grease pump does not move.........................................................1301
SHY017 - Trouble pump bearing lubrication.......................................................................1303
SHY018 - Abnormal track chain movement during digging...........................................................1304
SHY019 - Swing parking brake without function...................................................................1305
SHY020 - Travel parking brake without function..................................................................1306
8.3 Symptoms of the Mechanical System...........................................................................1307
SME001 - Abnormal noise is made.................................................................................1307
Judgment Table for SME001...................................................................................1308
SME002 - Abnormal noise around the PTO / hydraulic pumps........................................................1309
SME003 - Vibration is excessive (engine mountings)..............................................................1311
Judgment Table for SME003...................................................................................1312
SME004 - Vibration is excessive (engine torsion)................................................................1313
SME005 - There is a big shock when stopping swing...............................................................1314
SME006 - There is a big abnormal noise when moving/stopping swing...............................................1315
SME007 - Fan hub bearing noise is abnormal......................................................................1317
SME008 - Abnormal noise coming from a travel gearbox............................................................1318
SME009 - Abnormal noise coming from the work equipment (lack of grease).........................................1320
SME010 - Abnormal idler movement................................................................................1322
SME011 - Leak at the PTO shaft seal.............................................................................1323
8.4 Symptoms of Additional Systems..............................................................................1325
SAD001 - Air conditioner does not work..........................................................................1325
View onto the A/C unit (SAD001).............................................................................1326
SAD002 - Air conditioner compressor clutch is burnt.............................................................1327
View onto the A/C compressor and its mounting (SAD002)......................................................1328
SAD003 - Air conditioning system defective (pipes and hoses full of moisture)...................................1329
SAD004 - Travel alarm does not sound............................................................................1330
Wiring Diagram (60P140) for trouble code SAD004.............................................................1331
START PAGE Troubleshooting 40.pdf................................................................................... 0
40 TROUBLESHOOTING.............................................................................................. 839
50_DISASSEMBLY AND ASSEMBLY.pdf......................................................................................... 0
Table of Contents...................................................................................................1335
1 Introduction......................................................................................................1345
1.1 Contents of this binder.....................................................................................1346
1.2 Preface.....................................................................................................1347
1.2.1 Contacting the Service................................................................................1347
1.2.2 Guarantee.............................................................................................1347
2 SAFETY............................................................................................................1349
2.1 SAFETY INFORMATION..........................................................................................1351
2.2 OVERVIEW....................................................................................................1352
2.2.1 NORMAL OPERATIONS.....................................................................................1352
2.2.2 REGULAR MAINTENANCE...................................................................................1352
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR...............................................................1352
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR.......1352
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB..................................................................1353
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR....................................................1354
2.4.1 UNDERSTANDING THE MACHINE.............................................................................1354
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR................................................1354
2.4.2.1 ENSURING SAFE OPERATION.........................................................................1354
2.4.3 PREPARATIONS FOR SAFE OPERATION.......................................................................1354
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT..................................................1354
2.4.3.2 INSPECTING THE MACHINE..........................................................................1354
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT..............................................1355
2.4.3.4 KEEP MACHINE CLEAN..............................................................................1355
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT.......................................................1355
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT.....................................................1356
2.4.3.7 IF A PROBLEM IS FOUND...........................................................................1356
2.4.4 FIRE PREVENTION.......................................................................................1356
2.4.4.1 PRECAUTIONS TO PREVENT FIRE.....................................................................1356
2.4.4.2 ACTION IF FIRE OCCURS...........................................................................1357
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB..............................................................1358
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE........................................................1358
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE......................................1358
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE................................................................1358
2.4.5.3 NO PEOPLE ON THE ATTACHMENT.....................................................................1358
2.4.5.4 WORKING IN HIGH PLACES..........................................................................1358
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK...............................................................1359
2.4.5.6 LEAVING THE MACHINE.............................................................................1359
2.4.6 BURN PREVENTION.......................................................................................1360
