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KOMATSU PC8000E-11 HYDRAULIC MINING EXCAVATOR SHOP MANUAL 12121-xE-GB-0 – PDF
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KOMATSU PC8000E-11 HYDRAULIC MINING EXCAVATOR SHOP MANUAL 12121-xE-GB-0 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC8000E-11 HYDRAULIC MINING EXCAVATOR SHOP MANUAL 12121-xE-GB-0 – PDF DOWNLOAD
Language : English
Pages : 2014
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC8000E-11 HYDRAULIC MINING EXCAVATOR SHOP MANUAL 12121-xE-GB-0 – PDF DOWNLOAD
SHOP MANUAL PC8000E-11............................................................................................... 1
Change history................................................................................................... 2
00 FOREWORD & SAFETY................................................................................................. 3
1 Foreword....................................................................................................... 5
1.1 BEFORE READING THIS MANUAL............................................................................... 6
1.1.1 CSA (Canadian Standards Association)............................................................... 6
1.2 CONTENTS OF THIS BINDER.................................................................................. 7
1.2.1 Contacting the Service............................................................................. 7
1.2.2 Guarantee.......................................................................................... 7
1.3 DIVISION OF THE BINDER................................................................................... 8
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...................................................................... 11
2.3 SOUND PRESSURE AND VIBRATION LEVELS IN THE OPERATOR’S CAB................................................ 12
2.3.1 SOUND.............................................................................................. 12
2.3.2 VIBRATION.......................................................................................... 13
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR................................................. 14
2.4.1 UNDERSTANDING THE excavator........................................................................ 14
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR............................................. 14
2.4.2.1 ENSURING SAFE OPERATION...................................................................... 14
2.4.3 PREPARATIONS FOR SAFE OPERATION.................................................................... 14
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT............................................... 14
2.4.3.2 INSPECTING THE excavator..................................................................... 14
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT........................................... 15
2.4.3.4 KEEP excavator CLEAN......................................................................... 15
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT.................................................... 15
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT.................................................. 16
2.4.3.7 IF A PROBLEM IS FOUND........................................................................ 16
2.4.4 FIRE PREVENTION.................................................................................... 16
2.4.4.1 PRECAUTIONS TO PREVENT FIRE.................................................................. 16
2.4.4.2 ACTION IF FIRE OCCURS ON PC3000 Tier 2 and Electro........................................... 17
2.4.4.3 ACTION IF FIRE OCCURS ON PC3000 Tier 4, PC4000, PC5500, PC7000, PC8000....................... 18
2.4.4.4 EMERGENCY EXIT FROM OPERATOR’S CAB FOR PC3000................................................ 18
2.4.4.5 EMERGENCY EXIT FROM OPERATOR’S CAB FOR PC4000, PC5500, PC7000, PC8000........................ 19
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE EXCAVATOR................................................... 19
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE excavator................................. 19
2.4.5.2 NO JUMPING ON OR OFF THE excavator........................................................... 19
2.4.5.3 NO PEOPLE ON THE ATTACHMENT.................................................................. 19
2.4.5.4 WORKING IN HIGH PLACES....................................................................... 20
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK............................................................ 21
2.4.5.6 LEAVING THE excavator........................................................................ 21
2.4.6 BURN PREVENTION.................................................................................... 21
2.4.6.1 Hot coolant.................................................................................. 21
2.4.6.2 Hot oil...................................................................................... 22
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS................................................................ 22
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....................................................... 22
2.4.9 PRECAUTIONS RELATED TO AIRBOURNE AND EJECTED DEBRIS................................................ 23
2.4.9.1 UNAUTHORIZED MODIFICATION.................................................................... 23
2.4.9.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS............................................... 23
2.4.10 ELECTROMAGNETIC COMPATIBILITY (EMC)............................................................... 23
2.4.11 PRECAUTIONS AT JOBSITE............................................................................ 24
2.4.11.1 VISIBILITY FROM OPERATOR’S SEAT............................................................. 25
2.4.11.2 CAMERA SYSTEM WITH MONITORS................................................................. 25
2.4.11.3 ENSURE GOOD VISIBILITY...................................................................... 25
2.4.11.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS...................................................... 25
2.4.11.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS.................................................. 26
2.4.11.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES...................................................... 26
2.4.11.7 Lightning Strikes........................................................................... 27
2.4.11.8 WORKING ON LOOSE GROUND..................................................................... 27
2.4.11.9 GAS, DUST, STEAM, SMOKE AND EXHAUST FUMES................................................... 28
2.4.11.10 VENTILATION OF ENCLOSED AREAS.............................................................. 29
2.4.12 STARTING motor.................................................................................... 30
2.4.12.1 WARNING TAG................................................................................. 30
2.4.12.2 CHECKS BEFORE STARTING motor................................................................ 30
2.4.12.3 PRECAUTION WHEN STARTING motor.............................................................. 30
2.4.12.4 PRECAUTION IN COLD AREAS.................................................................... 31
2.4.13 OPERATION......................................................................................... 31
2.4.13.1 CHECKS BEFORE OPERATION..................................................................... 31
2.4.13.2 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE............................................ 32
2.4.13.3 PRECAUTIONS WHEN traveling.................................................................. 33
2.4.13.4 TRAVELING ON SLOPES......................................................................... 34
2.4.13.5 OPERATIONS ON SLOPES........................................................................ 35
2.4.13.6 PROHIBITED OPERATIONS....................................................................... 35
2.4.13.7 TRAVELING ON FROZEN OR SNOW COVERED SURFACES................................................ 36
2.4.13.8 PARKING THE excavator....................................................................... 36
2.4.13.9 TRANSPORTATION.............................................................................. 36
2.5 PRECAUTION FOR MAINTENANCE............................................................................... 37
2.5.1 GENERAL PRECAUTIONS................................................................................ 37
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES............................ 38
2.5.1.2 STOP motor FOR MAINTENANCE................................................................... 39
2.5.1.3 WARNING TAG.................................................................................. 39
2.5.1.4 Maintenance safety Switch.................................................................... 39
2.5.1.5 KEEP WORKPLACE CLEAN AND TIDY................................................................ 40
2.5.1.6 APPOINT LEADER WHEN WORKING WITH OTHERS...................................................... 41
2.5.1.7 TWO WORKERS FOR MAINTENANCE WHEN THE excavator IS RUNNING.................................... 41
2.5.1.8 INSTALLING, REMOVING OR STORING ATTACHMENTS.................................................. 41
2.5.1.9 PRECAUTIONS WHEN WORKING UNDER THE excavator OR EQUIPMENT.................................... 42
2.5.1.10 NOISE....................................................................................... 42
2.5.1.11 WHEN USING A HAMMER......................................................................... 42
2.5.1.12 PROPER TOOLS................................................................................ 43
2.5.1.13 ACCUMULATOR................................................................................. 43
2.5.1.14 PERSONNEL................................................................................... 43
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE......................................................... 44
2.5.2.1 PRECAUTION WHEN WELDING...................................................................... 44
2.5.2.2 BATTERY HANDLING............................................................................. 44
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID............................................................... 45
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE.......................................................... 46
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES....................................................... 47
2.5.3.3 REPLACEMENT OF HOSE LINES.................................................................... 47
2.5.3.4 INSPECTION OF HOSE LINES..................................................................... 47
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................ 48
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE................................................................. 48
2.5.3.7 AIR CONDITIONING MAINTENANCE................................................................. 48
2.5.3.8 COMPRESSED AIR............................................................................... 49
2.5.3.9 WASTE MATERIALS.............................................................................. 49
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS........................................ 50
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM................................................................. 50
2.6.2 TWO WORKERS ONLY WHEN THE EXCAVATOR IS RUNNING DURING ADJUSTMENTS.................................. 50
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR..................................................... 50
2.7 SPECIAL SAFETY EQUIPMENT................................................................................. 51
2.7.1 FRONT GUARD PROTECTIVE STRUCTURE ’FOPS’ FOR OPERATOR’S CAB......................................... 52
2.7.2 OBJECT HANDLING.................................................................................... 52
2.7.3 LIGHTING........................................................................................... 52
2.7.4 WARNING BEACON..................................................................................... 52
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)....................................... 52
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)................................. 52
2.7.5.2 INSTRUCTIONS FOR USE......................................................................... 53
2.7.5.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS...... 54
2.7.5.4 INSTRUCTIONS FOR USE......................................................................... 54
2.8 HIGH VOLTAGE SAFETY INSTRUCTIONS FOR MACHINES WITH ELECTRIC MOTOR........................................ 55
2.8.1 QUALIFICATION OF PERSONNEL......................................................................... 55
2.8.2 ELECTRICAL TOOLS................................................................................... 56
2.8.3 GENERAL PREPARATION BEFORE WORKING ON ELECTRICAL EQUIPMENT......................................... 56
2.8.4 CONNECTION OF PILOT LINE (GROUND CHECK WIRE)....................................................... 56
2.8.5 PREPARATION BEFORE WORKING ON THE CABLE DRUM....................................................... 56
2.8.6 PREPARATION BEFORE WORKING ON THE CABLE GUIDE...................................................... 57
2.8.7 MODIFICATION OF THE ELECTRICAL SYSTEM.............................................................. 57
2.8.8 FIRE............................................................................................... 57
2.8.9 GENERAL INSTRUCTIONS............................................................................... 58
2.8.10 GROUNDING PROCEDURE FOR THE HIGH VOLTAGE SYSTEM................................................... 58
2.8.10.1 INTRODUCTION................................................................................ 58
2.8.10.2 GENERAL PREPARATION BEFORE WORKING ON ELECTRICAL EQUIPMENT.................................. 59
2.8.10.3 WORKING EQUIPMENT & PERSONAL PROTECTION..................................................... 59
2.8.10.4 SPECIAL TOOLS REQUIRED...................................................................... 59
2.8.10.5 PERSONAL PROTECTION EQUIPMENT (PPE)......................................................... 60
2.8.10.6 PREPARING THE MACHINE FOR HIGH VOLTAGE MAINTENANCE.......................................... 60
2.8.10.7 POWER DISCONNECTION AND EARTHING............................................................ 61
2.8.10.8 THE THREE STEPS To DEACTIVATE POWER......................................................... 62
2.8.10.9 EARTHING PROCEDURES IN THE HV CABINET....................................................... 65
2.8.10.10 THREE STEPS TO RECONNECTING THE POWER AFTER MAINTENANCE WORK............................... 72
2.8.10.11 Step 1, inserting the key.................................................................. 72
2.8.10.12 Step 2, Switching earthing off............................................................. 72
2.8.10.13 Step 3, Switching load on.................................................................. 73
SPECIFICATION........................................................................................................ 75
PC8000E-11....................................................................................................... 77
10 STRUCTURE & FUNCTION.............................................................................................. 81
TOC.............................................................................................................. 83
1 Introduction................................................................................................... 95
1.1 Foreword................................................................................................. 96
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining excavators.... 97
1.3 Explanation of abbreviations............................................................................. 98
1.4 Diagrams and illustrations in this manual................................................................ 99
2 Specifications................................................................................................. 101
2.1 Lifting Gears............................................................................................ 102
2.2 Safety hints for sling accessory......................................................................... 104
2.3 Standard Tightening Torque Chart......................................................................... 105
2.4 Conversion Table......................................................................................... 106
2.5 Blind plugs.............................................................................................. 112
2.6 Classification of threads to nominal width............................................................... 114
2.7 Plugs and fittings according to ISO 8434-1 / DIN 2353.................................................... 115
3 Main assembly groups........................................................................................... 117
3.1 General layout........................................................................................... 118
3.2 Superstructure - side view............................................................................... 120
3.3 Superstructure - top view................................................................................ 122
3.4 Machinery house.......................................................................................... 124
3.5 Hydraulic oil tank....................................................................................... 126
3.6 Hydraulic oil cooler..................................................................................... 128
3.7 High voltage switch cabinet.............................................................................. 130
3.8 Cab support.............................................................................................. 136
3.8.1 Low voltage switch board (location 12)............................................................. 138
3.8.2 X2 board - ELV switch board - location 11.......................................................... 140
3.9 Slip ring unit........................................................................................... 142
3.10 Operator’s cab.......................................................................................... 146
3.11 Air conditioner......................................................................................... 148
3.12 Main control blocks..................................................................................... 150
3.13 Slew machinery.......................................................................................... 152
3.13.1 Slew gear type 2063............................................................................... 152
3.13.2 Slew gear type 632770............................................................................. 154
3.14 Undercarriage........................................................................................... 156
3.15 Attachments............................................................................................. 158
3.15.1 Front Shovel Attachment (FSA)..................................................................... 158
3.15.2 Backhoe Attachment (BHA).......................................................................... 160
3.16 Counterweight........................................................................................... 162
4 Drive.......................................................................................................... 165
4.1 Electric drive - Safety and operation instruction documents.............................................. 166
4.2 Prime drive assembly..................................................................................... 168
4.3 Electric motors.......................................................................................... 170
4.3.1 Location of attaching parts........................................................................ 170
4.3.1.1 Motor type plate............................................................................. 171
4.3.1.2 Type plate for motor bearings................................................................ 172
4.3.2 Motor bearings & grease equipment.................................................................. 174
