Komatsu Hydraulic Mining Shovel PC8000E-6 Shop Manual(12089-xE-GB-2) – PDF DOWNLOAD

Komatsu Hydraulic Mining Shovel PC8000E-6 Shop Manual(12089-xE-GB-2) – PDF DOWNLOAD

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Komatsu Hydraulic Mining Shovel PC8000E-6 Shop Manual(12089-xE-GB-2) – PDF DOWNLOAD

BEFORE READING THIS MANUAL
This manual gives details of the methods of inspection, maintenance and troubleshooting for this machine that
must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental
safety rules for the inspection, maintenance and troubleshooting of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
inspection, maintenance or troubleshooting. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that may involve a potential hazard when the machine is used. Therefore,
the safety messages in this manual and on the machine may not include all possible safety precautions. If
you carry out any inspection, maintenance and troubleshooting under conditions that are not described in this
manual, understand that it is your responsibility to take the necessary precautions to ensure safety. In no event
should you or others engage in prohibited uses or actions described in this manual. Improper inspection, maintenance
and troubleshooting of the machine can be hazardous and could result in serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
This manual uses the international units (SI) for units of measurement. For reference, units that have been used in
the past are given in ( ).
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of publication. Continuing improvements in the design of this machine may lead to additional
changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest
available information concerning your machine or with questions regarding information contained in this manual.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has
been shipped. If the machine has been purchased in another country, it may lack certain safety devices and specifications
that are necessary for use in your country. If there is any question about whether your product complies
with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before
operating the machine.
TABLE OF CONTENTS:

Komatsu Hydraulic Mining Shovel PC8000E-6 Shop Manual(12089-xE-GB-2) – PDF DOWNLOAD

SHOP MANUAL Cover…………………………………………………………………………………………. 1
00 FOREWORD………………………………………………………………………………………………. 3
1 Foreword……………………………………………………………………………………………. 5
1.1 BEFORE READING THIS MANUAL………………………………………………………………………. 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 FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR……. 11
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB………………………………………………………… 12
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR……………………………………………. 13
2.4.1 UNDERSTANDING THE MACHINE………………………………………………………………….. 13
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR………………………………………… 13
2.4.2.1 ENSURING SAFE OPERATION………………………………………………………………. 13
2.4.3 PREPARATIONS FOR SAFE OPERATION…………………………………………………………….. 13
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT………………………………………….. 13
2.4.3.2 INSPECTING THE MACHINE……………………………………………………………….. 13
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT………………………………………. 14
2.4.3.4 KEEP MACHINE CLEAN…………………………………………………………………… 14
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT………………………………………………. 14
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT…………………………………………….. 15
2.4.3.7 IF A PROBLEM IS FOUND………………………………………………………………… 15
2.4.4 FIRE PREVENTION…………………………………………………………………………… 15
2.4.4.1 PRECAUTIONS TO PREVENT FIRE…………………………………………………………… 15
2.4.4.2 ACTION IF FIRE OCCURS………………………………………………………………… 16
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB…………………………………………………….. 17
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE……………………………………………….. 17
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE……………………………….. 17
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE………………………………………………………. 17
2.4.5.3 NO PEOPLE ON THE ATTACHMENT…………………………………………………………… 17
2.4.5.4 WORKING IN HIGH PLACES……………………………………………………………….. 17