2.4.6.1 Hot coolant.....................................................................................1360
2.4.6.2 Hot oil.........................................................................................1360
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS...................................................................1360
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES..........................................................1361
2.4.8.1 UNAUTHORIZED MODIFICATION.......................................................................1361
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS..................................................1361
2.4.9 PRECAUTIONS AT JOBSITE................................................................................1362
2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT.................................................................1363
2.4.9.2 CAMERA SYSTEM WITH MONITORS.....................................................................1363
2.4.9.3 ENSURE GOOD VISIBILITY..........................................................................1363
2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS..........................................................1363
2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS......................................................1364
2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES..........................................................1364
2.4.9.7 WORKING ON LOOSE GROUND.........................................................................1365
2.4.9.8 GAS, DUST, STEAM AND SMOKE......................................................................1365
2.4.9.9 VENTILATION OF ENCLOSED AREAS...................................................................1366
2.4.10 STARTING ENGINE......................................................................................1367
2.4.10.1 WARNING TAG....................................................................................1367
2.4.10.2 CHECKS BEFORE STARTING ENGINE..................................................................1367
2.4.10.3 PRECAUTION WHEN STARTING ENGINE................................................................1367
2.4.10.4 PRECAUTION IN COLD AREAS.......................................................................1368
2.4.11 OPERATION............................................................................................1368
2.4.11.1 CHECKS BEFORE OPERATION........................................................................1368
2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE..............................................1369
2.4.11.3 PRECAUTIONS WHEN travelling....................................................................1370
2.4.11.4 TRAVELLING ON SLOPES...........................................................................1371
2.4.11.5 OPERATIONS ON SLOPES...........................................................................1372
2.4.11.6 PROHIBITED OPERATIONS..........................................................................1372
2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES..................................................1373
2.4.11.8 PARKING THE MACHINE............................................................................1373
2.4.11.9 TRANSPORTATION.................................................................................1373
2.5 PRECAUTION FOR MAINTENANCE..................................................................................1374
2.5.1 GENERAL PRECAUTIONS...................................................................................1374
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...............................1375
2.5.1.2 STOP ENGINE FOR MAINTENANCE.....................................................................1376
2.5.1.3 WARNING TAG.....................................................................................1377
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY...................................................................1378
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS.........................................................1378
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING.........................................1379
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS.....................................................1379
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT.........................................1380
2.5.1.9 NOISE...........................................................................................1380
2.5.1.10 WHEN USING A HAMMER............................................................................1380
2.5.1.11 PROPER TOOLS...................................................................................1381
2.5.1.12 ACCUMULATOR....................................................................................1381
2.5.1.13 PERSONNEL......................................................................................1381
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE............................................................1382
2.5.2.1 PRECAUTION WHEN WELDING.........................................................................1382
2.5.2.2 BATTERY HANDLING................................................................................1382
2.5.3 PRECAUTIONS WITH HIGH PRESSURE Fluid..................................................................1383
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE.............................................................1383
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES..........................................................1384
2.5.3.3 REPLACEMENT OF HOSE LINES.......................................................................1384
2.5.3.4 INSPECTION OF HOSE LINES........................................................................1384
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................1385
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE....................................................................1385
2.5.3.7 AIR CONDITIONING MAINTENANCE....................................................................1385
2.5.3.8 COMPRESSED AIR..................................................................................1386
2.5.3.9 WASTE MATERIALS.................................................................................1386
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS...........................................1387
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM....................................................................1387
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS.......................................1387
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR........................................................1387
2.7 SPECIAL SAFETY EQUIPMENT....................................................................................1388
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB.............................................1389
2.7.2 OBJECT HANDLING.......................................................................................1389
2.7.3 LIGHTING..............................................................................................1389
2.7.4 WARNING BEACON........................................................................................1389
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)..........................................1389
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)....................................1389
2.7.5.2 INSTRUCTIONS FOR USE............................................................................1391