4.3.3 Monitoring motor bearing temperature............................................................... 176
4.3.4 Monitoring motor winding temperature............................................................... 177
4.3.4.1 Temperature signal conversion................................................................ 177
4.3.5 Junction box for the motor monitoring device....................................................... 178
4.3.6 Checking bearing condition......................................................................... 179
4.3.7 Capacitor assembly................................................................................. 180
4.4 Air-to-air motor cooling system.......................................................................... 182
4.5 Initial Start-up procedure............................................................................... 183
4.5.1 Main supply cable.................................................................................. 184
4.5.2 Machine configuration (via CoDeSys)................................................................ 185
4.5.3 Motor protection relays (type Multilin 369)........................................................ 190
4.5.4 Motor alignment.................................................................................... 192
4.5.5 Motor rotation direction........................................................................... 194
4.5.6 Starting & Re-starting the electric motors......................................................... 194
4.5.7 Supervision during the first motor running period.................................................. 195
4.6 Flexible coupling........................................................................................ 196
4.6.1 Description of the flexible coupling............................................................... 198
4.6.2 Coupling inspection................................................................................ 199
4.6.2.1 Work to be performed during visual inspection................................................ 199
4.6.3 Coupling replacement information................................................................... 199
4.6.4 Coupling removal & replacement..................................................................... 200
4.6.5 Coupling run-out................................................................................... 202
4.6.6 Technical specification............................................................................ 203
4.7 Pump distributor gearbox (PTO) - type 2063............................................................... 204
4.7.1 Pump drive shaft housing / spline lubrication...................................................... 206
4.7.2 PTO lubrication and cooling........................................................................ 208
4.7.2.1 Checks and adjustments....................................................................... 210
4.7.3 Hydraulic pumps – location, drive speed & flow rates............................................... 212
5 Hydraulic oil tank............................................................................................. 215
5.1 General layout........................................................................................... 216
5.2 Location of the electric equipment....................................................................... 218
5.3 Suction oil tank with strainers.......................................................................... 220
5.4 Return oil collector pipe with strainer.................................................................. 222
5.4.1 Piston accumulator (pulsation damper).............................................................. 224
5.4.2 Maintenance of pulsation damper.................................................................... 225
5.5 Back pressure valve...................................................................................... 226
5.6 Transfer pump............................................................................................ 228
5.7 Return and leak oil filter............................................................................... 230
5.8 Breather filter.......................................................................................... 232
6 Hydraulic oil cooling.......................................................................................... 235
6.1 Overall view of the hydraulic oil cooling................................................................ 236
6.2 Function of the hydraulic oil cooling circuit............................................................ 238
6.2.1 Standard hydraulic oil cooling circuit............................................................. 238
6.2.2 Additional oil cooling circuit..................................................................... 240
6.3 Adjustment of the back pressure valve.................................................................... 242
6.4 Fan drive - standard oil cooler.......................................................................... 244
6.4.1 Two stage cooler fan drive RPM control............................................................. 244
6.4.2 Fixed displacement pump with variable setting...................................................... 246
6.4.3 Pressure relief valves............................................................................. 248
6.4.4 Solenoid valves.................................................................................... 250
6.5 Adjustment of the cooler fan drive speed................................................................. 252
6.5.1 Maximum speed...................................................................................... 252
6.5.2 Medium speed....................................................................................... 256
6.5.3 Function check of fan speed control................................................................ 257
6.6 Fan drive - additional oil cooler........................................................................ 258
6.6.1 Function of the additional cooler fan RPM control.................................................. 259
6.6.2 Adjustment of the additional cooler fan drive speed................................................ 259
7 Controlling.................................................................................................... 261
7.1 Safety circuit........................................................................................... 262
7.1.1 Wiring Diagram overview → 20S105 / 20S105a......................................................... 263
7.1.2 Wiring Diagram overview → 70B122a.................................................................. 264
7.1.3 Wiring Diagram overview → 55B023a.................................................................. 265
7.2 General layout........................................................................................... 266
7.3 Control and filter panels – location of components....................................................... 268
7.3.1 Main valve cartridge block......................................................................... 268
7.3.2 Pressure test ports overview....................................................................... 272
7.3.3 Control and filter panels mounted on the PTOs...................................................... 274
7.4 Pilot pressure supply and adjustments.................................................................... 276
7.4.1 Pilot pressure control (PPC) circuit............................................................... 277
7.4.2 Checks and adjustments of pilot pressure........................................................... 280
7.4.3 Remote control valves arrangement.................................................................. 282
7.5 Function of the electro-hydraulic control system......................................................... 284
7.5.1 Control lever signal flow.......................................................................... 286
7.6 Hand lever (joystick) control............................................................................ 288
7.7 Foot pedal control....................................................................................... 290
7.8 Proportional amplifier & ramp time function.............................................................. 292
7.8.1 Used amplifier modules............................................................................. 293
7.8.2 Amplifier terminal layout.......................................................................... 293
7.9 Amplifier & ramp time setting via WPC software tool...................................................... 294
7.9.1 Setting preparation................................................................................ 294
7.9.2 Basic setting...................................................................................... 295
7.9.3 Amplifier adjustment............................................................................... 296
7.10 Troubleshooting......................................................................................... 297
7.10.1 Error code chart.................................................................................. 298
7.10.2 LED indication at amplifier modules............................................................... 299
7.10.3 Adjustment values for amplifier & ramp time setting → FSA (example)............................... 300
7.10.4 Adjustment values for amplifier & ramp time setting → BHA (example)............................... 302
8 Components..................................................................................................... 305
8.1 Main control blocks and high pressure screens (FSA/BHA).................................................. 306
8.1.1 Control block circuits & valves (FSA).............................................................. 308
8.1.2 Main control blocks - spool & function (FSA)....................................................... 309
8.2 Distributor manifold – location of restrictor blocks & anti-cavitation valves (FSA)...................... 310
8.3 Distributor manifold - location of restrictor blocks & anti-cavitation valves (BHA)...................... 312
8.4 Restrictor block with secondary relief valve............................................................. 314
8.5 Anti-cavitation valve (ACV) block........................................................................ 316
8.5.1 ACV block on control blocks........................................................................ 316
8.5.2 ACV block on top of the manifold................................................................... 318
8.6 Remote control valves.................................................................................... 320
8.7 4/3 Directional solenoid valves.......................................................................... 322
8.8 Proportional solenoid valves............................................................................. 324
8.9 High pressure screen..................................................................................... 326
8.10 Control blocks and valves............................................................................... 328
8.10.1 Spin lock for valve blocks (ND52)................................................................. 329
8.10.2 Spool types....................................................................................... 330
8.10.3 4-spool valve block............................................................................... 332
8.10.4 Control block – spool positions................................................................... 334
8.10.5 Control blocks – valve types (MRV, SRV, ACV)...................................................... 336
8.10.6 Load holding valve................................................................................ 338
8.11 Travel brake valve...................................................................................... 340
8.12 Pressure reducing valve................................................................................. 342
8.13 4/2 Directional valves.................................................................................. 344
8.14 Pressure double stage valve............................................................................. 346
8.15 Hydraulic cylinder...................................................................................... 348
8.15.1 Hydraulic cylinder - Chesterton® 11KE sealing..................................................... 348
8.15.2 Cylinder data markings............................................................................ 351
9 Main hydraulic pumps and pump regulation....................................................................... 353
9.1 General layout........................................................................................... 354
9.1.1 Pump regulation system ("open sensing system")..................................................... 356
9.1.2 Pump regulation system - valve function............................................................ 358
9.2 Main pumps............................................................................................... 360
9.2.1 Pump bearing flushing / lubrication................................................................ 362
9.3 Operating principle of main pumps........................................................................ 364
9.3.1 Symbol of main hydraulic pump A4VSO750i............................................................ 366
9.3.2 Sectional drawing of regulating valves............................................................. 368
9.3.3 Main pumps at Qmin (190 l/min, no lever or pedal activated)........................................ 370
9.3.4 Main pump at Qmax.................................................................................. 372
9.3.5 Main pump at ½ Qmax................................................................................ 374
9.3.6 Main pump destroking............................................................................... 376
9.3.7 Main pump – pressure cut-off....................................................................... 378
9.4 Checks / adjustment - overview........................................................................... 380
9.5 Electronic pump regulation system........................................................................ 382
9.5.1 Electronic load limiting control – general......................................................... 383
9.5.2 Micro-controller RC4-4............................................................................. 384
9.5.3 Signal rectifier module............................................................................ 386
9.5.3.1 Checks and adjustment........................................................................ 388
9.6 Hydraulic constant regulation system (emergency mode).................................................... 390
9.6.1 General............................................................................................ 391
9.7 Pump regulation system, checks and adjustments........................................................... 392
9.7.1 Power Check........................................................................................ 392
9.7.2 Power check procedure.............................................................................. 394
9.7.3 Electronic load limit regulation, XLR basic adjustment............................................. 396
9.7.4 Method "A" with 24 V supply........................................................................ 398
9.7.5 Method "B" with BODAS software..................................................................... 400
9.7.6 Electronic load limit regulation, RC4 function check............................................... 404
9.7.7 Hydraulic Control (emergency mode)................................................................. 406
9.7.8 Pressure cut-off valve............................................................................. 408
9.8 Energy efficiency........................................................................................ 410
9.8.1 General............................................................................................ 411
9.8.2 Checks and adjustment.............................................................................. 412
10 Operating hydraulics.......................................................................................... 415
10.1 General................................................................................................. 416
10.2 Floating function for boom & stick cylinder (FSA)....................................................... 418
10.3 Hydraulics for the attachment cylinders................................................................. 420
10.3.1 Electric / hydraulic flowchart → Boom UP (FSA).................................................... 420
10.3.2 Electric / hydraulic flowchart → Boom UP (BHA).................................................... 422
10.3.3 Electric / hydraulic flowchart → Boom down (FSA) Auto-float ON.................................... 424
10.3.4 Electric / hydraulic flowchart → Boom down (FSA) Auto-float OFF................................... 426
10.3.5 Electric / hydraulic flowchart → Boom down (BHA).................................................. 428
10.3.6 Electric / hydraulic flowchart → Stick out (FSA).................................................. 430
10.3.7 Electric / hydraulic flowchart → Stick out (BHA).................................................. 432
10.3.8 Electric / hydraulic flowchart → Stick in (FSA), Auto-float ON.................................... 434
10.3.9 Electric / hydraulic flowchart → Stick in (FSA) Auto-float OFF.................................... 436
10.3.10 Electric / hydraulic flowchart → Stick in (BHA).................................................. 438
10.3.11 Electric / hydraulic flowchart → Bucket fill (FSA)............................................... 440
10.3.12 Electric / hydraulic flowchart → Bucket fill (BHA)............................................... 442
10.3.13 Electric / hydraulic flowchart → Bucket dump (FSA)............................................... 444
10.3.14 Electric / hydraulic flowchart → Bucket dump (BHA)............................................... 446
10.3.15 Electric / hydraulic flowchart → Clam open (FSA)................................................. 448
10.3.16 Electric / hydraulic flowchart → Clam close (FSA)................................................ 450
10.3.17 Checks & adjustments of main relief valves (MRV)................................................. 452
10.3.18 Checks and adjustments of secondary relief valves (SRV).......................................... 454
10.3.18.1 SRV boom cylinder, piston side → Boom up (FSA & BHA)....................................... 454
10.3.18.2 SRV boom cylinder, rod side → Boom down (FSA & BHA)........................................ 458
10.3.18.3 Stick cylinder, piston side → Stick out (FSA).............................................. 462
10.3.18.4 SRV Stick cylinder, rod side → Stick out (BHA)............................................. 466
10.3.18.5 SRV stick cylinder, rod side → Stick in (FSA).............................................. 470
10.3.18.6 SRV stick cylinder, piston side → Stick in (BHA)........................................... 474
10.3.18.7 SRV bucket cylinder, piston side → Bucket fill (FSA)....................................... 478
10.3.18.8 SRV bucket cylinder, piston side → Bucket fill (BHA)....................................... 482
10.3.18.9 SRV bucket cylinder, rod side → Bucket dump (FSA).......................................... 486
10.3.18.10 SRV bucket cylinder, rod side → Bucket dump (BHA)......................................... 490
10.3.18.11 SRV clam cylinder, rod side → Clam open (FSA)............................................. 494
10.3.18.12 SRV clam cylinder, piston side → Clam close (FSA)......................................... 498
10.3.19 Checks & adjustments of attachment cycle times................................................... 502
10.3.19.1 Check & adjustment → Boom lowering speed (FSA)............................................. 502
10.3.19.2 Check & adjustment → Boom lowering speed (BHA)............................................. 506
10.3.19.3 Check & adjustment → Stick retract speed (FSA)............................................. 510
10.3.19.4 Check & adjustment → Stick retract speed (BHA)............................................. 514
10.3.19.5 Check & adjustment → Bucket dump speed (FSA)............................................... 518
10.3.19.6 Check & adjustment → Bucket dump speed (BHA)............................................... 522