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK……………………………………………………… 18
2.4.5.6 LEAVING THE MACHINE………………………………………………………………….. 18
2.4.6 BURN PREVENTION…………………………………………………………………………… 19
2.4.6.1 Hot coolant…………………………………………………………………………. 19
2.4.6.2 Hot oil…………………………………………………………………………….. 19
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS…………………………………………………………. 19
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…………………………………………………. 20
2.4.8.1 UNAUTHORIZED MODIFICATION…………………………………………………………….. 20
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS………………………………………….. 20
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)…………………………………………………………. 21
2.4.10 PRECAUTIONS AT JOBSITE……………………………………………………………………. 22
2.4.10.1 VISIBILITY FROM OPERATOR’S SEAT………………………………………………………. 23
2.4.10.2 CAMERA SYSTEM WITH MONITORS………………………………………………………….. 23
2.4.10.3 ENSURE GOOD VISIBILITY………………………………………………………………. 23
2.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS………………………………………………… 23
2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS…………………………………………….. 24
2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES………………………………………………… 24
2.4.10.7 WORKING ON LOOSE GROUND……………………………………………………………… 25
2.4.10.8 GAS, DUST, STEAM AND SMOKE…………………………………………………………… 25
2.4.10.9 VENTILATION OF ENCLOSED AREAS………………………………………………………… 26
2.4.11 STARTING motor…………………………………………………………………………… 27
2.4.11.1 WARNING TAG………………………………………………………………………… 27
2.4.11.2 CHECKS BEFORE STARTING motor…………………………………………………………. 27
2.4.11.3 PRECAUTION WHEN STARTING motor……………………………………………………….. 27
2.4.11.4 PRECAUTION IN COLD AREAS…………………………………………………………….. 28
2.4.12 OPERATION……………………………………………………………………………….. 28
2.4.12.1 CHECKS BEFORE OPERATION……………………………………………………………… 28
2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE………………………………………. 29
2.4.12.3 PRECAUTIONS WHEN travelling………………………………………………………….. 30
2.4.12.4 TRAVELLING ON SLOPES………………………………………………………………… 31
2.4.12.5 OPERATIONS ON SLOPES………………………………………………………………… 32
2.4.12.6 PROHIBITED OPERATIONS……………………………………………………………….. 32
2.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES………………………………………….. 33
2.4.12.8 PARKING THE MACHINE…………………………………………………………………. 33
2.4.12.9 TRANSPORTATION……………………………………………………………………… 33
2.5 PRECAUTION FOR MAINTENANCE………………………………………………………………………. 34
2.5.1 GENERAL PRECAUTIONS……………………………………………………………………….. 34
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…………………………. 35
2.5.1.2 STOP motor FOR MAINTENANCE……………………………………………………………. 36
2.5.1.3 WARNING TAG…………………………………………………………………………. 37
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY…………………………………………………………. 38
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS………………………………………………… 38
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING………………………………….. 39
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS…………………………………………….. 39
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT………………………………….. 40
2.5.1.9 NOISE………………………………………………………………………………. 40
2.5.1.10 WHEN USING A HAMMER…………………………………………………………………. 40
2.5.1.11 PROPER TOOLS……………………………………………………………………….. 41
2.5.1.12 ACCUMULATOR………………………………………………………………………… 41
2.5.1.13 PERSONNEL………………………………………………………………………….. 41
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…………………………………………………… 42
2.5.2.1 PRECAUTION WHEN WELDING………………………………………………………………. 42
2.5.2.2 BATTERY HANDLING…………………………………………………………………….. 42
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID………………………………………………………… 43
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE……………………………………………………. 43
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES…………………………………………………. 44
2.5.3.3 REPLACEMENT OF HOSE LINES…………………………………………………………….. 44
2.5.3.4 INSPECTION OF HOSE LINES……………………………………………………………… 44
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………………………………………… 45
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE………………………………………………………….. 45
2.5.3.7 AIR CONDITIONING MAINTENANCE………………………………………………………….. 45
2.5.3.8 COMPRESSED AIR………………………………………………………………………. 46
2.5.3.9 WASTE MATERIALS……………………………………………………………………… 46