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL................................................1393
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1),.....1393
2.7.5.5 INSTRUCTIONS FOR USE............................................................................1395
3 Superstructure....................................................................................................1397
3.1 Superstructure overview.....................................................................................1398
3.2 Diesel engine...............................................................................................1400
3.2.1 Removal of the Diesel engine..........................................................................1400
3.2.2 Replacement of the Diesel engine......................................................................1408
3.2.3 Engine torque support and engine/PTO mounts...........................................................1410
3.2.3.1 Flexible mounts.................................................................................1411
3.2.3.2 Torque support..................................................................................1413
3.2.4 Alternator............................................................................................1414
3.2.4.1 Removal of the alternator.......................................................................1414
3.2.4.2 Replacement of the alternator...................................................................1415
3.2.5 Starter system........................................................................................1416
3.2.5.1 Removal of the starter motor....................................................................1416
3.2.5.2 Replacement of the starter motor................................................................1417
3.2.6 Batteries.............................................................................................1417
3.2.6.1 Removal of the batteries........................................................................1417
3.2.6.2 Replacement of the batteries....................................................................1419
3.3 Engine radiator assembly....................................................................................1420
3.3.1 Radiator fan assembly.................................................................................1420
3.3.1.1 Removal of the radiator fan bearing block and motor.............................................1421
3.3.1.2 Replacement of the radiator fan bearing block and motor.........................................1425
3.3.1.3 Removal of the radiator fan.....................................................................1427
3.3.1.4 Replacement of the radiator fan.................................................................1429
3.3.2 Radiator assembly.....................................................................................1430
3.3.2.1 Removal of the Radiator assembly................................................................1430
3.3.2.2 Replacement of the radiator assembly............................................................1435
3.3.3 Fuel cooler...........................................................................................1436
3.3.3.1 Removal of the fuel cooler......................................................................1436
3.3.3.2 Replacement of the fuel cooler..................................................................1438
3.4 Coupling assembly...........................................................................................1440
3.4.1 Geislinger coupling...................................................................................1440
3.4.1.1 Removal of the Geislinger coupling..............................................................1441
3.4.1.2 Replacement of the Geislinger coupling..........................................................1445
3.5 PTO.........................................................................................................1446
3.5.1 Overview of the PTO and the mounting of the pumps.....................................................1446
3.5.2 Main pumps............................................................................................1448
3.5.2.1 Preparatory works for main pump removal.........................................................1448
3.5.2.2 Removal of main pump 1..........................................................................1451
3.5.2.3 Replacement of main pump 1......................................................................1453
3.5.2.4 Removal of main pump 2..........................................................................1454
3.5.2.5 Replacement of main pump 2......................................................................1456
3.5.2.6 Removal of main pump 3..........................................................................1457
3.5.2.7 Replacement of main pump 3......................................................................1457
3.5.2.8 Removal of main pump 4..........................................................................1457
3.5.2.9 Replacement of main pump 4......................................................................1457
3.5.3 PTO oil circulation pump (auxiliary pump).............................................................1458
3.5.3.1 Removal of the oil circulation pump (auxiliary pump)............................................1458
3.5.3.2 Replacement of the oil circulation pump (auxiliary pump)........................................1460
3.5.4 Pilot oil pump........................................................................................1461
3.5.4.1 Removal of the pilot oil pump...................................................................1461
3.5.4.2 Replacement of the pilot oil pump...............................................................1461
3.5.5 Radiator drive pump...................................................................................1463
3.5.5.1 Removal of the radiator fan drive pump..........................................................1463
3.5.5.2 Replacement of the radiator fan drive pump......................................................1465
3.5.6 Hydraulic oil cooler fan drive pump...................................................................1466
3.5.6.1 Removal of the hydraulic oil cooler fan drive pump..............................................1466
3.5.6.2 Replacement of the hydraulic oil cooler fan drive pump..........................................1466
3.5.7 Pump distributor gearbox (PTO)........................................................................1468
3.5.7.1 Removal of the pump distributor gearbox (PTO)...................................................1470
3.5.7.2 Replacement of the pump distributor gearbox (PTO)...............................................1473
3.6 Hydraulics..................................................................................................1474
3.6.1 Hydraulic oil cooler assembly.........................................................................1474
3.6.1.1 Removal of hydraulic cooler fan.................................................................1475
3.6.1.2 Replacement of hydraulic cooler fan.............................................................1476
3.6.1.3 Removal of hydraulic cooler fan bearings and motors.............................................1477
3.6.1.4 Replacement of hydraulic cooler fan bearings and motors.........................................1479
3.6.1.5 Removal of the hydraulic oil coolers............................................................1480
3.6.1.6 Replacement of the hydraulic oil coolers........................................................1483