10.3.19.7 Check & adjustment → Clam close speed (FSA)................................................ 526
10.4 Hydraulics for the slew circuit......................................................................... 528
10.4.1 Slew circuit...................................................................................... 528
10.4.2 Slew motor........................................................................................ 532
10.4.3 Slew gearbox - type 2063.......................................................................... 534
10.4.4 Slew gearbox - type 632770........................................................................ 536
10.4.5 Slew parking brake - on slew gear type 2063....................................................... 538
10.4.6 Slew parking brake - on slew gear type 632770..................................................... 540
10.4.7 Slew brake valve.................................................................................. 542
10.4.8 Electric / hydraulic flowchart → Slew left........................................................ 546
10.4.9 Electric / hydraulic flowchart → Slew right....................................................... 548
10.4.10 Checks and adjustment for the slew circuit....................................................... 550
10.4.11 Function check for hydraulic slew brake.......................................................... 554
10.4.12 Function check for slew parking brake............................................................ 558
10.5 Hydraulics for travel circuit........................................................................... 562
10.5.1 Travel circuit.................................................................................... 564
10.5.2 Travel motor...................................................................................... 566
10.5.3 Rotary joint...................................................................................... 568
10.5.4 Travel gearbox.................................................................................... 570
10.5.5 Travel parking brake (on travel gear type 2063)................................................... 572
10.5.6 Travel parking brake (on travel gear type 631053)................................................. 574
10.5.7 Travel brake valve................................................................................ 576
10.5.8 Electric / hydraulic flowchart → Travel forward................................................... 578
10.5.9 Electric / hydraulic flowchart → Travel backward.................................................. 580
10.5.10 Checks & adjustment for travel circuit........................................................... 582
10.5.11 Function check for travel parking brake.......................................................... 584
11 Hydraulic track tensioning system............................................................................. 587
11.1 General................................................................................................. 588
11.2 Functional description.................................................................................. 590
11.2.1 Hydraulic circuit diagram (track tensioning)...................................................... 592
11.3 Double stage valve...................................................................................... 594
11.4 Tensioning cylinder..................................................................................... 596
11.5 Check & adjustment...................................................................................... 598
12 Access stairway, hydraulically operated....................................................................... 601
12.1 General................................................................................................. 602
12.2 Function of the hydraulically operated access stairway.................................................. 606
12.3 Checks / adjustment..................................................................................... 610
13 Central refilling system (service arm)........................................................................ 613
13.1 General................................................................................................. 614
13.2 Monitoring and control box.............................................................................. 616
13.3 Service arm initial calibration......................................................................... 618
13.4 Function................................................................................................ 620
13.5 System check............................................................................................ 622
14 Hints for reading hydraulic diagram........................................................................... 625
14.1 General................................................................................................. 626
14.2 Hydraulic symbols....................................................................................... 628
14.2.1 Lines, unions..................................................................................... 629
14.2.2 Components, valves................................................................................ 631
14.2.3 Sensors........................................................................................... 631
14.2.4 Valves, valve components.......................................................................... 632
14.2.5 Pump, motor, cylinder............................................................................. 636
15 Hints for reading electric wiring diagram..................................................................... 641
15.1 General................................................................................................. 642
15.2 Reference code of the electrical components............................................................. 643
15.2.1 Area code......................................................................................... 643
15.2.2 Component identifying letter...................................................................... 645
15.3 Graphical symbols....................................................................................... 646
15.4 Drawing concept......................................................................................... 650
15.5 Cable & connector marking............................................................................... 660
16 KOMTRAX Plus & MTC control system............................................................................. 663
16.1 General................................................................................................. 664
16.2 Specifications for operators............................................................................ 666
16.2.1 Start screen...................................................................................... 667
16.2.2 Opening screen.................................................................................... 667
16.2.3 Main gauge screens 1...3.......................................................................... 668
16.2.4 Energy consumption screen......................................................................... 672
16.2.5 Failure message history for operator.............................................................. 674
16.2.6 Main gauge screens - Changing of Time / SMR / Date................................................ 676
16.2.7 Maintenance monitor............................................................................... 678
16.2.8 Settings for operator............................................................................. 680
16.2.9 Automatic messages................................................................................ 688
16.3 Tables of all provided messages......................................................................... 690
16.3.1 Table of Error Codes & Messages................................................................... 691
16.3.2 Table of available Instruction Messages........................................................... 699
16.4 Flow charts (1...4) of KOMTRAX Plus main screens........................................................ 702
16.5 KOMTRAX Plus service level.............................................................................. 706
16.5.1 General........................................................................................... 707
16.5.2 Explanation of the button symbols (Service Level)................................................. 708
16.5.3 Service Menu Select Screen........................................................................ 709
16.5.4 Real Time Menu Select Screen...................................................................... 710
16.5.4.1 Real Time Menu → 01 Motor 1................................................................. 711
16.5.4.2 Real Time Menu → 02 Motor 2................................................................. 711
16.5.4.3 Real Time Menu → 03 PTO 1................................................................... 712
16.5.4.4 Real Time Menu → 04 PTO 2................................................................... 712
16.5.4.5 Real Time Menu → 05 Hydraulic............................................................... 713
16.5.4.6 Real Time Menu → 06 Slew.................................................................... 714
16.5.4.7 Real Time Menu → 07 Electrical Equipment.................................................... 715
16.5.4.8 Real Time Menu → 08 Emergency Stop.......................................................... 716
16.5.4.9 Real Time Menu → 09 Heater.................................................................. 717
16.5.4.10 Real Time Menu → 10 Manual Switch.......................................................... 718
16.5.4.11 Real Time Menu → 11 Central Lube System 1.................................................. 719
16.5.4.12 Real Time Menu → 12 Slew Ring Gear Lube System............................................. 720
16.5.4.13 Real Time Menu → 13 Central Lube System 2.................................................. 721
16.5.4.14 Real Time Menu → 14 Cable Drum............................................................. 722
16.5.4.15 Real Time Menu → 15 Windscreen Wiper....................................................... 723
16.5.4.16 Real Time Menu → 16 Ladder................................................................. 724
16.5.4.17 Real Time Menu → 17 Service Arm............................................................ 725
16.5.4.18 Real Time Menu → 18 Pilot Control.......................................................... 726
16.5.4.19 Real Time Menu → 19 Other Items............................................................ 727
16.5.4.20 Real Time Menu → 20 Output Signals......................................................... 728
16.5.4.21 Output signals with deactivated MTC evaluation............................................. 731
16.5.5 PM-Clinic......................................................................................... 732
16.5.5.1 General..................................................................................... 732
16.5.5.2 Power Check................................................................................. 733
16.5.6 Serial/GCC no. setting............................................................................ 734
16.5.7 Memory Clear...................................................................................... 735
16.5.7.1 Input Memory Clear ID....................................................................... 735
16.5.7.2 Memory Clear screen......................................................................... 736
16.5.8 Failure History................................................................................... 737
16.5.9 Maintenance Monitor............................................................................... 738
16.5.10 Snapshot......................................................................................... 739
16.5.11 Settings......................................................................................... 740
16.5.11.1 Central Lubrication System (CLS 1), screen 1/12............................................ 740
16.5.11.2 Slew ring gear Lubrication System (SLS), screen 2/12....................................... 741
16.5.11.3 Central Lubrication System (CLS 2), screen 3/12............................................ 742
16.5.11.4 Qmin - Qmax setting, screen 4/12........................................................... 743
16.5.11.5 Other Settings 1/2, screen 5/12............................................................ 743
16.5.11.6 Hydraulic Oil & PTO Gear Oil Definition Tables............................................. 744
16.5.11.7 Hydraulic oil temperature charts........................................................... 744
16.5.11.8 PTO gear oil temperature charts............................................................ 744
16.5.11.9 Other Settings 2/2, screen 6/12............................................................ 745
16.5.11.10 Messages ON/OFF........................................................................... 746
16.5.11.11 PLC-evaluation ON/OFF..................................................................... 747
16.5.11.12 Shutdown Bypass ON/OFF.................................................................... 748
16.6 Interface Connection KOMTRAX Plus controller & MTC...................................................... 752
16.6.1 KOMTRAX Plus controller........................................................................... 753
16.7 Wiring of KOMTRAX Plus controller....................................................................... 754
16.8 7-segment error code indication......................................................................... 757
16.9 MTC control system - global layout...................................................................... 758
16.9.1 MTC (Master Turbo Controller)..................................................................... 760
16.9.1.1 MTC flowchart............................................................................... 760
16.9.1.2 MTC features................................................................................ 760
16.9.1.3 MTC firmware and software................................................................... 761
16.9.1.4 CONNECTOR AND COMPONENT LOCATION IN THE CONTROL SYSTEM...................................... 761
16.9.1.5 View onto the MTC unit and its connectors................................................... 762
16.10 Global layout of the internal CAN BUS.................................................................. 764
16.10.1 General information on a CAN BUS system.......................................................... 764
16.10.1.1 General CAN BUS description................................................................ 765
16.10.1.2 CAN BUS troubleshooting.................................................................... 765
16.10.1.3 CAN BUS wiring............................................................................. 766
16.10.1.4 CAN BUS end resistor....................................................................... 768
16.11 The nodes in the CAN BUS system........................................................................ 770
16.11.1 Global layout.................................................................................... 770
16.11.2 Introduction..................................................................................... 772
16.11.2.1 ICN-V features............................................................................. 772
16.11.2.2 View onto an open ICN-V node with DIP switches & status LED................................ 774
16.11.2.3 General information on the LED control..................................................... 775
16.11.2.4 ICN-D features............................................................................. 776
16.11.2.5 View onto an ICN-D node without wiring..................................................... 777
16.11.2.6 View onto the Status LEDs at the ICN-D node................................................ 778
16.11.2.7 General information on the LED control..................................................... 779
16.11.3 Node DIP-switches................................................................................ 780
16.11.3.1 Detailed view onto the DIP switches........................................................ 781
16.11.4 Node box......................................................................................... 782
16.11.5 Node locations on the excavator.................................................................. 784
16.11.5.1 Node & location chart...................................................................... 785
16.11.5.2 View onto location 11 (cab base)........................................................... 786
17 Lubrication system............................................................................................ 789
17.1 General overview (SLS & CLS 1 / 2)...................................................................... 790
17.1.1 General description............................................................................... 791
17.2 Basic function of lubrication systems................................................................... 792
17.3 Lubrication systems (SLS & CLS1/2)...................................................................... 794
17.3.1 Lubrication pump station.......................................................................... 796
17.3.2 General Information on CLS1/2..................................................................... 798
17.3.3 General information on SLS........................................................................ 798
17.3.4 Manual lube activation............................................................................ 798
17.4 Lubrication cycle....................................................................................... 799
17.4.1 Operation and control............................................................................. 799
17.4.2 Lubrication cycle – processing.................................................................... 800
17.4.3 Time segments & switch points of a lubrication cycle.............................................. 801
17.4.4 Lubrication modes................................................................................. 802
17.4.4.1 Automatic lubrication mode.................................................................. 802
17.4.4.2 Manual lubrication mode..................................................................... 802
17.4.4.3 Reduced pause time for service.............................................................. 802
17.5 Hydraulically driven lube pump.......................................................................... 804
17.5.1 Adjustment of lube pump speed..................................................................... 806
17.5.1.1 Stroke speed adjustment..................................................................... 807
17.5.1.2 Working pressure............................................................................ 807
17.6 Lubricant injectors..................................................................................... 808
17.6.1 Tightening torques for fittings at grease injectors............................................... 809
17.6.2 Description....................................................................................... 809
17.6.3 Adjustment of the lubricant output................................................................ 810
17.6.4 Operation principle of lubricant injectors........................................................ 812
17.6.4.1 Function description........................................................................ 813
17.6.5 Connection of two or more injectors............................................................... 814
17.7 Vent valve & grease outlet filter....................................................................... 816
17.7.1 Vent valve description............................................................................ 817
17.8 End-line switch......................................................................................... 818
17.8.1 Description....................................................................................... 819
17.8.2 CLS1/2 end-line switch adjustment................................................................. 820
17.8.3 SLS end-line switch adjustment.................................................................... 822
17.9 Lubricant level sensors................................................................................. 824
