Komatsu PC8000E-6 Hydraulic Mining Shovel Shop Manual Sl No 12089-12093 – PDF DOWNLOAD

Description

Komatsu PC8000E-6 Hydraulic Mining Shovel Shop Manual

FILE DETAILS:

Komatsu PC8000E-6 Hydraulic Mining Shovel Shop Manual

Brands: Komatsu
Equipment Type: Hydraulic Shovel
Manuals Type: Shop Manual
Machine Model: PC8000E-6
Serial Number: 12089-12093
Language: English
Pages: 768
File Format: Portable Document Format (PDF)

KOMATSU PC8000E-6 HYDRAULIC MINING SHOVEL SHOP MANUAL SL NO 12089-12093 – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC8000E-6 Hydraulic Mining Shovel Shop Manual

FOREWORD:

Observe the instructions in these manuals for:
– your Personal SAFETY
– Operating SAFETY, and
– READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.

With this SERVICE MANUAL KOMATSU provides you with the description of the construction and the function of
the major systems of the Hydraulic Excavator PC8000-6D.
We describe for you all functions and how to carry out the inspections and adjustments.
How do you find “your” desired information?
In the TABLE OF CONTENT all the functions and components are shown in their sequence of the description.
NOTE! Periodic preventive inspections and maintenance are the surest means of keeping the machine in
proper working order. Prompt detection and correction of minor irregularities, and immediate replacement
of worn out or broken parts will prevent failures and avoid expenses.
Replace damaged graphics and symbols at the machine.
Observe safety precautions to prevent injury and damage.

1.5 DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL
Wiring Diagrams & Hydraulic Diagrams
– During work or troubleshooting always make sure to use your Wiring Diagrams and Hydraulic Diagrams which
are assigned to your machine.
– Due to variable requirements in many respects, the samples of diagrams shown in this manual can not meet
the actual state of each machine in every case.
Illustrations & technical drawings
– The illustrations and technical drawings shown in this manual correspond to state of the technology at the time
of press date.
– Modifications of shown components are possible prior notice.

TABLE OF CONTENTS:

Komatsu PC8000E-6 Hydraulic Mining Shovel Shop Manual

1 INTRODUCTION 1-1
11 CONTENTS OF THE BINDER 1-2
12 FOREWORD 1-2
13 RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION
AND MAINTENANCE OF HYDRAULIC MINING SHOVELS 1-4
14 EXPLANATION OF ABBREVIATIONS 1-5
15 DIAGRAMS AND ILLUSTRATIONS IN THIS MANUAL 1-6
2 SAFETY 2-1
21 SAFETY INFORMATION 2-2
22 OVERVIEW 2-3
221 NORMAL OPERATIONS 2-3
222 REGULAR MAINTENANCE 2-3
223 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR 2-3
224 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING
AND TRANSPORTATION OF THE EXCAVATOR 2-3
23 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB 2-4
24 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR 2-5
241 UNDERSTANDING THE MACHINE 2-5