3.6.1.7 Removal of the hydraulic oil cooler assembly....................................................1484
3.6.1.8 Replacement of the hydraulic oil cooler assembly................................................1489
3.6.2 Main gate valve.......................................................................................1490
3.6.2.1 Removal of the main gate valve..................................................................1490
3.6.2.2 Replacement of the main gate valve..............................................................1491
3.6.3 Hydraulic oil reservoir...............................................................................1492
3.6.3.1 Removal of the hydraulic oil reservoir..........................................................1493
3.6.3.2 Replacement of the hydraulic oil reservoir......................................................1499
3.6.4 Main control valve blocks.............................................................................1502
3.6.4.1 General information.............................................................................1502
3.6.4.2 Removal of the main control valve blocks........................................................1510
3.6.4.3 Replacement of the main control valve blocks....................................................1514
3.6.5 Main relief valves (MRV)..............................................................................1515
3.6.5.1 Removal of the MRV at the main control valve blocks.............................................1515
3.6.5.2 Replacement of the MRV at the main control valve blocks.........................................1516
3.6.6 Service line relief valves (SRV)......................................................................1519
3.6.6.1 Removal of SRV on main control valve block......................................................1519
3.6.6.2 Replacement of SRV on main control valve blocks.................................................1520
3.6.7 Anti-cavitation valves (ACV)..........................................................................1521
3.6.7.1 Removal of single ACV at the manifold...........................................................1523
3.6.7.2 Replacement of single ACV at the manifold.......................................................1526
3.6.7.3 Removal of ACV with attached check valve at the manifold........................................1527
3.6.7.4 Replacement of ACV with attached check valve at the manifold....................................1529
3.6.7.5 Removal of ACV on main control valve blocks.....................................................1531
3.6.7.6 Replacement of ACV on main control valve blocks.................................................1532
3.6.8 Throttle check valves.................................................................................1534
3.6.8.1 Removal of throttle check valves................................................................1537
3.6.8.2 Replacement of throttle check valves............................................................1539
3.6.9 Diffuser block (FSA only).............................................................................1540
3.6.9.1 Removal of the Diffuser block at the manifold...................................................1540
3.6.9.2 Replacement of the Diffuser block at the manifold...............................................1541
3.6.10 Manifold.............................................................................................1542
3.6.10.1 Removal of the manifold........................................................................1542
3.6.10.2 Replacement of the manifold....................................................................1544
3.7 Slew system.................................................................................................1545
3.7.1 Slew gear.............................................................................................1545
3.7.1.1 Removal of the slew gear........................................................................1547
3.7.1.2 Replacement of the slew gear....................................................................1550
3.7.2 Swing motor...........................................................................................1552
3.7.2.1 Removal of the swing motor......................................................................1553
3.7.2.2 Replacement of the swing motor..................................................................1555
3.7.3 Slew parking brake....................................................................................1556
3.7.3.1 Removal/disassembly of the slew parking brake (L&S).............................................1557
3.7.3.2 Replacement/assembly of the slew parking brake (L&S)............................................1560
3.7.3.3 Removal of the slew parking brake (siebenhaar)..................................................1563
3.7.3.4 Replacement of the slew parking brake (Siebenhaar)..............................................1566
3.7.4 Dynamic slew brake....................................................................................1570
3.7.4.1 Removal of the slew brake valve.................................................................1573
3.7.4.2 Replacement of the slew brake valve.............................................................1575
3.7.5 Swing circle..........................................................................................1576
3.7.5.1 Removal of the swing circle.....................................................................1577
3.7.5.2 Replacement of the swing circle.................................................................1580
3.7.6 Swing circle lubrication pinion (dummy wheel).........................................................1584
3.7.6.1 Removal of the lubrication pinion assembly......................................................1585
3.7.6.2 Replacement of the lubrication pinion assembly..................................................1587
3.8 Lubrication pumps...........................................................................................1588
3.8.1 Removal of the lubrication pump.......................................................................1588
3.8.2 Replacement of the lubricating pump...................................................................1590
3.9 Operator’s cab..............................................................................................1592
3.9.1 Removal of the operator’s cab.........................................................................1594
3.9.2 Replacement of the operator’s cab.....................................................................1600
3.9.3 Cab-mounts............................................................................................1602
3.9.3.1 Removal of the cab-mounts.......................................................................1602
3.9.3.2 replacement of the cab-mounts...................................................................1604
3.9.4 Front window..........................................................................................1606
3.9.4.1 Removal of the front window.....................................................................1606
3.9.4.2 Replacement of the front window.................................................................1607
3.9.5 Operator’s seat.......................................................................................1608
3.9.5.1 Removal of the operator’s seat..................................................................1608
3.9.5.2 Replacement of the operator’s seat..............................................................1609