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS……………………………………. 47
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM………………………………………………………….. 47
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS………………………………… 47
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR……………………………………………….. 47
2.7 SPECIAL SAFETY EQUIPMENT………………………………………………………………………… 48
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB……………………………………… 49
2.7.2 OBJECT HANDLING…………………………………………………………………………… 49
2.7.3 LIGHTING…………………………………………………………………………………. 49
2.7.4 WARNING BEACON……………………………………………………………………………. 49
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…………………………………… 49
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)……………………………… 49
2.7.5.2 INSTRUCTIONS FOR USE…………………………………………………………………. 51
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL………………………………………… 53
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1),….. 53
2.7.5.5 INSTRUCTIONS FOR USE…………………………………………………………………. 55
01 SPECIFICATION …………………………………………………………………………………………. 57
PC8000……………………………………………………………………………………………….. 59
10 STRUCTURE & FUNCTION
…………………………………………………………………………………… 67
TOC
…………………………………………………………………………………………………. 69
1 Introduction………………………………………………………………………………………… 81
1.1 Contents of the binder………………………………………………………………………….. 82
1.2 Foreword………………………………………………………………………………………. 82
1.3 Recommendations for environmentally friendly operation and maintenance of hydraulic mining shovels………. 84
1.4 Explanation of abbreviations…………………………………………………………………….. 85
1.5 Diagrams and illustrations in this manual…………………………………………………………. 86
2 SAFETY……………………………………………………………………………………………… 89
2.1 SAFETY INFORMATION……………………………………………………………………………… 90
2.2 OVERVIEW………………………………………………………………………………………. 91
2.2.1 NORMAL OPERATIONS…………………………………………………………………………. 91
2.2.2 REGULAR MAINTENANCE……………………………………………………………………….. 91
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR……………………………………………………… 91
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR……. 91
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB………………………………………………………… 92
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR……………………………………………. 93
2.4.1 UNDERSTANDING THE MACHINE………………………………………………………………….. 93
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR………………………………………… 93
2.4.2.1 ENSURING SAFE OPERATION………………………………………………………………. 93
2.4.3 PREPARATIONS FOR SAFE OPERATION…………………………………………………………….. 93
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT………………………………………….. 93
2.4.3.2 INSPECTING THE MACHINE……………………………………………………………….. 93
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT………………………………………. 94
2.4.3.4 KEEP MACHINE CLEAN…………………………………………………………………… 94
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT………………………………………………. 94
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT…………………………………………….. 95
2.4.3.7 IF A PROBLEM IS FOUND………………………………………………………………… 95
2.4.4 FIRE PREVENTION…………………………………………………………………………… 95
2.4.4.1 PRECAUTIONS TO PREVENT FIRE…………………………………………………………… 95
2.4.4.2 ACTION IF FIRE OCCURS………………………………………………………………… 96
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB…………………………………………………….. 97
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE……………………………………………….. 97
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE……………………………….. 97
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE………………………………………………………. 97
2.4.5.3 NO PEOPLE ON THE ATTACHMENT…………………………………………………………… 97
2.4.5.4 WORKING IN HIGH PLACES……………………………………………………………….. 97
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK……………………………………………………… 98
2.4.5.6 LEAVING THE MACHINE………………………………………………………………….. 98
2.4.6 BURN PREVENTION…………………………………………………………………………… 99
2.4.6.1 Hot coolant…………………………………………………………………………. 99
2.4.6.2 Hot oil…………………………………………………………………………….. 99
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS…………………………………………………………. 99
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…………………………………………………. 100
2.4.8.1 UNAUTHORIZED MODIFICATION…………………………………………………………….. 100
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS………………………………………….. 100
2.4.9 PRECAUTIONS AT JOBSITE…………………………………………………………………….. 101