242 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR 2-5
2421 ENSURING SAFE OPERATION 2-5
243 PREPARATIONS FOR SAFE OPERATION 2-5
2431 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT 2-5
2432 INSPECTING THE MACHINE 2-5
2433 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT 2-6
2434 KEEP MACHINE CLEAN 2-6
2435 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT 2-6
2436 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 2-7
2437 IF A PROBLEM IS FOUND 2-7
244 FIRE PREVENTION 2-7
2441 PRECAUTIONS TO PREVENT FIRE 2-7
2442 ACTION IF FIRE OCCURS 2-8
2443 EMERGENCY EXIT FROM OPERATOR’S CAB 2-9
245 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE 2-9
2451 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE 2-9
2452 NO JUMPING ON OR OFF THE MACHINE 2-9
2453 NO PEOPLE ON THE ATTACHMENT 2-9
2454 WORKING IN HIGH PLACES 2-9
2455 LEAVING OPERATOR’S SEAT WITH LOCK 2-10
2456 LEAVING THE MACHINE 2-10
246 BURN PREVENTION 2-11
2461 HOT COOLANT 2-11
2462 HOT OIL 2-11
247 PRECAUTIONS WHEN CLEANING CAB GLASS 2-11
248 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2-12
2481 UNAUTHORIZED MODIFICATION 2-12
TOC – 2 PC8000E-6 SM 12089-xE-GB-0
2482 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2-12
249 PRECAUTIONS AT JOBSITE 2-13
2491 VISIBILITY FROM OPERATOR’S SEAT 2-14
2492 CAMERA SYSTEM WITH MONITORS 2-14
2493 ENSURE GOOD VISIBILITY 2-14
2494 CHECKING SIGNS AND SIGNALMAN’S SIGNALS 2-14
2495 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2-15
2496 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES 2-15
2497 WORKING ON LOOSE GROUND 2-16
2498 GAS, DUST, STEAM AND SMOKE 2-16
2499 VENTILATION OF ENCLOSED AREAS 2-17
2410 STARTING ENGINE 2-18
24101 WARNING TAG 2-18
24102 CHECKS BEFORE STARTING ENGINE 2-18
24103 PRECAUTION WHEN STARTING ENGINE 2-18
24104 PRECAUTION IN COLD AREAS 2-19
2411 OPERATION 2-19
24111 CHECKS BEFORE OPERATION 2-19
24112 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE 2-20
24113 PRECAUTIONS WHEN TRAVELLING 2-21
24114 TRAVELLING ON SLOPES 2-22
24115 OPERATIONS ON SLOPES 2-23
24116 PROHIBITED OPERATIONS 2-23
24117 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES 2-24
24118 PARKING THE MACHINE 2-24
24119 TRANSPORTATION 2-24
25 PRECAUTION FOR MAINTENANCE 2-25
251 GENERAL PRECAUTIONS 2-25
2511 SELECTION AND QUALIFICATION OF PERSONNEL –
BASIC RESPONSIBILITIES 2-26
2512 STOP ENGINE FOR MAINTENANCE 2-27
2513 WARNING TAG 2-28
2514 KEEP WORKPLACE CLEAN AND TIDY 2-29
2515 APPOINT LEADER WHEN WORKING WITH OTHERS 2-29
2516 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING 2-30
2517 INSTALLING, REMOVING OR STORING ATTACHMENTS 2-30
2518 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT 2-31
2519 NOISE 2-31
25110 WHEN USING A HAMMER 2-31
25111 PROPER TOOLS 2-32
25112 ACCUMULATOR 2-32
25113 PERSONNEL 2-32
252 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2-33
2521 PRECAUTION WHEN WELDING 2-33
2522 BATTERY HANDLING 2-33
253 PRECAUTIONS WITH HIGH PRESSURE FLUID 2-34