3.10 Cab base...................................................................................................1610
3.10.1 Removal of the cab base..............................................................................1610
3.10.2 Replacement of the cab base..........................................................................1613
3.10.3 Pump controller......................................................................................1615
3.10.3.1 Removal of the pump controller.................................................................1615
3.10.3.2 Replacement of the pump controller.............................................................1615
3.10.4 VHMS.................................................................................................1616
3.10.4.1 Removal of the VHMS-controller.................................................................1616
3.10.4.2 Replacement of the VHMS-controller.............................................................1617
3.11 Access ladder..............................................................................................1618
3.11.1 Removal of the access ladder.........................................................................1619
3.11.2 Replacement of the access ladder.....................................................................1621
3.11.3 Removal of the access ladder cylinder................................................................1623
3.11.4 Replacement of the access ladder cylinder............................................................1625
3.12 Counterweight..............................................................................................1626
3.12.1 Removal of the counterweight.........................................................................1627
3.12.2 Replacement of the counterweight.....................................................................1629
3.13 Superstructure Lifting.....................................................................................1630
3.13.1 Remove the superstructure from the undercarriage.....................................................1630
3.13.2 Install the superstructure onto the undercarriage....................................................1635
3.14 Fuel tank..................................................................................................1638
3.14.1 General information..................................................................................1639
3.14.2 Removal of the fuel tank.............................................................................1640
3.14.3 Replacement of the fuel tank.........................................................................1646
4 Undercarriage.....................................................................................................1649
4.1 Undercarriage overview......................................................................................1650
4.2 Travel system...............................................................................................1652
4.2.1 Track group...........................................................................................1652
4.2.1.1 Changing of the track group.....................................................................1652
4.2.2 Sprocket..............................................................................................1657
4.2.2.1 Removal of the sprocket.........................................................................1657
4.2.2.2 Replacement of the sprocket.....................................................................1662
4.2.3 Guide wheels..........................................................................................1664
4.2.3.1 Removal of the guide wheel assembly.............................................................1664
4.2.3.2 Replacement of the guide wheel assembly.........................................................1666
4.2.4 Track tensioning accumulators.........................................................................1668
4.2.4.1 Removal of the low pressure accumulators........................................................1668
4.2.4.2 Replacement of the low pressure accumulators....................................................1670
4.2.4.3 Removal of the high pressure accumulators.......................................................1671
4.2.4.4 Replacement of the high pressure accumulators...................................................1672
4.2.5 Track tension valve block.............................................................................1673
4.2.5.1 Removal of the track tensioning valve block.....................................................1673
4.2.5.2 Replacement of the track tensioning valve block.................................................1675
4.2.6 Track tensioning cylinders............................................................................1676
4.2.6.1 Removal of the track tensioning cylinders.......................................................1676
4.2.6.2 Replacement of the track tensioning cylinders...................................................1678
4.2.7 Hydraulic hoses of the track tensioning system........................................................1679
4.2.7.1 Precursory work.................................................................................1679
4.2.7.2 Substitute the hydraulic hoses inside the car body..............................................1681
4.2.7.3 Substitute the hydraulic hoses between car body and crawler frame...............................1681
4.2.7.4 Substitute the hydraulic hoses inside the crawler frame.........................................1683
4.2.7.5 Subsequent work.................................................................................1683
4.2.8 Travel brake valve block (overspeed valve)............................................................1685
4.2.8.1 Removal of the travel brake valve block.........................................................1688
4.2.8.2 Replacement of the travel brake valve block.....................................................1689
4.2.9 Travel motors.........................................................................................1690
4.2.9.1 Removal of the travel motors....................................................................1690
4.2.9.2 Replacement of the travel motors................................................................1692
4.2.10 Travel parking brake.................................................................................1694
4.2.10.1 Travel parking brake overview..................................................................1694
4.2.10.2 Removal/disassembly of the travel parking brake (L&S)..........................................1699
4.2.10.3 Replacement/assembly of the travel parking brake (L&S).........................................1702
4.2.10.4 Removal/disassembly of the travel parking brake (Zollern)......................................1705
4.2.10.5 Replacement/assembly of the travel parking brake (Zollern).....................................1708
4.2.11 Travel gear box......................................................................................1710
4.2.11.1 Removal of the travel gear box.................................................................1711
4.2.11.2 Replacement of the travel gear box.............................................................1713
4.2.12 Carrier roller.......................................................................................1715
4.2.12.1 Removal of the carrier roller assembly.........................................................1715
4.2.12.2 Replacement of the carrier roller assembly.....................................................1718