17.9.1 Description....................................................................................... 825
17.9.2 Checks............................................................................................ 825
17.10 Commissioning.......................................................................................... 826
17.10.1 Commissioning of CLS 1/2 lubrication system...................................................... 826
17.10.2 Fine adjustment.................................................................................. 827
17.10.3 Commissioning of SLS lubrication system.......................................................... 828
18 Deep temperature equipment (option)........................................................................... 831
18.1 General information..................................................................................... 832
18.1.1 Introduction...................................................................................... 832
18.1.2 Deep temperature components overview.............................................................. 832
18.1.3 Power supply preconditions for preheating......................................................... 833
18.1.4 Power requirements for preheating systems......................................................... 834
18.2 Preheating procedure.................................................................................... 835
18.2.1 Global flow chart of the preheating procedure..................................................... 835
18.2.2 Starting the preheating procedure................................................................. 836
18.2.3 Preheating of operator’s cab and Diesel engine [coolant system]................................... 837
18.2.4 Preheating of lubricants and superstructure (Diesel) [electric system]............................ 838
18.3 Constant heating of travel motors (TTT equipment below-40°C only)....................................... 839
18.4 Component location...................................................................................... 840
18.4.1 Electric heating elements for hydraulic & batteries [electric excavator].......................... 840
18.4.2 Electric heating elements for hydraulics [Diesel excavator]....................................... 842
18.4.3 Electric heating elements for engines & batteries [Diesel excavator].............................. 844
18.5 Components of TT equipment.............................................................................. 846
18.5.1 Preheating components on a Diesel excavator....................................................... 846
18.5.2 Preheating components on an electric excavator.................................................... 847
18.5.3 Example Wiring Diagrams for preheating systems.................................................... 848
18.5.3.1 Wiring diagram "Hydraulic Oil Tank Preheating" part 1 of 3.................................. 848
18.5.3.2 Wiring diagram "Hydraulic Oil Tank Preheating" part 2 of 3.................................. 849
18.5.3.3 Wiring diagram "Hydraulic Oil Tank Preheating" part 3 of 3.................................. 850
18.5.3.4 Wiring diagram "Suction Oil Manifold Preheating"............................................ 851
18.5.3.5 Wiring diagram "PTO Preheating"............................................................. 852
18.5.3.6 Wiring diagram "Battery heater pads"........................................................ 853
19 Cable guide & Cable drum...................................................................................... 855
19.1 General layout of the cable guide....................................................................... 856
19.1.1 Safety............................................................................................ 857
19.2 General layout of the cable drum........................................................................ 858
19.2.1 Safety............................................................................................ 860
19.3 Service switch.......................................................................................... 862
19.4 Drive system............................................................................................ 864
19.4.1 Drive motor....................................................................................... 866
19.4.2 Connecting the drive motor........................................................................ 868
19.4.3 Drive motor resistor.............................................................................. 868
19.4.4 Drive torque regulation........................................................................... 868
19.4.5 Cable strain...................................................................................... 869
19.4.6 Chain lubrication & chain tension................................................................. 870
19.5 Drum Body............................................................................................... 872
19.5.1 Slip ring assembly................................................................................ 873
19.5.2 Carbon graphite brushes........................................................................... 873
19.5.3 Location of dryer and heater units in the drum body............................................... 874
19.5.4 Dryer system...................................................................................... 875
19.6 High voltage interlock system........................................................................... 876
19.7 Switch boxes for the cable drum......................................................................... 878
19.7.1 Install and connect the cable..................................................................... 880
19.7.2 Winding up the cable.............................................................................. 882
19.8 Cable guide drive mechanism............................................................................. 884
19.8.1 Proximity switches on the cable guide drive mechanism............................................. 886
19.8.2 Cable deflection & drum full/empty control........................................................ 888
19.8.2.1 Monitoring the drum min/max winding status.................................................. 890
19.8.3 Checks and adjustments............................................................................ 892
19.9 Travel motion control................................................................................... 894
19.9.1 Ground contact control............................................................................ 895
19.10 Overview on switches & control elements on the cable drum.............................................. 896
19.11 Slew angle monitoring & Attention message.............................................................. 898
19.12 Commissioning cable drum............................................................................... 900
19.12.1 Cable drum configuration for the MTC (CoDeSys)................................................... 902
19.12.2 Lubricate drum drive side bearing with grease.................................................... 904
19.12.3 Tool set for manual motor rotation............................................................... 904
19.12.4 Cable drum maintenance........................................................................... 904
19.13 Excavator relocation................................................................................... 905
40 TROUBLESHOOTING................................................................................................... 907
TOC.............................................................................................................. 909
1 Introduction................................................................................................... 925
1.1 Overview................................................................................................. 926
1.1.1 General advice when using troubleshooting charts................................................... 926
1.2 General Precautions...................................................................................... 927
2 General Information for Troubleshooting........................................................................ 929
2.1 Preparation For Work..................................................................................... 930
2.2 Precautions During Work.................................................................................. 930
2.3 Precautions When Carrying Out Any Operation.............................................................. 931
2.3.1 Precautions when carrying out removal work......................................................... 931
2.3.2 Precautions when carrying out installation work.................................................... 931
2.3.3 Precautions when completing the operation.......................................................... 932
2.4 Fundamental Requirements for Trouble shooting............................................................ 933
2.4.1 Technical documentation............................................................................ 933
2.4.2 Tools.............................................................................................. 933
2.4.2.1 Reference Guide for Deutsch Removal Tools.................................................... 937
2.4.3 Personnel.......................................................................................... 938
2.5 Points To Remember When Trouble Shooting................................................................. 938
2.6 Sequence Of Events In Troubleshooting.................................................................... 940
2.7 Checks Before Troubleshooting............................................................................ 941
2.8 Handling Of Electric Equipment And Hydraulic Components.................................................. 942
2.8.1 Points to remember when handling electric equipment................................................ 942
2.8.2 Points To Remember When Handling Hydraulic Equipment............................................... 945
2.9 General working procedures............................................................................... 947
2.9.1 Air Bleeding of Various Hydraulic Parts............................................................ 947
2.9.2 Air bleeding from hydraulic pumps.................................................................. 947
2.9.3 Air bleeding from hydraulic cylinders.............................................................. 947
2.10 Cylinder bypass test.................................................................................... 948
2.11 Basics about "How to crimp" (with strain relief)........................................................ 949
2.11.1 Crimp tool & repair kit........................................................................... 949
2.11.2 General........................................................................................... 950
2.11.3 Select the required connector components.......................................................... 950
2.11.4 Stripping a wire.................................................................................. 951
2.11.5 Crimping.......................................................................................... 952
2.11.6 Connector assembly after crimping................................................................. 953
2.12 Cable Shielding......................................................................................... 954
3 Mounting Locations and Connector Types......................................................................... 955
3.1 General layout........................................................................................... 956
3.2 Superstructure - side view............................................................................... 958
3.3 Superstructure - top view................................................................................ 960
3.4 Machinery house.......................................................................................... 962
3.5 Slip ring unit & Rotary joint............................................................................ 964
3.5.1 Slip Ring Unit in Detail........................................................................... 966
3.6 Capacitors............................................................................................... 968
3.7 High Voltage Switch Cabinet - View 1..................................................................... 970
3.7.1 High Voltage Switch Cabinet - View 2............................................................... 972
3.8 Cab Support.............................................................................................. 974
3.8.1 X2 board - ELV switch board - location 11.......................................................... 976
3.8.2 Low voltage switch board (location 12)............................................................. 978
3.9 Arrangement of the Slew Angle Sensor..................................................................... 980
3.9.1 Slew Angle Sensor 60B059 in the Wiring Diagram..................................................... 981
3.10 Location of hydraulic components........................................................................ 982
3.10.1 Location of main control blocks................................................................... 982
3.11 Control & filter panels - location of components........................................................ 984
3.12 Main valve cartridge block.............................................................................. 986
3.13 Arrangement of Remote Control Valves.................................................................... 988
3.14 Location of Suction Oil tank with strainers............................................................. 990
3.15 Hydraulic Oil Tank - Location of the Electrical Components.............................................. 992
3.16 General overview on SLS & CLS1/2........................................................................ 994
3.17 Batteries, Battery Main Switches & Safety Switch for Maintenance........................................ 996
3.18 Hydraulically operated access stairway.................................................................. 998
3.19 Service arm.............................................................................................1000
3.20 Connector Types Overview................................................................................1002
3.20.1 Connector (10-pole) for ICN-D nodes (Phoenix Contact).............................................1006
3.20.2 Connector for ICN-V nodes (55 pins)...............................................................1007
4 Standard Value Table for Electrical Components.................................................................1009
5 References for Troubleshooting (CAN Bus & Node Outputs)........................................................1021
5.1 CAN Bus Trouble or Node Output Trouble...................................................................1022
5.1.1 Trouble CAN BUS or CAN Hardware (G00308)...........................................................1023
5.1.2 Trouble output short circuit (G00043)..............................................................1024
5.2 Sequence of CAN nodes in the CAN BUS.....................................................................1026
5.3 Troubleshooting for Relay Monitored Node Outputs.........................................................1027
5.3.1 Relay Check........................................................................................1027
G00107 - Trouble slew parking brake control 56K250a..........................................................1028
Example view onto CoDeSys visualization screen for message G00107........................................1030
Wiring Diagram (56K250a & 56K250b) for message G00107....................................................1031
5.3.2 Output Check.......................................................................................1032
G00108 - Trouble slew parking brake control Output to 56K250a................................................1033
View onto CoDeSys Visualization screen for message G00108................................................1035
Wiring Diagram (56K250a & 56K250b) for message G00108....................................................1036
6 Tables for Testing and Troubleshooting.........................................................................1037
6.1 Test Value Table for Temperature Sensors (PT100) g Centigrade - Volt.....................................1038
6.2 Test Value Table for Temperature Sensors (PT100) g Centigrade - Ohm......................................1039
6.3 Test value tables for transducers........................................................................1040
6.3.1 Pump press. transducers............................................................................1040
6.3.2 Hydraulic oil pressure transducers.................................................................1041
6.3.3 Miscellaneous pressure transducers.................................................................1042
6.3.4 Temperature transducers............................................................................1043
6.4 Hydraulic oil temperature charts.........................................................................1044
6.5 PTO gear oil temperature charts..........................................................................1044
6.6 Table of trouble codes (G-codes).........................................................................1045
6.6.1 Table of Error Codes & Messages....................................................................1046
6.6.2 Monitoring codes without readout...................................................................1053
6.7 Table of Instruction Messages............................................................................1054
6.8 Table of Binary Codes....................................................................................1057
6.8.1 Table of Add-On Binary Codes for G00308............................................................1062
6.9 Tables of Symptom Codes..................................................................................1063
6.9.1 Symptoms of E-Motors and Related parts.............................................................1063
6.9.2 Symptoms of Hydraulic System.......................................................................1063
6.9.3 Symptoms Mechanical System.........................................................................1064
6.9.4 SYMPTOMS OF ADDITIONAL SYSTEMS.....................................................................1064
6.10 Power Supply............................................................................................1064
6.11 Cable colour identification.............................................................................1065
7 Troubleshooting by Trouble Code................................................................................1067
G00001 - Trouble Shut-Off (gate) valve.......................................................................1068
View onto the gap of proximity switch 40B031.............................................................1070
Input signal of proximity switch 40B031 on REAL TIME MONITOR.............................................1071
View onto setting for SHUTDOWN BYPASS on K+ monitor......................................................1071
Wiring Diagram (40B031) for message G00001 (Trouble Shut-Off (gate) valve)...............................1072
G00003 - Trouble pump controller.............................................................................1073
G00005 - Low hydraulic oil level.............................................................................1082
Wiring Diagram, oil level label, and defined position of the attachment (G00005).........................1084
G00007 - Trouble hydraulic oil level.........................................................................1085
Hydraulic oil level at defined position of the attachment................................................1086
Wiring Diagram for 40B004 (message G00007)...............................................................1087
G00012 - Central lubrication system grease level too low.....................................................1088
G00013 - Slew ring gear lubr. system grease level too low....................................................1088
Wiring Diagram - grease level sensors 62B108b & 62B109b for G00012 & G00013..............................1091