2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT……………………………………………………….. 102
2.4.9.2 CAMERA SYSTEM WITH MONITORS…………………………………………………………… 102
2.4.9.3 ENSURE GOOD VISIBILITY……………………………………………………………….. 102
2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS…………………………………………………. 102
2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS……………………………………………… 103
2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES…………………………………………………. 103
2.4.9.7 WORKING ON LOOSE GROUND………………………………………………………………. 104
2.4.9.8 GAS, DUST, STEAM AND SMOKE……………………………………………………………. 104
2.4.9.9 VENTILATION OF ENCLOSED AREAS…………………………………………………………. 105
2.4.10 STARTING ENGINE………………………………………………………………………….. 106
2.4.10.1 WARNING TAG………………………………………………………………………… 106
2.4.10.2 CHECKS BEFORE STARTING ENGINE………………………………………………………… 106
2.4.10.3 PRECAUTION WHEN STARTING ENGINE………………………………………………………. 106
2.4.10.4 PRECAUTION IN COLD AREAS…………………………………………………………….. 107
2.4.11 OPERATION……………………………………………………………………………….. 107
2.4.11.1 CHECKS BEFORE OPERATION……………………………………………………………… 107
2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE………………………………………. 108
2.4.11.3 PRECAUTIONS WHEN travelling………………………………………………………….. 109
2.4.11.4 TRAVELLING ON SLOPES………………………………………………………………… 110
2.4.11.5 OPERATIONS ON SLOPES………………………………………………………………… 111
2.4.11.6 PROHIBITED OPERATIONS……………………………………………………………….. 111
2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES………………………………………….. 112
2.4.11.8 PARKING THE MACHINE…………………………………………………………………. 112
2.4.11.9 TRANSPORTATION……………………………………………………………………… 112
2.5 PRECAUTION FOR MAINTENANCE………………………………………………………………………. 113
2.5.1 GENERAL PRECAUTIONS……………………………………………………………………….. 113
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…………………………. 114
2.5.1.2 STOP ENGINE FOR MAINTENANCE…………………………………………………………… 115
2.5.1.3 WARNING TAG…………………………………………………………………………. 116
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY…………………………………………………………. 117
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS………………………………………………… 117
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING………………………………….. 118
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS…………………………………………….. 118
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT………………………………….. 119
2.5.1.9 NOISE………………………………………………………………………………. 119
2.5.1.10 WHEN USING A HAMMER…………………………………………………………………. 119
2.5.1.11 PROPER TOOLS……………………………………………………………………….. 120
2.5.1.12 ACCUMULATOR………………………………………………………………………… 120
2.5.1.13 PERSONNEL………………………………………………………………………….. 120
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…………………………………………………… 121
2.5.2.1 PRECAUTION WHEN WELDING………………………………………………………………. 121
2.5.2.2 BATTERY HANDLING…………………………………………………………………….. 121
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID………………………………………………………… 122
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE……………………………………………………. 122
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES…………………………………………………. 123
2.5.3.3 REPLACEMENT OF HOSE LINES…………………………………………………………….. 123
2.5.3.4 INSPECTION OF HOSE LINES……………………………………………………………… 123
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………………………………………… 124
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE………………………………………………………….. 124
2.5.3.7 AIR CONDITIONING MAINTENANCE………………………………………………………….. 124
2.5.3.8 COMPRESSED AIR………………………………………………………………………. 125
2.5.3.9 WASTE MATERIALS……………………………………………………………………… 125
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS……………………………………. 126
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM………………………………………………………….. 126
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS………………………………… 126
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR……………………………………………….. 126
2.7 SPECIAL SAFETY EQUIPMENT………………………………………………………………………… 128
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB……………………………………… 129
2.7.2 OBJECT HANDLING…………………………………………………………………………… 129
2.7.3 LIGHTING…………………………………………………………………………………. 129
2.7.4 WARNING BEACON……………………………………………………………………………. 129
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…………………………………… 129