4.2.13 Track roller.........................................................................................1719
4.2.13.1 Removal of the track roller assembly...........................................................1719
4.2.13.2 Replacement of the track roller assembly.......................................................1721
4.3 Car body....................................................................................................1722
4.3.1 Removal of the car body and the crawler carriers (type with mounting pins)............................1722
4.3.2 Replacement of the car body and the crawler carriers (type with mounting pins)........................1726
4.3.3 Removal of the car Body and the crawler carriers (type with bolted connection)........................1730
4.3.4 Replacement of the car body and the crawler carriers (type with bolted connection)....................1736
4.3.5 Rotary joint..........................................................................................1745
4.3.5.1 Removal of the rotary joint.....................................................................1747
4.3.5.2 Replacement of the rotary joint.................................................................1750
5 Attachment........................................................................................................1753
5.1 Backhoe.....................................................................................................1754
5.1.1 Boom..................................................................................................1755
5.1.1.1 Removal of the Boom.............................................................................1755
5.1.1.2 Replacement of the boom.........................................................................1758
5.1.1.3 Removal of the boom cylinders...................................................................1760
5.1.1.4 Replacement of the boom cylinders...............................................................1765
5.1.2 Stick.................................................................................................1770
5.1.2.1 Removal of the Stick............................................................................1770
5.1.2.2 Replacement of the Stick........................................................................1774
5.1.2.3 Removal of the Stick Cylinders..................................................................1776
5.1.2.4 Replacement of the Stick cylinders..............................................................1781
5.1.3 Bucket................................................................................................1786
5.1.3.1 Removal of the bucket...........................................................................1786
5.1.3.2 Replacement of the bucket.......................................................................1789
5.1.3.3 Removal of the Bucket Cylinders.................................................................1790
5.1.3.4 Replacement of the Bucket Cylinders.............................................................1796
5.1.4 Bucket link rod and steering rods.....................................................................1799
5.1.4.1 Removal of the bucket link rod..................................................................1799
5.1.4.2 Replacement of the bucket link rod..............................................................1801
5.1.4.3 Removal of the steering rods....................................................................1802
5.1.4.4 Replacement of the steering rods................................................................1805
5.1.5 Ground engaging tools (GET)...........................................................................1806
5.1.5.1 Removal and replacement of the GET..............................................................1806
5.1.6 Hydraulic hoses at the backhoe attachment.............................................................1808
5.1.6.1 Substitute the boom arc hoses...................................................................1808
5.1.6.2 Substitute the boom cylinder hoses..............................................................1814
5.1.6.3 Substitute the stick cylinder hoses.............................................................1818
5.1.6.4 Substitute the bucket cylinder hoses............................................................1822
5.2 Faceshovel..................................................................................................1826
5.2.1 Using the installation tools for hydraulic cylinders..................................................1827
5.2.2 Boom..................................................................................................1828
5.2.2.1 Removal of the boom.............................................................................1828
5.2.2.2 Replacement of the boom.........................................................................1835
5.2.2.3 Removal of the boom cylinders...................................................................1840
5.2.2.4 Replacement of the boom cylinders...............................................................1844
5.2.3 Stick.................................................................................................1848
5.2.3.1 Removal of the stick............................................................................1848
5.2.3.2 Replacement of the stick........................................................................1852
5.2.3.3 Removal of the stick cylinders..................................................................1856
5.2.3.4 Replacement of the stick cylinders..............................................................1860
5.2.4 Bull Clam bucket......................................................................................1864
5.2.4.1 Removal of the bull clam bucket.................................................................1864
5.2.4.2 Replacement of the bull clam bucket.............................................................1870
5.2.4.3 Removal of the bucket cylinders.................................................................1872
5.2.4.4 Replacement of the bucket cylinders.............................................................1876
5.2.4.5 Removal of the clam cylinders...................................................................1880
5.2.4.6 Replacement of the clam cylinders...............................................................1884
5.2.5 Ground engaging tools (GET)...........................................................................1887
5.2.5.1 Removal and replacement of the GET..............................................................1887
5.2.6 Hydraulic hoses at the Faceshovel attachment..........................................................1888
5.2.6.1 Substitute the boom arc hoses...................................................................1888
5.2.6.2 Substitute the boom cylinder hoses..............................................................1894
5.2.6.3 Substitute the stick arc hoses..................................................................1898
5.2.6.4 Substitute the stick cylinder hoses.............................................................1902
5.2.6.5 Substitute the bucket cylinder hoses............................................................1906
5.2.6.6 Substitute the clam cylinder hoses..............................................................1910
5.3 Metering valves (grease injectors) at the attachment........................................................1918
5.3.1 Operation test of the metering valves (grease injectors)..............................................1919