Wiring Diagram - junction box for G00012 & G00013........................................................1092
G00020 - Trouble Shut-Off (gate) valve (Start blocked).......................................................1093
View onto the gap of proximity switch 40B031 (G00020)....................................................1095
Wiring Diagram (40B031) for message G00020 (Main gate valve closed)......................................1096
Input signal (analog) of proximity switch 40B031 on REAL TIME MONITOR....................................1097
View onto setting for SHUTDOWN BYPASS on KOMTRAX Plus monitor............................................1097
G00033 - Trouble KOMTRAX Plus controller.....................................................................1098
G00034 - Trouble KOMTRAX Plus display........................................................................1099
G00035 - Trouble totally loss gear oil (PTO 1)...............................................................1100
G00036 - Trouble totally loss gear oil (PTO 2)...............................................................1100
Location of sensor 57B175-1/-2 at PTO-1/-2 (G00035 & G00036).............................................1102
Input signal (analog) of gear oil sensor 57B175-1/-2 on REAL TIME MONITOR................................1103
View onto setting for SHUTDOWN BYPASS on K+ monitor......................................................1103
Example Wiring Diagram (57B175-1/-2) for messages G00035 & G00036........................................1104
G00040 - Emergency shut-down pump compartment................................................................1105
Wiring Diagram - emergency circuit.......................................................................1107
G00041 - Emergency shut-down pump compartment................................................................1108
Wiring Diagram - emergency circuit.......................................................................1110
G00043 - Trouble output short-circuit........................................................................1111
G00046 - Reverse travel cut out bypassed by horn.............................................................1112
G00047 - Travel cut out by cable drum........................................................................1113
Temperature sensor 91B979 & module 95B980 for message G00047.............................................1114
Cable drum temperature on REAL TIME MONITOR..............................................................1115
G00048 - Trouble emergency safety circuit....................................................................1116
Wiring Diagram - 11K044a (G00048)........................................................................1117
G00049 - Trouble cab heating 1...............................................................................1118
Wiring Diagram - cab heater 1 - location 20 - below operator’s seat......................................1119
Wiring Diagram for cab heater 1 - location 12 (LV board) - overheating protection control................1120
Wiring Diagram - cab heater 1 - location 12 - blower control & after-run.................................1121
Wiring Diagram - cab heater 1 - location 12 - 3 step heater regulation...................................1122
G00050 - Trouble cab heating 2...............................................................................1123
G00051 - Trouble cab heating 1...............................................................................1124
G00052 - Trouble cab heating 2...............................................................................1124
View onto heater air inlet & outlet grids in operator’s cab..............................................1125
Wiring Diagram - cab heater 1 (example)..................................................................1126
G00053 - Reset emergency safety circuit......................................................................1127
G00054 - Monitoring idle position cut off....................................................................1128
Wiring Diagram (11K032) for message G00054...............................................................1129
Input signal (analog) of relay 11K032 on REAL TIME MONITOR (G00054)......................................1130
Example view onto KOMTRAX Plus Failure History (G00054)..................................................1130
G00055 - Trouble monitoring cable drum motor temperature.....................................................1132
Wiring Diagram (91B979 & 95B980) for message G00055......................................................1133
G00059 - Fire in the switch cabinet..........................................................................1134
Wiring Diagram for fire suppression system...............................................................1135
G00060 - Fire in the power house.............................................................................1136
Wiring Diagram for fire warning system...................................................................1137
G00063 - Trouble monitoring hydraulic oil temp...............................................................1138
REAL TIME MONITOR and Wiring Diagram (59B015) for message G00063.........................................1139
G00064 - Trouble monitoring hydraulic oil level..............................................................1140
Real Time Monitor and Wiring Diagram (40B004) for message G00064.........................................1142
G00065 - Very low hydraulic oil level........................................................................1143
View onto the hydraulic oil level label..................................................................1143
G00066 - Trouble hydraulic oil temperature...................................................................1144
Principle of hydraulic oil cooling.......................................................................1146
G00067 - Trouble battery voltage too high....................................................................1147
Wiring Diagram (11T080) and component location at the X2 board...........................................1148
Wiring Diagram (13T002 & 13T004) for message G00067......................................................1149
Input signal of 11T080 on REAL TIME MONITOR for message G00067...........................................1149
G00068 - Trouble gear lubrication (PTO 2)....................................................................1149
G00069 - Trouble monitoring oil temperature gear (PTO 1).....................................................1150
Input signal of 57B049-1 on REAL TIME MONITOR (G00069)...................................................1151
Gear oil temperature (PTO 1 & PTO 2) on Main Gauge Screen................................................1151
Wiring Diagram (57B049-1 & 57B049-2) and component location (G00069 & G00083)............................1152
G00070 - Trouble oil temperature gear (PTO 1)................................................................1153
Location of PTO gear oil level dipstick & temperature sensor 57B049-1/-2.................................1155
G00071 - Trouble gear lubrication (PTO 1)....................................................................1156
Real Time Monitor & Wiring Diagram (57B017-1/-2) for messages G00071 & G00068............................1157
G00072 - Trouble monitoring hydraulic oil level..............................................................1158
REAL TIME MONITOR and Wiring Diagram (40B105) for G00072.................................................1159
G00076 - Trouble monitoring pressure suction tank............................................................1160
REAL TIME MONITOR and Wiring Diagram (59B162) for G00076.................................................1161
G00079 - Trouble monitoring pressure oil cooler 1............................................................1162
REAL TIME MONITOR and Wiring Diagram (40B165) for G00079.................................................1163
G00080 - Trouble monitoring pressure pre-load valve..........................................................1164
REAL TIME MONITOR and Wiring Diagram (40B166) for G00080.................................................1165
G00081 - Trouble lubrication system..........................................................................1166
Operation cycles of the lubrication systems..............................................................1168
Wiring Diagram (11K050) for message G00081...............................................................1169
G00083 - Trouble monitoring oil temperature gear (PTO 2).....................................................1169
G00084 - Trouble oil temperature gear (PTO 2)................................................................1169
G00086 - SHUTDOWN............................................................................................1170
G00090 - Trouble power supply................................................................................1172
REAL TIME MONITOR and Wiring Diagram for G00090 & G00099.................................................1173
G00091 - Pilot control cut out...............................................................................1174
G00092 - Emergency shut-down at access ladder................................................................1175
G00093 - Emergency shut-down at valve block..................................................................1175
G00095 - Emergency shut-down in cabin........................................................................1175
G00096 - Pilot control cut out...............................................................................1176
REAL TIME MONITOR and Wiring Diagram (20S094) for message G00096.........................................1177
G00097 - Emergency shut-down at counterweight................................................................1177
G00099 - Trouble power supply................................................................................1177
G00100 - Maintenance Safety Switch...........................................................................1178
Wiring Diagram (50S058) for message G00100...............................................................1179
G00103 - Faulty switch 20M004................................................................................1180
Wiring Diagram 1 (windscreen wiper) for message G00103...................................................1182
G00107 - Trouble slew parking brake control 56K250a..........................................................1184
View onto CoDeSys visualization screen for message G00107................................................1186
Wiring Diagram (56K250a & 56K250b) for message G00107....................................................1187
G00108 - Trouble slew parking brake control Output to 56K250a................................................1188
View onto CoDeSys Visualization screen for message G00108................................................1190
Wiring Diagram (56K250a & 56K250b) for message G00108....................................................1191
G00109 - Trouble slew parking brake control 56K250b..........................................................1192
G00110 - Trouble slew parking brake control Output to 56K250b................................................1192
G00111 - Trouble travel parking brake control 56K251a........................................................1192
56K251a & 56K251b (relay check) on REAL TIME MONITOR (G00111 & G00113)...................................1192
G00112 - Trouble travel parking brake control Output to 56K251a..............................................1193
56K251a & 56K251b (output check) on REAL TIME MONITOR (G00112 & G00114)..................................1193
G00113 - Trouble travel parking brake control 56K251b........................................................1194
G00114 - Trouble travel parking brake control Output to 56K251b..............................................1194
G00115 - Trouble slew hydraulic brake control 56K252a........................................................1194
56K252a & 56K252b (relay check) on REAL TIME MONITOR (G00115 & G00117)...................................1194
G00116 - Trouble slew hydraulic brake control Output to 56K252a..............................................1195
56K252a & 56K252b (output check) on REAL TIME MONITOR (G00116 & G00118)..................................1195
G00117 - Trouble slew hydraulic brake control 56K252b........................................................1195
G00118 - Trouble slew hydraulic brake control Output to 56K252b..............................................1195
G00119 - Trouble cable drum wind up control 95K257a..........................................................1196
95K257a & 95K257b (relay check) on REAL TIME MONITOR (G00119 & G00121)...................................1196
G00120 - Trouble cable drum wind up control Output to 95K257a................................................1197
95K257a & 95K257b (output check) on REAL TIME MONITOR (G00120 & G00122)..................................1197
G00121 - Trouble cable drum wind up control 91K257b..........................................................1197
G00122 - Trouble cable drum wind up control Output to 91K257b................................................1197
G00123 - Trouble cable drum unwind control 95K258a...........................................................1198
95K258a & 95K258b (relay check) on REAL TIME MONITOR (G00123 & G00125)...................................1198
G00124 - Trouble cable drum wind up control Output to 95K258a................................................1199
95K258a & 95K258b (output check) on REAL TIME MONITOR (G00124 & G00126)..................................1199
G00125 - Trouble cable drum unwind control 91K258b...........................................................1199
G00126 - Trouble cable drum wind up control Output to 91K258b................................................1199
G00127 - Trouble cable drum torque control 95K259a...........................................................1200
95K259a & 95K259b (relay check) on REAL TIME MONITOR (G00127 & G00129)...................................1200
G00128 - Trouble cable drum torque control Output to 95K259a.................................................1201
95K259a & 95K259b (output check) on REAL TIME MONITOR (G00128 & G00130)..................................1201
G00129 - Trouble cable drum torque control 95K259b...........................................................1201
G00130 - Trouble cable drum torque control Output to 95K259b.................................................1201
G00139 - Trouble monitoring X1-2 pressure....................................................................1202
G00140 - Trouble monitoring X1-1 pressure....................................................................1202
Wiring Diagram (57B085-1 & 57B085-2) for messages G00139 & G00140........................................1204
G00141 - Trouble monitoring X2 pressure......................................................................1205
Wiring Diagram (57B086) for message G00141...............................................................1207
G00143 - Trouble monitoring 61B087a..........................................................................1208
G00144 - Trouble monitoring 61B087b..........................................................................1208
G00145 - Trouble monitoring 61B087c..........................................................................1208
G00146 - Trouble monitoring 61B087d..........................................................................1208
Wiring Diagram (61B087a...d) for message G00143...146....................................................1210
G00147 - Trouble monitoring gear lubrication (PTO 1).........................................................1212
G00150 - Trouble monitoring gear lubrication (PTO 2).........................................................1212
Wiring Diagram (57B017-1 & 57B017-2) for messages G00147 & G00150........................................1215
G00149 - Trouble monitoring ambient temperature..............................................................1216
REAL TIME MONITOR and Wiring Diagram (13B090) for G00149.................................................1217
G00150 - Trouble monitoring gear lubrication (PTO 2).........................................................1217
G00151 - Trouble monitoring gear (PTO) oil filter 1..........................................................1218
Wiring Diagram (57B027-1/-2) for messages G00151 & G00193................................................1221
G00154 - Trouble monitoring return oil filter................................................................1222
Wiring Diagram (40B163) for message G00154...............................................................1224
G00155 - Trouble monitoring leak oil filter..................................................................1225
Wiring Diagram (40B164) for message G00155...............................................................1227
G00159 - Trouble monitoring breather filter..................................................................1228
Wiring Diagram (40B024) for message G00159...............................................................1230
G00161 - Trouble monitoring battery voltage..................................................................1231
Wiring Diagram (11T080) and component location for message G00161........................................1233
G00165 - Trouble breather filter hydraulic oil tank..........................................................1234
Sight glass, hydraulic oil temperature information, and defined positions (G00165).......................1235
G00166 - Trouble oil filter gear (PTO 1).....................................................................1236
Location of PTO 1/2 gear oil filters with pressure sensors 57B027-1 & 57B027-2...........................1237
G00169 - Trouble return oil filter hydraulic oil tank........................................................1238
G00170 - Trouble leak oil filter hydraulic oil tank..........................................................1239
G00176 - Trouble battery voltage too low.....................................................................1240
Input signal of 11T080 on REAL TIME MONITOR for message G00176...........................................1241
Wiring Diagram (11T080) and component location at X2 board...............................................1242
Wiring Diagram (13T002 & 13T004) for message G00176......................................................1243
G00179 - Trouble control pressure X1-1.......................................................................1244
View onto the valve cartridge block for X1 pressure adjustment...........................................1245
G00180 - Trouble pilot pressure X2 too low...................................................................1246
Valve cartridge block with X2 pressure sensor 57B086 & M1.2..............................................1247
G00181 - Trouble pilot pressure X2 too high..................................................................1248
Control and filter panel 1 with X2 pressure sensor 57B086 & M1.2.........................................1249
G00182 - Trouble control pressure X1-2.......................................................................1249
G00184 - Central lubrication system empty....................................................................1250
G00185 - Trouble central lubrication system..................................................................1252
Allocation of vent valves and end-of-line switches.......................................................1253
Action chart for lube cycles.............................................................................1254
View onto the vent valve (62Q507a - 62Q509a - 62Q642a)...................................................1255
(Wiring Diagram (60B043/62B046/80B043) for messages G00185/G00188/G00203.................................1256
G00186 - Trouble central lubrication system..................................................................1257
Allocation of vent valves................................................................................1257
Action chart for lube cycles.............................................................................1258
View onto vent valve (62Q507a - 62Q509a - 62Q642a).......................................................1259
G00187 - Slew ring gear lubrication system empty.............................................................1260
G00188 - Trouble slew ring gear lubrication system...........................................................1260