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)……………………………… 129
2.7.5.2 INSTRUCTIONS FOR USE…………………………………………………………………. 131
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL………………………………………… 133
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1),…. 133
2.7.5.5 INSTRUCTIONS FOR USE…………………………………………………………………. 135
3 Specifications………………………………………………………………………………………. 137
3.1 Lifting Gears………………………………………………………………………………….. 138
3.2 Safety hints for sling accessory…………………………………………………………………. 140
3.3 Standard Tightening Torque Chart…………………………………………………………………. 141
3.4 Conversion Table……………………………………………………………………………….. 142
3.5 Blind plugs……………………………………………………………………………………. 148
3.6 Classification of threads to the nominal width…………………………………………………….. 150
3.7 Plugs and fittings according to ISO 8434-1 / DIN 2353………………………………………………. 151
4 Main assembly groups…………………………………………………………………………………. 153
4.1 General layout…………………………………………………………………………………. 154
4.2 Superstructure…………………………………………………………………………………. 156
4.3 Machine house………………………………………………………………………………….. 160
4.4 Hydraulic oil tank……………………………………………………………………………… 162
4.5 Hydraulic oil cooler……………………………………………………………………………. 164
4.6 High voltage switch cabinet……………………………………………………………………… 166
4.7 Cab support……………………………………………………………………………………. 172
4.7.1 X2 – Low voltage switch board (location 12)………………………………………………….. 173
4.7.2 Extra low voltage switch board (location 11)…………………………………………………. 175
4.8 Slip ring unit…………………………………………………………………………………. 176
4.9 Operator’s cab…………………………………………………………………………………. 180
4.10 Control blocks………………………………………………………………………………… 182
4.11 Swing machinery……………………………………………………………………………….. 184
4.11.1 Swing machinery L&S………………………………………………………………………. 184
4.11.2 Swing machinery SIEBENHAAR………………………………………………………………… 186
4.12 Undercarriage…………………………………………………………………………………. 188
4.13 Attachments…………………………………………………………………………………… 190
4.13.1 Front Shovel Attachment (FSA)……………………………………………………………… 190
4.13.2 Backhoe Attachment (BHA)………………………………………………………………….. 192
5 Drive………………………………………………………………………………………………. 195
5.1 Electric drive – Safety and operation instruction documents…………………………………………. 196
5.2 Prime drive assembly……………………………………………………………………………. 198
5.3 Electric motors………………………………………………………………………………… 200
5.3.1 Location of attaching parts………………………………………………………………… 200
5.3.1.1 Motor type plate…………………………………………………………………….. 201
5.3.1.2 Type plate for the motor bearings……………………………………………………… 202
5.3.2 Motor bearings & grease equipment…………………………………………………………… 204
5.3.3 Monitoring of the motor bearing temperature………………………………………………….. 206
5.3.4 Monitoring of the motor winding temperature………………………………………………….. 207
5.3.5 Junction box for the motor monitoring device…………………………………………………. 208
5.3.6 Checking of the bearing condition…………………………………………………………… 209
5.3.7 Capacitor assembly………………………………………………………………………… 210
5.4 Air-to-air motor cooling system………………………………………………………………….. 212
5.5 Initial Start-up procedure………………………………………………………………………. 213
5.5.1 Main supply cable…………………………………………………………………………. 214
5.5.2 Machine configuration (via CoDeSys)…………………………………………………………. 215
5.5.3 Motor protection relay (SPAM 150 C)…………………………………………………………. 220
5.5.4 Motor alignment…………………………………………………………………………… 222
5.5.5 Motor rotation direction…………………………………………………………………… 224
5.5.6 Starting & Re-starting the electric motors…………………………………………………… 224
5.5.7 Supervision during the first motor running period…………………………………………….. 225
5.6 Flexible coupling………………………………………………………………………………. 226
5.6.1 Coupling inspection……………………………………………………………………….. 227
5.6.2 Coupling replacement………………………………………………………………………. 228
5.7 Pump distributor gearbox (PTO)…………………………………………………………………… 230
5.7.1 Pump drive shaft housing / spline lubrication………………………………………………… 232
5.7.2 PTO lubrication and cooling………………………………………………………………… 234
5.7.2.1 Checks and adjustments……………………………………………………………….. 236
5.7.3 Hydraulic pumps – location, drive speed and flow rates………………………………………… 238
6 Hydraulic oil tank…………………………………………………………………………………… 241
6.1 General layout…………………………………………………………………………………. 242
6.2 Location of the electric equipment……………………………………………………………….. 244