2531 PRECAUTIONS WITH HIGH FUEL PRESSURE 2-34
2532 HANDLING HIGH PRESSURES HOSES OR PIPES 2-35
2533 REPLACEMENT OF HOSE LINES 2-35
2534 INSPECTION OF HOSE LINES 2-35
2535 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 2-36
SM 12089-xE-GB-0 PC8000E-6 TOC – 3
2536 PRECAUTIONS FOR HIGH VOLTAGE 2-36
2537 AIR CONDITIONING MAINTENANCE 2-36
2538 COMPRESSED AIR 2-37
2539 WASTE MATERIALS 2-37
26 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS 2-38
261 INSPECTION OF THE HYDRAULIC SYSTEM 2-38
262 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS 2-38
263 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR 2-38
27 SPECIAL SAFETY EQUIPMENT 2-40
271 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB 2-41
272 OBJECT HANDLING 2-41
273 LIGHTING 2-41
274 WARNING BEACON 2-41
275 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) 2-41
2751 SAFETY HARNESS IN CONFORMITY WITH EN 361
(EUROPEAN STANDARD) 2-41
2752 INSTRUCTIONS FOR USE 2-43
2753 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL 2-45
2754 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS
AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), 2-45
2755 INSTRUCTIONS FOR USE 2-47
3 SPECIFICATIONS 3-1
31 LIFTING GEARS 3-2
32 SAFETY HINTS FOR SLING ACCESSORY 3-4
33 STANDARD TIGHTENING TORQUE CHART 3-5
34 CONVERSION TABLE 3-6
35 BLIND PLUGS 3-12
36 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH 3-14
37 PLUGS AND FITTINGS ACCORDING TO ISO 8434-1 / DIN 2353 3-15
4 MAIN ASSEMBLY GROUPS 4-1
41 GENERAL LAYOUT 4-2
42 SUPERSTRUCTURE 4-4
43 MACHINE HOUSE 4-8
44 HYDRAULIC OIL TANK 4-10
45 HYDRAULIC OIL COOLER 4-12
46 HIGH VOLTAGE SWITCH CABINET 4-14
47 CAB SUPPORT 4-20
471 X2 – LOW VOLTAGE SWITCH BOARD (LOCATION 12) 4-21
472 EXTRA LOW VOLTAGE SWITCH BOARD (LOCATION 11) 4-23
48 SLIP RING UNIT 4-24
49 OPERATOR’S CAB 4-28
410 CONTROL BLOCKS 4-30
411 SWING MACHINERY 4-32
4111 SWING MACHINERY L&S 4-32
TOC – 4 PC8000E-6 SM 12089-xE-GB-0
4112 SWING MACHINERY SIEBENHAAR 4-34
412 UNDERCARRIAGE 4-36
413 ATTACHMENTS 4-38
4131 FRONT SHOVEL ATTACHMENT (FSA) 4-38
4132 BACKHOE ATTACHMENT (BHA) 4-40
5 DRIVE 5-1
51 ELECTRIC DRIVE – SAFETY AND OPERATION INSTRUCTION DOCUMENTS 5-2
52 PRIME DRIVE ASSEMBLY 5-4
53 ELECTRIC MOTORS 5-6
531 LOCATION OF ATTACHING PARTS 5-6
5311 MOTOR TYPE PLATE 5-7
5312 TYPE PLATE FOR THE MOTOR BEARINGS 5-8
532 MOTOR BEARINGS & GREASE EQUIPMENT 5-10
533 MONITORING OF THE MOTOR BEARING TEMPERATURE 5-12
534 MONITORING OF THE MOTOR WINDING TEMPERATURE 5-13
535 JUNCTION BOX FOR THE MOTOR MONITORING DEVICE 5-14
536 CHECKING OF THE BEARING CONDITION 5-15
537 CAPACITOR ASSEMBLY 5-16
54 AIR-TO-AIR MOTOR COOLING SYSTEM 5-18
55 INITIAL START-UP PROCEDURE 5-19
551 MAIN SUPPLY CABLE 5-20
552 MACHINE CONFIGURATION (VIA CODESYS) 5-21
553 MOTOR PROTECTION RELAY (SPAM 150 C) 5-26
554 MOTOR ALIGNMENT 5-28
555 MOTOR ROTATION DIRECTION 5-30
556 STARTING & RE-STARTING THE ELECTRIC MOTORS 5-30
557 SUPERVISION DURING THE FIRST MOTOR RUNNING PERIOD 5-31