G00189 - Trouble slew ring gear lubrication system...........................................................1260
G00191 - Trouble oil filter gear (PTO 2).....................................................................1260
G00193 - Trouble monitoring gear (PTO) oil filter 2..........................................................1260
G00203 - Trouble attachment lubrication system...............................................................1260
G00204 - Trouble attachment lubrication system...............................................................1260
G00210 - Trouble electric motor 1 winding temperature........................................................1261
G00211 - Trouble electric motor 2 winding temperature........................................................1261
Wiring Diagram - motor winding temp. motor 1 for G00210..................................................1262
Monitoring winding temperature on REAL TIME MONITOR......................................................1262
G00212 - Trouble electric motor 1 bearing temperature........................................................1263
G00213 - Trouble electric motor 2 bearing temperature........................................................1263
Motor 1 bearing temperature on REAL TIME MONITOR.........................................................1264
Wiring Diagram - motor 1 bearing temperature - for G00212................................................1265
G00214 - Trouble transformer 1 temperature...................................................................1266
G00215 - Trouble transformer 2 temperature...................................................................1266
Net-line voltage & transformer temperature on REAL TIME MONITOR..........................................1266
Wiring Diagram (temperature control for transformer A), message G00214...................................1267
G00216 - Trouble software not compatible.....................................................................1268
G00218 - Switch off all motors for running transfer pump.....................................................1269
G00219 - Return oil tank empty...............................................................................1270
Sensor 40B068 (return oil level) on REAL TIME MONITOR....................................................1270
G00220 - Trouble transfer pump motor overheated..............................................................1271
Wiring Diagram (transfer pump) for message G00220........................................................1272
G00231 - Trouble pilot control lever 20S019..................................................................1273
G00232 - Trouble pilot control lever 20S020..................................................................1273
Wiring Diagram (20S019) for message G00231...............................................................1274
Wiring Diagram (20S020) for message G00232...............................................................1275
G00233 - Trouble pilot control 11Q045........................................................................1276
Electronic power relay 11Q045 on REAL TIME MONITOR.......................................................1276
Wiring Diagram (11Q045) for message G00233...............................................................1277
G00234 - Trouble pilot control 11K111a.......................................................................1278
11K111a & 11K111b (relay check) on REAL TIME MONITOR (G00234 & G00236)...................................1278
G00235 - Trouble pilot control Output to 11K111a.............................................................1279
11K111a & 11K111b (output check) on REAL TIME MONITOR (G00235 & G00237)..................................1279
G00236 - Trouble pilot control 11K111b.......................................................................1279
G00237 - Trouble pilot control Output to 11K111b.............................................................1279
G00238 - Trouble supply by key switch 11Q044.................................................................1280
Input signal of 11Q044 on REAL TIME MONITOR (G00238).....................................................1280
G00239 - Trouble electrical matter...........................................................................1282
Wiring Diagram - signal line 10K352......................................................................1283
G00240 - Trouble hydraulic oil temperature...................................................................1284
G00241 - Motor 1 already running.............................................................................1285
G00246 - Hydraulic oil temperature...........................................................................1285
G00250 - Electric motor 2 already running....................................................................1286
G00252 - Emergency shut-down at access ladder................................................................1286
G00253 - Emergency shut-down at valve block..................................................................1286
G00255 - Emergency shut-down in cabin........................................................................1286
G00256 - Operator warning system.............................................................................1287
Pull switch signals on REAL TIME MONITOR.................................................................1287
G00257 - Hydraulic oil temperature...........................................................................1288
G00258 - Emergency shut-down at counterweight................................................................1288
G00261 - Maintenance Safety Switch...........................................................................1289
G00262 - Trouble screen at hydr. cooler entry clogged........................................................1290
40B166 and 40B165 on REAL TIME MONITOR...................................................................1290
Location of 40B166 and 40B165 at the hydraulic oil tank (G00262).........................................1291
G00263 - Trouble monitoring motor 1 bearing temperature......................................................1292
G00264 - Trouble monitoring motor 2 bearing temperature......................................................1292
View onto the terminal box at motor side.................................................................1293
Wiring Diagram - motor 1 bearing temperature - for G00263................................................1294
G00265 - Trouble monitoring emergency voltage................................................................1295
REAL TIME MONITOR and Wiring Diagram for 12T082..........................................................1297
G00266 - Trouble emergency voltage too high..................................................................1298
Wiring Diagram - 13T003 - for message G00266.............................................................1299
G00267 - Trouble emergency voltage too low...................................................................1300
G00270 - Trouble monitoring motor 1 current..................................................................1302
G00271 - Trouble monitoring motor 2 current..................................................................1302
Wiring Diagram for 12T431................................................................................1304
G00272 - Trouble monitoring high voltage.....................................................................1305
Wiring Diagram for 12T431................................................................................1307
G00274 - Trouble monitoring motor 1 winding temperature......................................................1308
G00276 - Trouble monitoring motor 2 winding temperature......................................................1308
View onto terminal box at motor side.....................................................................1309
Wiring Diagram - monitoring motor 1 winding temp. - for G00274...........................................1310
G00277 - Trouble high voltage capacitor 1....................................................................1312
REAL TIME MONITOR and Wiring Diagram - capacitor pressure monitoring.....................................1313
G00278 - Earth fault tripped.................................................................................1314
G00281 - Ground leakage tripped..............................................................................1316
Wiring Diagram (12F431) for message G00281 (example).....................................................1317
G00283 - Trouble monitoring motor 1 power....................................................................1318
G00284 - Trouble monitoring motor 2 power....................................................................1318
Extract from User Instruction 12P004-1/-2................................................................1319
View onto 12P004-1/-2....................................................................................1320
Wiring Diagram (12P004-1)................................................................................1321
G00285 - Trouble motor 1.....................................................................................1322
G00286 - Trouble motor 2.....................................................................................1322
Wiring Diagram - motor protection relays & node inputs - for message G00285/286..........................1323
Wiring Diagram - motor protection relay motor 1..........................................................1324
G00287 - Trouble 3 phase current rotation direction..........................................................1325
Phase sequence relay monitoring & Wiring Diagram for message G00287......................................1326
G00288 - Trouble restart motor 1, temperature too high.......................................................1327
G00289 - Trouble restart motor 2, temperature too high.......................................................1327
G00290 - Trouble motor main relay 1..........................................................................1328
REAL TIME MONITOR & Wiring Diagram - 32Q701-1 & 32Q701-2.................................................1329
Wiring Diagram - 32Q701-1/-2 and connection to 12K408-1/-2...............................................1330
G00291 - Reverse travel cut out by cable drum................................................................1332
Wiring Diagram - 91B904a, 91B911, 91B919 for message G00291..............................................1333
G00292 - Reverse travel left track cut out by cable drum.....................................................1334
G00293 - Reverse travel right track cut out by cable drum....................................................1334
Wiring Diagram - diagonal cable pull for messages G00292 & G00293........................................1335
G00294 - Forward travel cut out by cable drum................................................................1336
Wiring Diagram - 91B904b & 91B912...915 for message G00294...............................................1337
G00295 - Trouble temperature cab base........................................................................1338
Cab base temperature on REAL TIME MONITOR................................................................1338
Wiring Diagram - 12B001 for message G00295...............................................................1339
G00296 - Trouble temperature high voltage cabinet............................................................1340
HV-cabinet temperature on REAL TIME MONITOR..............................................................1340
Wiring Diagram - 32B802 for message G00296...............................................................1341
G00301 - Trouble high voltage supply was interrupted.........................................................1342
Motor voltage (12T431-3) on REAL TIME MONITOR............................................................1342
Wiring Diagram 12T431- HV monitoring at pin 16...........................................................1343
Wiring Diagram - HV monitoring continued.................................................................1344
G00303 - Trouble high voltage capacitor 2....................................................................1345
G00304 - Start Motor 1 blocked...............................................................................1345
G00305 - Start Motor 2 blocked...............................................................................1345
G00306 - Trouble motor main relay 2..........................................................................1346
G00307 - Attention ! Cable drum !............................................................................1346
G00308 - Trouble CAN-Bus or CAN-Hardware.....................................................................1347
G00309 - Trouble ladder up 56K253a...........................................................................1350
56K253a & 56K253b (relay check) on REAL TIME MONITOR.....................................................1350
G00310 - Trouble ladder up Output to 56K253a.................................................................1351
56K253a & 56K253b (output check) on REAL TIME MONITOR....................................................1351
G00311 - Trouble ladder up redundant 56K253b.................................................................1351
G00312 - Trouble ladder up redundant Output to 56K253b.......................................................1352
G00313 - Trouble ladder down 56K254a.........................................................................1352
56K254a & 56K254b (relay check) on REAL TIME MONITOR.....................................................1352
G00314 - Trouble ladder down Output to 56K254a...............................................................1353
56K254a & 56K254b (output check) on REAL TIME MONITOR....................................................1353
G00315 - Trouble ladder down redundant 56K254b...............................................................1353
G00316 - Trouble ladder down redundant Output to 56K254b.....................................................1354
G00317 - Trouble service arm up 56K255a......................................................................1354
56K255a & 56K255b (relay check) on REAL TIME MONITOR.....................................................1354
G00318 - Trouble service arm up Output to 56K255a............................................................1355
56K255a & 56K255b (output check) on REAL TIME MONITOR....................................................1355
G00319 - Trouble service arm up redundant 56K255b............................................................1355
G00320 - Trouble service arm up redundant Output to 56K255b..................................................1356
G00321 - Trouble service arm down 56K256a....................................................................1356
56K256a & 56K256b (relay check) on REAL TIME MONITOR.....................................................1356
G00322 - Trouble service arm down Output to 56K256a..........................................................1357
56K256a & 56K256b (output check) on REAL TIME MONITOR....................................................1357
G00323 - Trouble service arm down redundant 56K256b..........................................................1358
G00324 - Trouble service arm down redundant Output to 56K256.................................................1358
G00325 - Trouble service arm Input...........................................................................1359
G00326 - Trouble ladder Input................................................................................1359
G00327 - Trouble parking brake Input.........................................................................1359
G00328 - Trouble start Input.................................................................................1359
G00329 - Protection switch tripped...........................................................................1362
Additional protection switches on REAL TIME MONITOR (G00329).............................................1362
G00334 -Trouble cab heater contactor.........................................................................1363
Wiring Diagram for cab heating - 3 step heater regulation................................................1364
G00335 - Trouble cab heater safety relay.....................................................................1365
Wiring Diagram (heater safety relays) for message G00335.................................................1367
G00337 - Trouble motor on control 12K408a-1..................................................................1368
12K408a-1/-2 & 12K408b-1/-2 (relay check) on REAL TIME MONITOR...........................................1368
G00338 - Trouble motor on control Output to 12K408a-1........................................................1369
12K408a-1/-2 & 12K408b-1/-2 (output check) on REAL TIME MONITOR..........................................1369
G00339 - Trouble motor on control 12K408b-1..................................................................1370
G00340 - Trouble motor on control Output to 12K408b-1........................................................1370
G00341 - Trouble motor on control 12K408a-2..................................................................1370
G00342 - Trouble motor on control Output to 12K408a-2........................................................1370
G00343 - Trouble motor on control 12K408b-2..................................................................1370
G00344 - Trouble motor on control Output to 12K408b-2........................................................1370
G00345 - E-Motor 2 running...................................................................................1371
G00346 - E-Motor 2 standstill................................................................................1371
G00347 - E-Motor 1 running...................................................................................1372
G00348 - E-Motor 1 standstill................................................................................1372
G00354 - Emergency shut-down cable drum......................................................................1372
G00355 - Emergency shut-down cable drum......................................................................1372
G00417 - Communication failure PLC [MTC] <=> KOMTRAX Plus controller.........................................1373
G00420 - Connector sel error.................................................................................1374
G00421 - Farm sys error......................................................................................1375
G00425 - Settings impossible to take over into the PLC [MTC].................................................1376
Wiring Diagram overview: K+ monitor → K+ controller → MTC................................................1377
G00491 - Communication failure MH800 <=> KOMTRAX Plus controller.............................................1378
Wiring Diagram overview: MH801 ↔ K+ controller...........................................................1379
8 Troubleshooting by Symptoms....................................................................................1381
8.1 Symptoms of E-motors and related parts...................................................................1382
SEM001 - Starting E-motor(s) is not possible.............................................................1382
Wiring Diagram (main key switch & start buttons) for SEM001..........................................1383
SEM002 - Stopping E-motor(s) is not possible.............................................................1384
Wiring Diagram (motor stop switches) for SEM002......................................................1384
SEM003 - E-motor has excessive vibration.................................................................1386
View onto coupling for SEM003........................................................................1387
SEM004 - Abnormal noise coming from E-motor(s)...........................................................1388
SEM005 - E-motor lacks output (low power)................................................................1390
View onto PM CLINIC sheet (power check) for SEM005...................................................1391
SEM006 - Air-to-Air motor cooling system not sufficient..................................................1392
Example view onto Air-to-Air motor cooling system for SEM006.........................................1393
SEM007 - Motor shuts down during start...................................................................1394