6.3 Suction oil tank with strainers………………………………………………………………….. 246
6.4 Return oil collector pipe with strainer…………………………………………………………… 248
6.5 Back pressure valve…………………………………………………………………………….. 250
6.6 Transfer pump………………………………………………………………………………….. 252
6.7 Return and leak oil filter………………………………………………………………………. 254
6.8 Breather filter………………………………………………………………………………… 256
7 Hydraulic oil cooling………………………………………………………………………………… 259
7.1 Overall view of the hydraulic oil cooling…………………………………………………………. 260
7.2 Function of the hydraulic oil cooling circuit……………………………………………………… 262
7.2.1 Standard hydraulic oil cooling circuit………………………………………………………. 262
7.2.2 Additional oil cooling circuit……………………………………………………………… 264
7.3 Adjustment of the back pressure valve…………………………………………………………….. 266
7.4 Fan drive – standard oil cooler………………………………………………………………….. 268
7.4.1 Two stage cooler fan drive RPM control………………………………………………………. 268
7.4.2 Fixed displacement pump with variable setting………………………………………………… 270
7.4.3 Pressure relief valves…………………………………………………………………….. 272
7.4.4 Solenoid valves…………………………………………………………………………… 274
7.5 Adjustment of the cooler fan drive speed………………………………………………………….. 276
7.5.1 Maximum speed…………………………………………………………………………….. 276
7.5.2 Medium speed……………………………………………………………………………… 278
7.6 Fan drive – additional oil cooler………………………………………………………………… 280
7.6.1 Function of the additional cooler fan RPM control…………………………………………….. 281
7.6.2 Adjustment of the additional cooler fan drive speed…………………………………………… 281
8 Controlling…………………………………………………………………………………………. 283
8.1 General layout…………………………………………………………………………………. 284
8.2 Control and filter panels – location of components…………………………………………………. 286
8.2.1 Main valve cartridge block…………………………………………………………………. 286
8.2.2 Control and filter panels mounted on the PTOs………………………………………………… 292
8.3 Pilot pressure supply and adjustments…………………………………………………………….. 294
8.3.1 Pilot pressure circuit…………………………………………………………………….. 295
8.3.2 Checks and adjustments of pilot pressure…………………………………………………….. 298
8.3.3 Remote control valves arrangement…………………………………………………………… 302
8.4 Function of the electro-hydraulic control system…………………………………………………… 304
8.5 Hand lever (joystick) control……………………………………………………………………. 308
8.6 Foot pedal control……………………………………………………………………………… 310
8.7 Proportional amplifier module, type A…………………………………………………………….. 312
8.8 Proportional amplifier module, type B…………………………………………………………….. 314
8.9 Ramp time module……………………………………………………………………………….. 316
8.10 Adjustment of amplifier modules…………………………………………………………………. 318
8.10.1 General…………………………………………………………………………………. 319
8.10.2 Adjusting the amplifier module, type A……………………………………………………… 320
8.10.3 Adjusting the amplifier module, type B……………………………………………………… 322
8.11 Adjusting the ramp time module………………………………………………………………….. 324
9 Components………………………………………………………………………………………….. 329
9.1 Main control blocks and high pressure filters (FSA)………………………………………………… 330
9.2 Distributor manifold – location of restrictor blocks and anti-cavitation valves……………………….. 334
9.3 Restrictor block with secondary relief valve………………………………………………………. 336
9.4 Anti-cavitation valve (ACV) block………………………………………………………………… 338
9.4.1 ACV block on control blocks………………………………………………………………… 338
9.4.2 ACV block on top of the manifold……………………………………………………………. 340
9.5 Remote control valves…………………………………………………………………………… 342
9.6 4/3 Directional solenoid valves………………………………………………………………….. 344
9.7 Proportional solenoid valves…………………………………………………………………….. 346
9.8 High-pressure filter (screen)……………………………………………………………………. 348
9.9 CONTROL blocks and valves……………………………………………………………………….. 350
9.10 Travel brake valve…………………………………………………………………………….. 362
9.11 Pressure reducing valve………………………………………………………………………… 364
9.12 4/2 Directional valves…………………………………………………………………………. 366
9.13 Pressure double stage valve…………………………………………………………………….. 368
9.14 Hydraulic cylinder…………………………………………………………………………….. 370
10 Main hydraulic pumps and pump regulation………………………………………………………………. 373
10.1 General………………………………………………………………………………………. 374