56 FLEXIBLE COUPLING 5-32
561 COUPLING INSPECTION 5-33
562 COUPLING REPLACEMENT 5-34
57 PUMP DISTRIBUTOR GEARBOX (PTO) 5-36
571 PUMP DRIVE SHAFT HOUSING / SPLINE LUBRICATION 5-38
572 PTO LUBRICATION AND COOLING 5-40
5721 CHECKS AND ADJUSTMENTS 5-42
573 HYDRAULIC PUMPS – LOCATION, DRIVE SPEED AND FLOW RATES 5-44
6 HYDRAULIC OIL TANK 6-1
61 GENERAL LAYOUT 6-2
62 LOCATION OF THE ELECTRIC EQUIPMENT 6-4
63 SUCTION OIL TANK WITH STRAINERS 6-6
64 RETURN OIL COLLECTOR PIPE WITH STRAINER 6-8
65 BACK PRESSURE VALVE 6-10
66 TRANSFER PUMP 6-12
67 RETURN AND LEAK OIL FILTER 6-14
68 BREATHER FILTER 6-16
SM 12089-xE-GB-0 PC8000E-6 TOC – 5
7 HYDRAULIC OIL COOLING 7-1
71 OVERALL VIEW OF THE HYDRAULIC OIL COOLING 7-2
72 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT 7-4
721 STANDARD HYDRAULIC OIL COOLING CIRCUIT 7-4
722 ADDITIONAL OIL COOLING CIRCUIT 7-6
73 ADJUSTMENT OF THE BACK PRESSURE VALVE 7-8
74 FAN DRIVE – STANDARD OIL COOLER 7-10
741 TWO STAGE COOLER FAN DRIVE RPM CONTROL 7-10
742 FIXED DISPLACEMENT PUMP WITH VARIABLE SETTING 7-12
743 PRESSURE RELIEF VALVES 7-14
744 SOLENOID VALVES 7-16
75 ADJUSTMENT OF THE COOLER FAN DRIVE SPEED 7-18
751 MAXIMUM SPEED 7-18
752 MEDIUM SPEED 7-20
76 FAN DRIVE – ADDITIONAL OIL COOLER 7-22
761 FUNCTION OF THE ADDITIONAL COOLER FAN RPM CONTROL 7-23
762 ADJUSTMENT OF THE ADDITIONAL COOLER FAN DRIVE SPEED 7-23
8 CONTROLLING 8-1
81 GENERAL LAYOUT 8-2
82 CONTROL AND FILTER PANELS – LOCATION OF COMPONENTS 8-4
821 MAIN VALVE CARTRIDGE BLOCK 8-4
822 CONTROL AND FILTER PANELS MOUNTED ON THE PTOS 8-10
83 PILOT PRESSURE SUPPLY AND ADJUSTMENTS 8-12
831 PILOT PRESSURE CIRCUIT 8-13
832 CHECKS AND ADJUSTMENTS OF PILOT PRESSURE 8-16
833 REMOTE CONTROL VALVES ARRANGEMENT 8-20
84 FUNCTION OF THE ELECTRO-HYDRAULIC CONTROL SYSTEM 8-22
85 HAND LEVER (JOYSTICK) CONTROL 8-26
86 FOOT PEDAL CONTROL 8-28
87 PROPORTIONAL AMPLIFIER MODULE, TYPE A 8-30
88 PROPORTIONAL AMPLIFIER MODULE, TYPE B 8-32
89 RAMP TIME MODULE 8-34
810 ADJUSTMENT OF AMPLIFIER MODULES 8-36
8101 GENERAL 8-37
8102 ADJUSTING THE AMPLIFIER MODULE, TYPE A 8-38
8103 ADJUSTING THE AMPLIFIER MODULE, TYPE B 8-40
811 ADJUSTING THE RAMP TIME MODULE 8-42
9 COMPONENTS 9-1
91 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTERS (FSA) 9-2
92 DISTRIBUTOR MANIFOLD – LOCATION OF RESTRICTOR BLOCKS
AND ANTI-CAVITATION VALVES 9-6
93 RESTRICTOR BLOCK WITH SECONDARY RELIEF VALVE 9-8
94 ANTI-CAVITATION VALVE (ACV) BLOCK 9-10
941 ACV BLOCK ON CONTROL BLOCKS 9-10
TOC – 6 PC8000E-6 SM 12089-xE-GB-0
942 ACV BLOCK ON TOP OF THE MANIFOLD 9-12
95 REMOTE CONTROL VALVES 9-14
96 4/3 DIRECTIONAL SOLENOID VALVES 9-16
97 PROPORTIONAL SOLENOID VALVES 9-18
98 HIGH-PRESSURE FILTER (SCREEN) 9-20
99 CONTROL BLOCKS AND VALVES 9-22
910 TRAVEL BRAKE VALVE 9-34
911 PRESSURE REDUCING VALVE 9-36
912 4/2 DIRECTIONAL VALVES 9-38
913 PRESSURE DOUBLE STAGE VALVE 9-40
914 HYDRAULIC CYLINDER 9-42
10 MAIN HYDRAULIC PUMPS AND PUMP REGULATION 10-1