5.3.2 Removal of the metering valves (grease injectors).....................................................1920
5.3.3 Replacement of the metering valves (grease injectors).................................................1922
5.4 Cylinder bypass test........................................................................................1923
6 Service Information...............................................................................................1925
6.1 Fluids and lubricants.......................................................................................1926
6.2 Filling capacities..........................................................................................1927
6.3 Work instructions...........................................................................................1928
6.3.1 Remove / install the crawler carrier..................................................................1928
6.4 Weight tables...............................................................................................1929
6.4.1 Superstructure........................................................................................1929
6.4.2 Undercarriage.........................................................................................1931
6.4.3 Backhoe attachment (BHA)..............................................................................1932
6.4.4 Face shovel attachment (FSA)..........................................................................1933
6.5 Torque charts according to KOMATSU company standard.........................................................1934
6.5.1 Metric standard thread................................................................................1934
6.5.2 Metric fine thread....................................................................................1935
6.5.3 Cummins motor torques - metric........................................................................1936
6.5.4 Cummins motor torques - U.S. customary................................................................1936
6.5.5 Flange connections....................................................................................1937
6.6 Blind plugs.................................................................................................1938
6.6.1 Dummy plates for SAE–flanges..........................................................................1938
6.6.2 Classification of threads to the nominal width........................................................1940
6.6.3 Plugs and fittings according to DIN 2353..............................................................1941
6.7 Conversion table............................................................................................1942
6.7.1 Method of using the conversion table..................................................................1942
6.7.2 Millimeter - inch & kilogram - pound..................................................................1943
6.7.3 Liter - U.S. gallon & liter - U.K. gallon.............................................................1944
6.7.4 Nm- ft.lb.............................................................................................1945
6.7.5 Bar - PSI - kPa - MPa.................................................................................1946
6.7.6 Basic values in Ohm according to ISO 43 76............................................................1947
6.7.7 Temperature...........................................................................................1948
6.8 Tools.......................................................................................................1949
6.8.1 Standard tool case....................................................................................1949
6.8.2 Used special tools (Overview).........................................................................1951
7 Tools catalogue...................................................................................................1953
8 Parts & Service News..............................................................................................2009
8.1 List of the PARTS AND SERVICE NEWS..........................................................................2010
AH00511h....................................................................................................2013
AH00514.....................................................................................................2035
AH00515c....................................................................................................2047
AH01512.....................................................................................................2057
AH01531.....................................................................................................2065
AH02513.....................................................................................................2075
AH02521.....................................................................................................2079
AH03506.....................................................................................................2089
AH03509.....................................................................................................2095
AH03510.....................................................................................................2121
AH03538.....................................................................................................2141
AH04518.....................................................................................................2167
AH05510.....................................................................................................2169
AH05518.....................................................................................................2175
AH05535.....................................................................................................2177
AH05537.....................................................................................................2201
AH05546.....................................................................................................2217
AH06524.....................................................................................................2219
AH06530.....................................................................................................2221
AH06544.....................................................................................................2223
AH06545.....................................................................................................2235
AH08502.....................................................................................................2239
AH08504.....................................................................................................2247
AH08508.....................................................................................................2249
AH08512.....................................................................................................2253
AH09522.....................................................................................................2273
AH10530.....................................................................................................2275
9 Supplier’s documentation..........................................................................................2419
START PAGE Disassembly and Assembly 50.pdf.......................................................................... 0
50 DISASSEMBLY AND ASSEMBLY.....................................................................................1333
KOMATSU PC4000-6 HYDRAULIC MINING SHOVEL SHOP MANUAL SM-PC4000-8199 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