10.1.1 Layout………………………………………………………………………………….. 374
10.1.2 Pump regulation system (“open sensing system”)………………………………………………. 377
10.1.3 Pump regulation system — valve function…………………………………………………….. 378
10.2 Main pumps……………………………………………………………………………………. 380
10.2.1 Pump bearing flushing / lubrication………………………………………………………… 382
10.2.2 Operating principle………………………………………………………………………. 384
10.2.3 Checks / adjustments……………………………………………………………………… 400
10.2.3.1 Qmax and Qmin adjustment bolts……………………………………………………….. 402
10.3 Electronic pump regulation system……………………………………………………………….. 404
10.3.1 Electronic load limiting control – general………………………………………………….. 405
10.3.2 Microcontroller RC4-4…………………………………………………………………….. 406
10.3.3 Signal rectifier module…………………………………………………………………… 408
10.3.3.1 Checks and adjustments………………………………………………………………. 410
10.4 Hydraulic constant regulation system (emergency mode)……………………………………………… 412
10.4.1 General…………………………………………………………………………………. 413
10.5 Pump regulation system, checks and adjustments……………………………………………………. 415
10.5.1 Power Check……………………………………………………………………………… 415
10.5.2 Electronic load limit regulation, XLR basic adjustment……………………………………….. 418
10.5.2.1 Method “A” with 24 V supply………………………………………………………….. 420
10.5.2.2 Method “B” with BODAS software……………………………………………………….. 422
10.5.3 Electronic load limit regulation, RC4 function check…………………………………………. 426
10.5.4 Hydraulic Control (emergency mode)…………………………………………………………. 428
10.5.5 Pressure cut-off valve……………………………………………………………………. 430
10.6 Energy efficiency……………………………………………………………………………… 432
10.6.1 General…………………………………………………………………………………. 433
10.6.2 Checks and adjustments……………………………………………………………………. 434
11 Operating hydraulics………………………………………………………………………………… 437
11.1 General………………………………………………………………………………………. 438
11.1.1 Floating function for boom and stick cylinder (FSA)………………………………………….. 440
11.2 Hydraulics for the attachment cylinders FSA………………………………………………………. 442
11.2.1 Electric / hydraulic flowchart “Boom UP” (FSA)………………………………………………. 442
11.2.2 Electric / hydraulic flowchart “Boom down” (FSA), Auto-float ON……………………………….. 444
11.2.3 Electric / hydraulic flowchart “Boom down” (FSA), Auto-float OFF………………………………. 446
11.2.4 Electric / hydraulic flowchart “Stick out” (FSA)…………………………………………….. 448
11.2.5 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float ON………………………………… 450
11.2.6 Electric / hydraulic flowchart “Stick in” (FSA), Auto-float OFF……………………………….. 452
11.2.7 Electric / hydraulic flowchart “Bucket fill” (FSA)…………………………………………… 454
11.2.8 Electric / hydraulic flowchart “Bucket dump” (FSA)…………………………………………… 456
11.2.9 Electric / hydraulic flowchart “Clam open” (FSA)…………………………………………….. 458
11.2.10 Electric / hydraulic flowchart “Clam close” (FSA)…………………………………………… 460
11.2.11 Checks and adjustments of the main relief valves (MRV), FSA………………………………….. 462
11.2.12 Checks and adjustments of the secondary relief valves (SRV), FSA……………………………… 464
11.2.12.1 Boom cylinder, piston side (FSA)…………………………………………………….. 464
11.2.12.2 Boom cylinder, piston rod side (FSA)…………………………………………………. 468
11.2.12.3 Stick cylinder, piston side (FSA)……………………………………………………. 472
11.2.12.4 Stick cylinder, piston rod side (FSA)………………………………………………… 476
11.2.12.5 Bucket cylinder, piston side (FSA)…………………………………………………… 480
11.2.12.6 Bucket cylinder, piston side (FSA)…………………………………………………… 484
11.2.12.7 Clam cylinder, piston rod side (FSA), clam open……………………………………….. 488
11.2.12.8 Clam cylinder, piston side (FSA), clam close………………………………………….. 492
11.2.13 Checks and adjustments of the lowering speed – boom…………………………………………. 496
11.2.14 Checks and adjustments of the lowering speed – stick………………………………………… 500
11.2.15 Checks and adjustments of the lowering speed – Bucket……………………………………….. 504
11.2.16 Checks and adjustments of the lowering speed – clam…………………………………………. 508
11.3 Hydraulics for the swing circuit………………………………………………………………… 510
11.3.1 Swing circuit……………………………………………………………………………. 510
11.3.2 Swing motor……………………………………………………………………………… 514
11.3.3 Swing gearbox (L&S)………………………………………………………………………. 518
11.3.4 Swing gearbox (SIEBENHAAR)………………………………………………………………… 520