101 GENERAL 10-2
1011 LAYOUT 10-2
1012 PUMP REGULATION SYSTEM (“OPEN SENSING SYSTEM”) 10-5
1013 PUMP REGULATION SYSTEM — VALVE FUNCTION 10-6
102 MAIN PUMPS 10-8
1021 PUMP BEARING FLUSHING / LUBRICATION 10-10
1022 OPERATING PRINCIPLE 10-12
1023 CHECKS / ADJUSTMENTS 10-28
10231 QMAX AND QMIN ADJUSTMENT BOLTS 10-30
103 ELECTRONIC PUMP REGULATION SYSTEM 10-32
1031 ELECTRONIC LOAD LIMITING CONTROL – GENERAL 10-33
1032 MICROCONTROLLER RC4-4 10-34
1033 SIGNAL RECTIFIER MODULE 10-36
10331 CHECKS AND ADJUSTMENTS 10-38
104 HYDRAULIC CONSTANT REGULATION SYSTEM (EMERGENCY MODE) 10-40
1041 GENERAL 10-41
105 PUMP REGULATION SYSTEM, CHECKS AND ADJUSTMENTS 10-43
1051 POWER CHECK 10-43
1052 ELECTRONIC LOAD LIMIT REGULATION, XLR BASIC ADJUSTMENT 10-46
10521 METHOD “A” WITH 24 V SUPPLY 10-48
10522 METHOD “B” WITH BODAS SOFTWARE 10-50
1053 ELECTRONIC LOAD LIMIT REGULATION, RC4 FUNCTION CHECK 10-54
1054 HYDRAULIC CONTROL (EMERGENCY MODE) 10-56
1055 PRESSURE CUT-OFF VALVE 10-58
106 ENERGY EFFICIENCY 10-60
1061 GENERAL 10-61
1062 CHECKS AND ADJUSTMENTS 10-62
11 OPERATING HYDRAULICS 11-1
111 GENERAL 11-2
1111 FLOATING FUNCTION FOR BOOM AND STICK CYLINDER (FSA) 11-4
112 HYDRAULICS FOR THE ATTACHMENT CYLINDERS FSA 11-6
1121 ELECTRIC / HYDRAULIC FLOWCHART “BOOM UP” (FSA) 11-6
SM 12089-xE-GB-0 PC8000E-6 TOC – 7
1122 ELECTRIC / HYDRAULIC FLOWCHART “BOOM DOWN” (FSA), AUTO-FLOAT ON 11-8
1123 ELECTRIC / HYDRAULIC FLOWCHART “BOOM DOWN” (FSA), AUTO-FLOAT OFF 11-10
1124 ELECTRIC / HYDRAULIC FLOWCHART “STICK OUT” (FSA) 11-12
1125 ELECTRIC / HYDRAULIC FLOWCHART “STICK IN” (FSA), AUTO-FLOAT ON 11-14
1126 ELECTRIC / HYDRAULIC FLOWCHART “STICK IN” (FSA), AUTO-FLOAT OFF 11-16
1127 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET FILL” (FSA) 11-18
1128 ELECTRIC / HYDRAULIC FLOWCHART “BUCKET DUMP” (FSA) 11-20
1129 ELECTRIC / HYDRAULIC FLOWCHART “CLAM OPEN” (FSA) 11-22
11210 ELECTRIC / HYDRAULIC FLOWCHART “CLAM CLOSE” (FSA) 11-24
11211 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES (MRV), FSA 11-26
11212 CHECKS AND ADJUSTMENTS OF THE SECONDARY RELIEF VALVES (SRV), FSA 11-28
112121 BOOM CYLINDER, PISTON SIDE (FSA) 11-28
112122 BOOM CYLINDER, PISTON ROD SIDE (FSA) 11-32
112123 STICK CYLINDER, PISTON SIDE (FSA) 11-36
112124 STICK CYLINDER, PISTON ROD SIDE (FSA) 11-40
112125 BUCKET CYLINDER, PISTON SIDE (FSA) 11-44
112126 BUCKET CYLINDER, PISTON SIDE (FSA) 11-48
112127 CLAM CYLINDER, PISTON ROD SIDE (FSA), CLAM OPEN 11-52
112128 CLAM CYLINDER, PISTON SIDE (FSA), CLAM CLOSE 11-56
11213 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED – BOOM 11-60
11214 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED – STICK 11-64
11215 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED – BUCKET 11-68
11216 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED – CLAM 11-72
113 HYDRAULICS FOR THE SWING CIRCUIT 11-74
1131 SWING CIRCUIT 11-74
1132 SWING MOTOR 11-78
1133 SWING GEARBOX (L&S) 11-82
1134 SWING GEARBOX (SIEBENHAAR) 11-84