Wiring Diagram - Motor protection relay 12F404-1/-2 for message SEM007...............................1395
Wiring Diagram - motor protection relay motor 1/2....................................................1396
SEM008 - Substation main circuit breaker tripped.........................................................1397
Net-line supply overview.............................................................................1398
Net-line supply overview.............................................................................1398
Motor current overview with soft start...............................................................1399
8.2 Symptoms of Hydraulic System.............................................................................1400
SHY001 - All work equipment shows lack of power or slow movement (especially "boom up" function).........1400
SHY002 - No work equipment, travel or slew movement......................................................1402
SHY003 - Work equipment has too much hydraulic drift.....................................................1403
SHY004 - Work equipment has big time lag.................................................................1404
SHY005 - Excavator deviates during travel movement.......................................................1405
SHY006 - Hydraulic system has lack of power (Energy Efficiency)..........................................1406
SHY007 - Excavator does not slew.........................................................................1408
Slew brake block (SHY007)............................................................................1409
SHY008 - Slew acceleration is poor.......................................................................1410
SHY009 - Excessive overrun when stopping slew movement...................................................1412
SHY010 - Floating system without function (FSA only).....................................................1414
SHY011 - Abnormal noise coming from SRV or MRV...........................................................1415
SHY012 - Track tensioning system without function........................................................1416
Track tensioning - overview (SHY012).................................................................1417
SHY013 - Stairway does not move, or slow movement........................................................1418
SHY014 - Refilling arm does not move, or slow movement...................................................1420
SHY015 - Hydraulic driven grease pump does not move......................................................1422
SHY016 - Trouble pump bearing lubrication................................................................1424
SHY017 - Abnormal track chain movement during digging....................................................1425
SHY018 - Slew parking brake without function.............................................................1426
SHY019 - Travel parking brake without function...........................................................1427
8.3 Symptoms of Mechanical System............................................................................1428
SME001 - Abnormal noise around PTOs / hydraulic pumps....................................................1428
SME002 - There is a big shock when stopping slew movement................................................1430
SME003 - There is a big abnormal noise when moving/stopping slew movement................................1432
SME004 - Abnormal noise coming from a travel gearbox.....................................................1434
SME005 - Abnormal noise coming from work equipment (lack of grease)......................................1436
SME006 - Abnormal idler movement.........................................................................1438
SME007 - Leak at PTO shaft seal..........................................................................1440
8.4 Symptoms of Additional Systems...........................................................................1442
SAD001 - Air conditioner for cabin does not work.........................................................1442
View onto A/C unit (SAD001)..........................................................................1443
SAD002 - Air conditioner LV cabinet does not work........................................................1444
SAD003 - Air conditioner HV cabinet does not work........................................................1444
View onto an A/C filling and service station.........................................................1445
SAD004 - CAN BUS failure (message G00308 displayed)......................................................1446
50 DISASSEMBLY & ASSEMBLY............................................................................................1453
TOC..............................................................................................................1455
1 Introduction...................................................................................................1463
1.1 Foreword.................................................................................................1464
1.2 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels.......1465
1.3 Diagrams and illustrations in this manual................................................................1465
1.4 Procedures for disassembling and assembling in this manual...............................................1466
2 Safety.........................................................................................................1467
2.1 Overview.................................................................................................1469
2.1.1 Method of using this manual........................................................................1469
2.2 General precautions......................................................................................1471
2.2.1 General............................................................................................1471
2.2.2 Personal protective clothing.......................................................................1471
2.2.3 When using a hammer................................................................................1472
2.2.4 Proper tools.......................................................................................1472
2.2.5 Personnel..........................................................................................1472
2.2.6 Fire prevention....................................................................................1473
2.2.7 Unauthorized modification..........................................................................1473
2.3 Precautions for maintenance and repair...................................................................1474
2.3.1 General precautions................................................................................1474
2.3.2 Keep work place clean and tidy.....................................................................1474
2.3.3 Precautions when welding...........................................................................1475
2.3.4 Precaution with high pressure fluids...............................................................1475
2.3.4.1 Handling high pressure hoses and pipes.......................................................1475
2.3.5 Compressed air.....................................................................................1475
2.3.6 Waste materials....................................................................................1476
2.4 Grounding procedure of the high voltage system...........................................................1477
2.4.1 Isolate the excavator using the transfer pump......................................................1481
2.4.2 Isolate the excavator..............................................................................1481
2.4.3 De-isolate the excavator...........................................................................1482
3 Superstructure.................................................................................................1483
3.1 Superstructure overview..................................................................................1484
3.2 Machinery house..........................................................................................1488
3.2.1 service crane (optional)...........................................................................1489
3.2.1.1 Disassembling of the service crane...........................................................1489
3.2.1.2 Assembling of the service crane..............................................................1490
3.2.2 Machinery house roof...............................................................................1492
3.2.2.1 Disassembling of the machinery house roof plates.............................................1494
3.2.2.2 Assembling of the machinery house roof plates................................................1498
3.2.2.3 Disassembling of the front roof cover section................................................1499
3.2.2.4 Assembling of the front roof cover section...................................................1502
3.2.3 Lubrication pump station...........................................................................1504
3.2.3.1 Disassembling of the lubrication pump station................................................1504
3.2.3.2 Assembling of the lubricating pump station...................................................1506
3.3 Electric motors..........................................................................................1508
3.3.1 Disassembling of the electric motor (Motor 1 or 2).................................................1508
3.3.2 Assembling of the electric motor (motor 1 or 2)....................................................1512
3.3.3 Final alignment of the electric motors.............................................................1515
3.3.4 Capacitor assemblies...............................................................................1518
3.3.4.1 Disassembling of the capacitor assembly......................................................1519
3.3.4.2 Assembling of the capacitor assembly.........................................................1521
3.3.5 Batteries..........................................................................................1522
3.3.5.1 Disassembling of the batteries...............................................................1522
3.3.5.2 Assembling of the batteries..................................................................1524
3.4 Flexible drive coupling..................................................................................1526
3.4.1 CENTA coupling.....................................................................................1526
3.4.1.1 Disassembling of the CENTA coupling..........................................................1527
3.4.1.2 Assembling of the CENTA coupling.............................................................1529
3.4.1.3 Assembling of the link units.................................................................1531
3.5 PTO......................................................................................................1532
3.5.1 Main pumps.........................................................................................1532
3.5.1.1 Disassembling of the main pumps..............................................................1534
3.5.1.2 Assembling of the main pumps.................................................................1536
3.5.2 Auxiliary pumps....................................................................................1539
3.5.2.1 Disassembling of the pilot oil pump..........................................................1539
3.5.2.2 Assembling of the pilot oil pump.............................................................1540
3.5.2.3 Disassembling of the PTO oil pumps...........................................................1542
3.5.2.4 Assembling of the PTO oil pumps..............................................................1543
3.5.3 Cooler fan drive pumps.............................................................................1545
3.5.3.1 Disassembling of the cooler fan drive pumps..................................................1545
3.5.3.2 Assembling of the cooler fan drive pumps.....................................................1547
3.5.4 Pump distributor gearbox (PTO).....................................................................1550
3.5.4.1 Disassembling of the pump distributor gearbox (PTO)..........................................1552
3.5.4.2 Assembling of the pump distributor gearbox (PTO).............................................1555
3.6 Hydraulic System.........................................................................................1558
3.6.1 Hydraulic oil cooler assembly......................................................................1558
3.6.1.1 Disassembling of the hydraulic oil cooler fan assemblies.....................................1560
3.6.1.2 Assembling of the hydraulic oil cooler fan assemblies........................................1562
3.6.1.3 Disassembling of the hydraulic oil cooler fan and motor......................................1566
3.6.1.4 Assembling of the hydraulic oil cooler fan and motor.........................................1568
3.6.1.5 Removal of the hydraulic oil cooler elements.................................................1570
3.6.1.6 Assembling of the hydraulic oil cooler elements..............................................1573
3.6.1.7 Removal of the hydraulic oil cooler assembly.................................................1575
3.6.1.8 Assembling of the hydraulic oil cooler assembly..............................................1579
3.6.2 Additional hydraulic oil cooler assembly...........................................................1582
3.6.2.1 Disassembling of the fan cross-head assembly on the additional hydraulic oil cooler..........1583
3.6.2.2 Assembling of the fan cross-head assembly on the additional hydraulic oil cooler.............1585
3.6.2.3 Disassembling of additional hydraulic oil cooler fans and motors.............................1586
3.6.2.4 Assembling of additional hydraulic oil cooler fans and motors................................1588
3.6.2.5 Disassembling of the additional hydraulic oil cooler elements................................1590
3.6.2.6 Assembling of the additional hydraulic oil cooler elements...................................1593
3.6.2.7 Disassembling of the additional hydraulic oil cooler assembly................................1595
3.6.2.8 Assembling of additional hydraulic oil cooler assembly.......................................1597
3.6.3 Hydraulic oil tank.................................................................................1600
3.6.3.1 Disassembling of the main shut-off valve.....................................................1604
3.6.3.2 Assembling of the main shut-off valve........................................................1605
3.6.3.3 Disassembling of the hydraulic oil tank......................................................1606
3.6.3.4 Assembling of the hydraulic oil tank.........................................................1609
3.6.4 Main control valve blocks..........................................................................1613
3.6.4.1 Disassembling of the main control valve blocks...............................................1613
3.6.4.2 Assembling of the main control valve blocks..................................................1616
3.6.4.3 Disassembling of the MRV at the main control valve blocks....................................1619
3.6.4.4 Assembling of the MRV on the main control valve block........................................1620
3.6.4.5 Disassembling of SRV on main control valve block.............................................1621
3.6.4.6 Assembling of SRV on main control valve blocks...............................................1622
3.6.4.7 Disassembling of ACV-/SRV-blocks on main control valve blocks................................1623
3.6.4.8 Assembling of ACV-/SRV-blocks on main control valve blocks...................................1624
3.6.5 Distributor manifold...............................................................................1626
3.6.5.1 Disassembling of the distributor manifold....................................................1626
3.6.5.2 Assembling of the distributor manifold.......................................................1628
3.6.5.3 Disassembling of the restrictor blocks on the distributor manifold...........................1630
3.6.5.4 Assembling of the restrictor blocks on the distributor manifold..............................1632
3.6.5.5 Disassembling of the ACV on the distributor manifold.........................................1634
3.6.5.6 Assembling of the ACV on the distributor manifold............................................1636
3.7 Slew system..............................................................................................1638
3.7.1 Slew gear..........................................................................................1638
3.7.1.1 Disassembling of the slew gear...............................................................1639
3.7.1.2 Assembling of the slew gear..................................................................1641
3.7.2 slew brake Valve block.............................................................................1644
3.7.2.1 Disassembling of the slew brake valve block..................................................1644
3.7.2.2 Assembling of the slew brake valve block.....................................................1646
3.7.3 Hydraulic slew motors..............................................................................1648
3.7.3.1 Disassembling of the slew motor..............................................................1649
3.7.3.2 Assembling of the slew motor.................................................................1652
3.7.4 Slew parking brake.................................................................................1654
3.7.4.1 Disassembling of the slew parking brake of type 2063.........................................1655
3.7.4.2 Assembling of the slew parking brake of type 2063............................................1658
3.7.4.3 Disassembling of the slew parking brake of type 632770.......................................1661
3.7.4.4 Assembling of the slew parking brake of type 632770..........................................1664
3.7.5 slew circle........................................................................................1666
3.7.5.1 Disassembling of the slew circle.............................................................1666
3.7.5.2 Assembling of the slew circle................................................................1670
3.7.6 Slew circle lubrication pinion (dummy wheel).......................................................1672
3.7.6.1 Disassembling of the lubrication pinion assembly.............................................1673
3.7.6.2 Assembling of the lubrication pinion assembly................................................1674
3.8 Operator’s cab...........................................................................................1676
3.8.1 Disassembling of the operator’s cab................................................................1677
3.8.2 Assembling of the operator’s cab...................................................................1681
3.8.3 Disassembling of the operator’s cab together with the cab support frame............................1684
3.8.4 Assembling of the operator’s cab together with the cab support frame...............................1688
3.8.5 Cab-mounts.........................................................................................1691
3.8.5.1 Disassembling of the cab-mounts..............................................................1691
3.8.5.2 Assembling of the cab-mounts.................................................................1693
3.8.6 Front window.......................................................................................1695
3.8.6.1 Disassembling of the front window............................................................1695
3.8.6.2 Assembling of the front window...............................................................1696
3.8.7 Operator’s seat....................................................................................1697
3.8.7.1 Removal of the operator’s seat...............................................................1697
3.8.7.2 Assembling of the operator’s seat............................................................1698
3.9 Cab base (medium voltage switch cabinet).................................................................1699
3.9.1 Disassembling of the cab support frame.............................................................1699