1135 SWING PARKING BRAKE (L&S) 11-86
1136 SWING PARKING BRAKE (SIEBENHAAR) 11-88
1137 SWING BRAKE VALVE 11-90
1138 ELECTRIC / HYDRAULIC FLOWCHART “SWING LEFT” 11-94
1139 ELECTRIC / HYDRAULIC FLOWCHART “SWING RIGHT” 11-96
11310 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT 11-98
11311 FUNCTION CHECK FOR HYDRAULIC SWING BRAKE 11-102
11312 FUNCTION CHECK FOR THE SWING PARKING BRAKE 11-104
114 HYDRAULICS FOR THE TRAVEL CIRCUIT 11-108
1141 TRAVEL CIRCUIT 11-109
1142 TRAVEL MOTOR 11-112
1143 ROTARY JOINT 11-114
1144 TRAVEL GEARBOX 11-116
1145 TRAVEL PARKING BRAKE (L&S) 11-118
1146 TRAVEL PARKING BRAKE (ZOLLERN) 11-120
1147 TRAVEL BRAKE VALVE 11-122
1148 ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL FORWARD” 11-124
1149 ELECTRIC / HYDRAULIC FLOWCHART “TRAVEL BACKWARDS” 11-126
11410 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT 11-128
11411 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE 11-130
TOC – 8 PC8000E-6 SM 12089-xE-GB-0
12 HYDRAULIC TRACK TENSIONING SYSTEM 12-1
121 GENERAL 12-2
122 FUNCTIONAL DESCRIPTION 12-4
123 DOUBLE-STAGE VALVE 12-8
124 TENSIONING CYLINDER 12-10
125 ADJUSTMENTS / CHECKS 12-12
13 ACCESS LADDER, HYDRAULICALLY OPERATED 13-1
131 GENERAL 13-2
132 FUNCTION OF THE HYDRAULICALLY OPERATED ACCESS LADDER 13-4
133 ADJUSTMENTS / CHECKS 13-8
14 CENTRAL REFILLING SYSTEM (SERVICE ARM) 14-1
141 SERVICE ARM 14-2
142 MONITORING AND CONTROL BOX 14-4
143 FUNCTION 14-6
144 CHECKS AND ADJUSTMENTS 14-8
15 HINTS FOR READING THE HYDRAULIC DIAGRAM 15-1
151 GENERAL 15-2
152 HYDRAULIC SYMBOLS 15-4
1521 LINES, UNIONS 15-5
1522 COMPONENTS, VALVES 15-7
1523 SENSORS 15-7
1524 VALVES, VALVE COMPONENTS 15-8
1525 PUMP, MOTOR, CYLINDER 15-12
16 HINTS FOR READING THE ELECTRIC WIRING DIAGRAM 16-1
161 GENERAL 16-2
162 REFERENCE CODE OF THE ELECTRICAL COMPONENTS 16-3
1621 AREA CODE 16-3
1622 COMPONENT IDENTIFYING LETTER 16-5
163 GRAPHICAL SYMBOLS 16-6
164 DRAWING CONCEPT 16-10
165 CABLE MARKING 16-20
17 KOMTRAX PLUS & MTC CONTROL SYSTEM 17-1
171 GENERAL 17-2
172 SPECIFICATIONS FOR OPERATORS 17-5
1721 SEQUENCE OF DISPLAYS 17-6
1722 OPENING SCREEN 17-6
1723 MAIN GAUGE SCREENS 1 TO 3 17-7
1724 ENERGY CONSUMPTION SCREEN 17-10
1725 FAILURE MESSAGE HISTORY FOR THE OPERATOR 17-12
1726 MAIN GAUGE SCREENS – CHANGING OF TIME / SMR / DATE 17-14
SM 12089-xE-GB-0 PC8000E-6 TOC – 9
1727 MAINTENANCE MONITOR 17-15
1728 SETTINGS FOR OPERATOR 17-17
1729 AUTOMATIC MESSAGES 17-24
173 TABLES OF ALL PROVIDED MESSAGES 17-27
1731 TABLE OF G-CODES 17-28
1732 TABLE OF AVAILABLE INSTRUCTION MESSAGES 17-36
174 FLOW CHARTS (1-4) OF KOMTRAX PLUS MAIN SCREENS 17-39
175 KOMTRAX PLUS SERVICE LEVEL 17-44
1751 EXPLANATION OF THE BUTTON SYMBOLS (SERVICE LEVEL) 17-46
1752 SERVICE MENU SELECT SCREEN 17-47
1753 REAL TIME MENU SELECT SCREEN 17-48
17531 REAL TIME MENU, OPTION: 01 MOTOR 1 17-49
17532 REAL TIME MENU, OPTION: 02 MOTOR 2 17-49
17533 REAL TIME MENU, OPTION: 03 PTO 1 17-50
17534 REAL TIME MENU, OPTION: 04 PTO 2 17-50
17535 REAL TIME MENU, OPTION: 05 HYDRAULIC 17-51
17536 REAL TIME MENU, OPTION: 06 SLEW 17-52
17537 REAL TIME MENU, OPTION: 07 ELECTRICAL EQUIPMENT 17-53
17538 REAL TIME MENU, OPTION: 08 EMERGENCY STOP 17-54
17539 REAL TIME MENU, OPTION: 09 HEATER 17-55
175310 REAL TIME MENU, OPTION: 10 MANUAL SWITCH 17-56
175311 REAL TIME MENU, OPTION: 11 CENTRAL LUBE SYSTEM 1 17-57
175312 REAL TIME MENU, OPTION: 12 SLEW RING GEAR LUBE SYSTEM 17-58
175313 REAL TIME MENU, OPTION: 13 CENTRAL LUBE SYSTEM 2 17-59
175314 REAL TIME MENU, OPTION: 14 CABLE DRUM 17-60
175315 REAL TIME MENU, OPTION: 15 WINDSCREEN WIPER 17-61
175316 REAL TIME MENU, OPTION: 16 LADDER 17-62
175317 REAL TIME MENU, OPTION: 17 SERVICE ARM 17-63
175318 REAL TIME MENU, OPTION: 18 PILOT CONTROL 17-64
175319 REAL TIME MENU, OPTION: 19 OTHER ITEMS 17-65
175320 REAL TIME MENU, OPTION: 20 OUTPUT SIGNALS 17-66
175321 OUTPUT SIGNALS WITH DEACTIVATED MTC EVALUATION 17-69
1754 PM-CLINIC 17-71
17541 GENERAL 17-71
17542 POWER CHECK 17-72
1755 SERIAL/GCC NO SETTING 17-73
1756 MEMORY CLEAR 17-74
17561 INPUT MEMORY CLEAR ID 17-74
17562 MEMORY CLEAR SCREEN 17-75
1757 FAILURE HISTORY 17-76
1758 MAINTENANCE MONITOR 17-77
1759 SNAPSHOT 17-78
17510 SETTINGS 17-79
175101 CENTRAL LUBRICATION SYSTEM (CLS 1), SCREEN 1/12 17-79
175102 SWING LUBRICATION SYSTEM (SLS), SCREEN 2/12 17-80
175103 CENTRAL LUBRICATION SYSTEM (CLS 2), SCREEN 3/12 17-81
175104 QMIN – QMAX SETTING, SCREEN 4/12 17-82
175105 OTHER SETTINGS 1/2, SCREEN 5/12 17-82
175106 OTHER SETTINGS 2/2, SCREEN 6/12 17-84
175107 SHUTDOWN BYPASS ON/OFF 17-87
TOC – 10 PC8000E-6 SM 12089-xE-GB-0
176 INTERFACE-CONNECTION KOMTRAX PLUS CONTROLLER 17-90
1761 KOMTRAX PLUS CONTROLLER 17-91
177 WIRING OF THE KOMTRAX PLUS CONTROLLER 17-92
178 MTC CONTROL SYSTEM GLOBAL LAYOUT 17-96
1781 MTC (MASTER TURBO CONTROLLER) 17-98
17811 MTC FLOWCHART 17-98
17812 MTC FEATURES 17-98
17813 MTC FIRMWARE AND SOFTWARE 17-99
17814 VIEW ONTO THE MTC UNIT AND ITS CONNECTORS 17-100
179 GLOBAL LAYOUT OF THE INTERNAL CAN BUS 17-102
1791 GENERAL INFORMATION ON A CAN BUS SYSTEM 17-102
17911 GENERAL CAN BUS DESCRIPTION 17-103
17912 CAN BUS TROUBLESHOOTING 17-103
17913 CAN BUS WIRING 17-104
17914 CAN BUS END RESISTOR 17-106
1710THE NODES IN THE CAN BUS SYSTEM 17-108
17101 GLOBAL LAYOUT 17-108
17102 INTRODUCTION 17-110
171021 ICN-V FEATURES 17-110
171022 ICN-D FEATURES 17-112
17103 NODE DIP-SWITCHES 17-113
17104 NODE BOX 17-114
17105 NODE LOCATIONS ON THE MACHINE 17-116
171051 NODE & LOCATION CHART 17-117
171052 EXEMPLARY VIEW ONTO THE CAN BUS CONTROL COMPONENTS
IN A CAB BASE 17-118
18 LUBRICATION SYSTEM 18-1
181 GENERAL OVERVIEW (SLS & CLS1/2) 18-2
1811 GENERAL DESCRIPTION 18-3
182 BASIC FUNCTION OF THE LUBRICATION SYSTEMS 18-4
183 CENTRAL LUBRICATION SYSTEM (CLS 1&2) 18-6
1831 GENERAL INFORMATION ON THE CLS (CLS1/2) 18-8
18311 MANUAL LUBE ACTIVATION 18-8
184 SWING CIRCLE LUBRICATION SYSTEM (SLS) 18-10
1841 GENERAL INFORMATION ON THE SLS 18-12