3.9.2 Assembling of the cab support frame................................................................1701
3.9.3 Disassembling of the cab base......................................................................1703
3.9.4 Assembling of the cab base.........................................................................1705
3.10 Stairways, ladders and platforms........................................................................1707
3.10.1 Hydraulic access Stairway.........................................................................1707
3.10.1.1 Disassembling of the hydraulic access stairway..............................................1707
3.10.1.2 Assembling of the hydraulic access stairway.................................................1709
3.10.1.3 Disassembling of the access stairway cylinder...............................................1711
3.10.1.4 Assembling of the access stairway cylinder..................................................1713
3.10.2 stairway Assembly.................................................................................1714
3.10.2.1 Disassembling of the stairway assembly......................................................1714
3.10.2.2 Assembling of the Stairway assembly.........................................................1716
3.10.3 Platforms.........................................................................................1717
3.10.3.1 Disassembling of the high voltage switch cabinet platform...................................1717
3.10.3.2 Assembling of the high voltage switch cabinet platform......................................1718
3.10.3.3 Disassembling of the cab base platform......................................................1719
3.10.3.4 Assembling of the cab base platform.........................................................1720
3.10.3.5 Disassembling of the front platforms........................................................1721
3.10.3.6 Assembling of the front platforms...........................................................1722
3.10.4 Emergency escape ladders..........................................................................1723
3.10.4.1 Disassembling of the emergency escape ladder assembly at the cab base.......................1723
3.10.4.2 Assembling of the emergency escape ladder assembly at the cab base..........................1724
3.10.4.3 Disassembling of the emergency escape ladder assembly at the machinery house................1725
3.10.4.4 Assembling of the emergency escape ladder assembly at the machinery house...................1727
3.11 Counterweight...........................................................................................1728
3.11.1 Disassembling of the counterweight................................................................1730
3.11.2 Assembling of the counterweight...................................................................1732
3.12 High voltage switch cabinet.............................................................................1735
3.12.1 General information regarding disassembling and assembling........................................1735
3.12.2 Disassembling of the high voltage switch cabinet..................................................1735
3.12.3 Assembling of the high voltage switch cabinet.....................................................1738
3.13 Slip ring unit..........................................................................................1741
3.13.1 Disassembling of the slip ring unit...............................................................1741
3.13.2 Assembling of the slip ring unit..................................................................1744
3.14 Superstructure lifting..................................................................................1746
3.14.1 Disassembling the superstructure from the undercarriage...........................................1746
3.14.2 Assembling the superstructure onto the undercarriage..............................................1750
4 Undercarriage..................................................................................................1755
4.1 Undercarriage overview...................................................................................1756
4.2 Travel system............................................................................................1758
4.2.1 Crawler track......................................................................................1758
4.2.1.1 Changing of the crawler track................................................................1758
4.2.1.2 Disassembling of the sprocket assembly.......................................................1764
4.2.1.3 Assembling of the sprocket assembly..........................................................1770
4.2.2 Guide wheel assembly...............................................................................1773
4.2.2.1 Disassembling of the guide wheel assembly....................................................1773
4.2.2.2 Assembling of the guide wheel assembly.......................................................1776
4.2.3 Track tensioning accumulators......................................................................1779
4.2.3.1 Disassembling of the low pressure accumulators...............................................1779
4.2.3.2 Assembling of the low pressure accumulators..................................................1781
4.2.3.3 Disassembling of the high pressure accumulators..............................................1783
4.2.3.4 Assembling of the high pressure accumulators.................................................1785
4.2.4 Track tensioning valve block.......................................................................1786
4.2.4.1 Disassembling of the track tensioning valve block............................................1786
4.2.4.2 Assembling of the track tensioning valve block...............................................1788
4.2.5 Track tensioning cylinders.........................................................................1789
4.2.5.1 Disassembling of the track tensioning cylinders..............................................1789
4.2.5.2 Assembling of the track tensioning cylinders.................................................1791
4.2.6 Replace the hydraulic hoses of the track tensioning system.........................................1793
4.2.6.1 precursory work..............................................................................1793
4.2.6.2 Replace the hydraulic hoses inside the undercarriage center body.............................1795
4.2.6.3 Replace the hydraulic hose between undercarriage center body and crawler frame...............1795
4.2.6.4 Replace the hydraulic hoses inside the crawler frame.........................................1797
4.2.6.5 Subsequent work..............................................................................1797
4.2.7 Travel brake valve block (overspeed valve).........................................................1798
4.2.7.1 Disassembling of the travel brake valve block................................................1798
4.2.7.2 Assembling of the travel brake valve block...................................................1799
4.2.8 Travel motor.......................................................................................1800
4.2.8.1 Disassembling of the travel motors...........................................................1800
4.2.8.2 Assembling of the travel motors..............................................................1802
4.2.9 Travel parking brake...............................................................................1804
4.2.9.1 Disassembling of the travel parking brake of type 631053 and 2063............................1805
4.2.9.2 Assembling of the travel parking brake of type 631053 and type 2063..........................1809
4.2.10 Travel gearbox....................................................................................1814
4.2.10.1 Disassembling of the travel gearbox.........................................................1815
4.2.10.2 Assembling of the travel gearbox............................................................1817
4.2.11 Carrier rollers...................................................................................1820
4.2.11.1 Disassembling of the carrier roller assembly................................................1820
4.2.11.2 Assembling of the carrier roller assembly...................................................1822
4.2.12 Track rollers.....................................................................................1824
4.2.12.1 Disassembling of the track roller assembly..................................................1824
4.2.12.2 Assembling of the track roller assembly.....................................................1826
4.2.13 Hydraulic hoses in the traveling system...........................................................1829
4.2.13.1 Disassembling of the hydraulic hoses........................................................1829
4.2.13.2 assembling of the hydraulic hoses...........................................................1831
4.3 Undercarriage center body................................................................................1833
4.3.1 Disassembling of the undercarriage center body and the crawler carriers............................1833
4.3.2 Assembling of the undercarriage center body and the crawler carriers...............................1838
4.3.2.1 Install crawler carrier mounting bolts.......................................................1843
4.3.3 Rotary joint.......................................................................................1844
4.3.3.1 Disassembling of the rotary joint............................................................1844
4.3.3.2 Assembling of the rotary joint...............................................................1848
4.4 Cable drum assembly......................................................................................1852
4.4.1 Disassembling of the cable drum assembly...........................................................1853
4.4.2 Assembling of the cable drum assembly..............................................................1855
5 Attachment.....................................................................................................1859
5.1 Repair procedures........................................................................................1860
5.1.1 Replacement of bushings at the attachment..........................................................1860
5.1.1.1 Disassembling of the bushings................................................................1860
5.1.1.2 Assembling of the bushings...................................................................1861
5.1.2 General installation instructions for attachment pins..............................................1862
5.2 Attachment bearings at superstructure....................................................................1864
5.2.1 Boom foot bearings with full floating pins.........................................................1864
5.2.1.1 Disassembling of the boom foot bearings......................................................1865
5.2.1.2 Assembling of the boom foot bearings.........................................................1867
5.2.2 Boom cylinder foot bearings with full floating pins................................................1870
5.2.2.1 Disassembling of the boom cylinder foot bearings - FSA arrangement...........................1871
5.2.2.2 Assembling of the boom cylinder foot bearings - FSA arrangement..............................1873
5.3 Face Shovel (FSA)........................................................................................1874
5.3.1 Using the cylinder mounting device for front shovel attachments (PN 967 000 40)....................1875
5.3.1.1 Designated usage.............................................................................1876
5.3.1.2 Non-designated usage.........................................................................1876
5.3.2 Boom...............................................................................................1877
5.3.2.1 Disassembling of the boom....................................................................1877
5.3.2.2 Assembling of the boom.......................................................................1879
5.3.2.3 Disassembling of the boom cylinders..........................................................1881
5.3.2.4 Assembling of the boom cylinders.............................................................1885
5.3.3 Stick..............................................................................................1891
5.3.3.1 Disassembling of the stick...................................................................1891
5.3.3.2 Assembling of the stick......................................................................1896
5.3.3.3 Disassembling of the stick cylinders.........................................................1901
5.3.3.4 Assembling of the stick cylinders............................................................1905
5.3.4 Bull clam bucket...................................................................................1909
5.3.4.1 Disassembling of the bull clam bucket........................................................1909
5.3.4.2 Assembling of the bull clam bucket...........................................................1913
5.3.4.3 Disassembling of the bucket cylinders........................................................1917
5.3.4.4 Assembling of the bucket cylinders...........................................................1922
5.3.4.5 Disassembling of the clam cylinders..........................................................1928
5.3.4.6 Assembling of the clam cylinders.............................................................1934
5.3.4.7 Disassembling of the clam....................................................................1938
5.3.4.8 Assembling of the clam.......................................................................1941
5.3.5 Hydraulic hoses at the face shovel attachment......................................................1942
5.3.5.1 Replace the boom arc hoses...................................................................1942
5.3.5.2 Replace the lubrication hoses................................................................1946
5.3.5.3 Replace the boom cylinder hoses..............................................................1947
5.3.5.4 Replace the stick arc hoses..................................................................1949
5.3.5.5 Replace the stick cylinder hoses.............................................................1951
5.3.5.6 Replace the bucket cylinder hoses............................................................1953
5.3.5.7 Replace the clam cylinder hoses..............................................................1956
5.4 Metering valves (grease injectors) at the attachment.....................................................1962
5.4.1 Check the operation of the metering valves (grease injectors)......................................1963
5.4.2 Removal of the metering valves (grease injectors)..................................................1964
5.4.3 Assembling of the metering valves (grease injectors)...............................................1966
5.5 Ground engaging tools (GET)..............................................................................1968
5.5.1 Disassembling and assembling of the GET............................................................1969
5.6 Cylinder bypass test.....................................................................................1971
6 Service Information............................................................................................1973
6.1 Fluids and lubricants....................................................................................1974
6.2 Lifting Gears............................................................................................1974
6.3 Safety hints for sling accessory.........................................................................1976
6.4 Weight tables............................................................................................1977
6.4.1 Superstructure.....................................................................................1977
6.4.2 Undercarriage......................................................................................1980
6.4.3 Face shovel attachment (FSA).......................................................................1981
6.5 Torque charts according to KOMATSU company standard......................................................1983
6.5.1 Metric standard thread.............................................................................1983
6.5.2 Metric fine thread.................................................................................1984
6.5.3 Cummins motor torques - metric.....................................................................1985
6.5.4 Cummins motor torques - U.S. customary.............................................................1985
6.5.5 Torque Charts for Flange Joints....................................................................1986
6.5.6 Tightening Torque for hydraulic hose connecting nut................................................1988
6.6 Blind plugs..............................................................................................1990
6.6.1 Dummy plates for hydraulic–flanges.................................................................1990
6.6.2 Classification of threads to the nominal width.....................................................1992
6.6.3 Plugs and fittings according to DIN 2353...........................................................1993
6.7 Conversion table.........................................................................................1994
6.7.1 Method of using the conversion table...............................................................1994
6.7.2 Millimeter - inch & kilogram - pound...............................................................1995
6.7.3 Liter - U.S. gallon & liter - U.K. gallon..........................................................1996
6.7.4 Nm- ft.lb..........................................................................................1997
6.7.5 Bar - PSI - kPa - MPa..............................................................................1998
6.7.6 Temperature........................................................................................1999
6.8 Tools....................................................................................................2000
6.8.1 Standard tool case.................................................................................2000
6.8.2 Used special tools (Overview)......................................................................2002
6.9 Work instructions........................................................................................2005
6.9.1 Bleeding the track tensioning system...............................................................2005
6.9.2 General installation procedures for hydraulic hose lines...........................................2007
6.9.3 Remove / install the crawler carrier...............................................................2010
6.9.4 Repair procedure for the radiator assembly.........................................................2011
7 Parts & Service News...........................................................................................2013
7.1 List of the PARTS AND SERVICE NEWS.......................................................................2014DESCRIPTION:
KOMATSU PC8000E-11 HYDRAULIC MINING EXCAVATOR SHOP MANUAL 12121-xE-GB-0 – PDF DOWNLOAD
- This manual gives details of the methods of inspection, maintenance and troubleshooting for this excavator that must be obeyed in order to use the excavator safely. Most accidents are caused by the failure to follow fundamental safety rules for the inspection, maintenance and troubleshooting of excavators.
- Read, understand and follow all precautions and warnings in this manual and on the excavator 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 excavator is used. Therefore, the safety messages in this manual and on the excavator 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 excavator can be hazardous and could result in serious injury or death.
- If you sell the excavator, be sure to give this manual to the new owner together with the excavator.
- 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 excavator 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 excavator or with questions regarding information contained in this manual.
- Komatsu delivers excavators that comply with all applicable regulations and standards of the country to which it has been shipped. If the excavator 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 excavator.
S.S 26/12/24