18411 MANUAL LUBE ACTIVATION 18-12
185 LUBRICATION CYCLE 18-13
1851 OPERATION AND CONTROL 18-13
1852 LUBRICATION CYCLE – COMPONENTS 18-14
1853 LUBRICATION CYCLE – PROCESSING 18-16
1854 TIME SEGMENTS & SWITCH POINTS OF A LUBRICATION CYCLE 18-17
1855 LUBRICATION MODES 18-18
18551 AUTOMATIC LUBRICATION MODE 18-18
18552 MANUAL LUBRICATION MODE 18-18
18553 VHMS SERVICE MODE 18-18
186 HYDRAULICALLY DRIVEN LUBE PUMP 18-20
1861 ADJUSTMENT OF LUBE PUMP SPEED & WORKING PRESSURE 18-22
SM 12089-xE-GB-0 PC8000E-6 TOC – 11
18611 STROKE SPEED ADJUSTMENT 18-23
18612 WORKING PRESSURE ADJUSTMENT 18-24
187 LUBRICANT INJECTORS 18-26
1871 TIGHTENING TORQUES FOR FITTINGS AT GREASE INJECTORS 18-27
1872 INJECTOR TYPE DESCRIPTION 18-28
1873 ADJUSTMENT OF THE LUBRICANT OUTPUT 18-28
1874 OPERATION PRINCIPLE OF LUBRICANT INJECTORS 18-30
18741 FUNCTION DESCRIPTION 18-31
1875 CONNECTION OF ONE OR MORE INJECTORS 18-32
188 VENT VALVE 18-34
1881 DESCRIPTION 18-35
189 END-LINE SWITCH 18-36
1891 DESCRIPTION 18-37
1892 CLS END-LINE SWITCH ADJUSTMENT 18-38
1893 SLS END-LINE SWITCH ADJUSTMENT 18-40
1810IN-LINE FILTER 18-42
18101 DESCRIPTION 18-43
18102 MAINTENANCE PROCEDURE 18-43
1811LUBRICANT LEVEL SENSOR 18-44
18111 DESCRIPTION 18-45
181111 LEDS AT THE SONAR SENSOR 18-46
1812COMMISSIONING 18-48
18121 COMMISSIONING OF THE CLS1 & CLS2 LUBRICATION SYSTEMS 18-48
18122 FINE ADJUSTMENT 18-49
18123 COMMISSIONING OF THE SLS LUBRICATION SYSTEM 18-50
19 DEEP TEMPERATURE EQUIPMENT (OPTION) 19-1
191 GENERAL INFORMATION 19-2
1911 INTRODUCTION 19-2
1912 DEEP TEMPERATURE COMPONENTS OVERVIEW 19-2
1913 POWER SUPPLY PRECONDITIONS FOR PREHEATING 19-3
1914 POWER REQUIREMENTS FOR PREHEATING SYSTEMS 19-4
192 PREHEATING PROCEDURE 19-5
1921 GLOBAL FLOW CHART OF THE PREHEATING PROCEDURE 19-5
1922 STARTING THE PREHEATING PROCEDURE 19-6
1923 PREHEATING OF OPERATOR’S CAB AND DIESEL ENGINE
[COOLANT SYSTEM] 19-7
1924 PREHEATING OF LUBRICANTS AND SUPERSTRUCTURE (DIESEL)
[ELECTRIC SYSTEM] 19-8
193 CONSTANT HEATING OF TRAVEL MOTORS (TTT EQUIPMENT BELOW-40°C ONLY) 19-9
194 COMPONENT LOCATION 19-10
1941 ELECTRIC HEATING ELEMENTS FOR HYDRAULIC & BATTERIES
[ELECTRIC MACHINE] 19-10
1942 ELECTRIC HEATING ELEMENTS FOR HYDRAULICS
[DIESEL MACHINE] 19-12
1943 ELECTRIC HEATING ELEMENTS FOR ENGINES & BATTERIES
[DIESEL MACHINE] 19-14
195 COMPONENTS OF TT EQUIPMENT 19-16
TOC – 12 PC8000E-6 SM 12089-xE-GB-0
1951 PREHEATING COMPONENTS ON A DIESEL MACHINE 19-16
1952 PREHEATING COMPONENTS ON AN ELECTRIC MACHINE 19-17
1953 EXEMPLARY WIRING DIAGRAMS FOR PREHEATING SYSTEMS 19-18
19531 WIRING DIAGRAM “HYDRAULIC OIL TANK PREHEATING” PART 1 OF 3 19-18
19532 WIRING DIAGRAM “HYDRAULIC OIL TANK PREHEATING” PART 2 OF 3 19-19
19533 WIRING DIAGRAM “HYDRAULIC OIL TANK PREHEATING” PART 3 OF 3 19-20
19534 WIRING DIAGRAM “SUCTION OIL MANIFOLD PREHEATING” 19-21
19535 WIRING DIAGRAM “PTO PREHEATING” 19-22
19536 WIRING DIAGRAM “BATTERY HEATER PADS” 19-23

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.