11.3.5 Swing parking brake (L&S)…………………………………………………………………. 522
11.3.6 Swing parking brake (SIEBENHAAR)…………………………………………………………… 524
11.3.7 Swing brake valve………………………………………………………………………… 526
11.3.8 Electric / hydraulic flowchart “Swing left”…………………………………………………. 530
11.3.9 Electric / hydraulic flowchart “Swing right”………………………………………………… 532
11.3.10 Checks and adjustments for the swing circuit……………………………………………….. 534
11.3.11 Function check for hydraulic swing brake…………………………………………………… 538
11.3.12 Function check for the swing parking brake…………………………………………………. 540
11.4 Hydraulics for the travel circuit……………………………………………………………….. 544
11.4.1 Travel circuit…………………………………………………………………………… 545
11.4.2 Travel motor…………………………………………………………………………….. 548
11.4.3 Rotary joint…………………………………………………………………………….. 550
11.4.4 Travel gearbox…………………………………………………………………………… 552
11.4.5 Travel parking brake (L&S)………………………………………………………………… 554
11.4.6 Travel parking brake (ZOLLERN)…………………………………………………………….. 556
11.4.7 Travel brake valve……………………………………………………………………….. 558
11.4.8 Electric / hydraulic flowchart “Travel forward”……………………………………………… 560
11.4.9 Electric / hydraulic flowchart “Travel backwards”……………………………………………. 562
11.4.10 Checks and adjustments for the travel circuit………………………………………………. 564
11.4.11 Function check for the travel parking brake………………………………………………… 566
12 Hydraulic track tensioning system…………………………………………………………………….. 569
12.1 General………………………………………………………………………………………. 570
12.2 Functional description…………………………………………………………………………. 572
12.3 Double-stage valve…………………………………………………………………………….. 576
12.4 Tensioning cylinder……………………………………………………………………………. 578
12.5 Adjustments / checks…………………………………………………………………………… 580
13 Access ladder, hydraulically operated…………………………………………………………………. 583
13.1 General………………………………………………………………………………………. 584
13.2 Function of the hydraulically operated access ladder………………………………………………. 586
13.3 Adjustments / checks…………………………………………………………………………… 590
14 Central refilling system (service arm)………………………………………………………………… 593
14.1 Service arm…………………………………………………………………………………… 594
14.2 Monitoring and control box……………………………………………………………………… 596
14.3 Function……………………………………………………………………………………… 598
14.4 Checks and adjustments…………………………………………………………………………. 600
15 Hints for reading the hydraulic diagram……………………………………………………………….. 603
15.1 General………………………………………………………………………………………. 604
15.2 Hydraulic symbols……………………………………………………………………………… 606
15.2.1 Lines, unions……………………………………………………………………………. 607
15.2.2 Components, valves……………………………………………………………………….. 609
15.2.3 Sensors…………………………………………………………………………………. 609
15.2.4 Valves, valve components………………………………………………………………….. 610
15.2.5 Pump, motor, cylinder…………………………………………………………………….. 614
16 Hints for reading the electric wiring diagram………………………………………………………….. 619
16.1 General………………………………………………………………………………………. 620
16.2 Reference code of the electrical components………………………………………………………. 621
16.2.1 Area code……………………………………………………………………………….. 621
16.2.2 Component identifying letter………………………………………………………………. 623
16.3 Graphical symbols……………………………………………………………………………… 624
16.4 Drawing concept……………………………………………………………………………….. 628
16.5 Cable marking…………………………………………………………………………………. 638
17 KOMTRAX Plus & MTC control system…………………………………………………………………….. 639
17.1 General………………………………………………………………………………………. 640
17.2 Specifications for operators……………………………………………………………………. 643
17.2.1 Sequence of displays……………………………………………………………………… 644
17.2.2 Opening screen…………………………………………………………………………… 644
17.2.3 Main gauge screens 1 to 3…………………………………………………………………. 645
17.2.4 Energy consumption screen…………………………………………………………………. 648
17.2.5 Failure message history for the operator……………………………………………………. 650
17.2.6 Main gauge screens – Changing of Time / SMR / Date…………………………………………… 652
17.2.7 Maintenance monitor………………………………………………………………………. 653
17.2.8 Settings for operator…………………………………………………………………….. 655
17.2.9 Automatic messages……………………………………………………………………….. 662
17.3 Tables of all provided messages…………………………………………………………………. 665
17.3.1 Table of G-Codes…………………………………………………………………………. 666
17.3.2 Table of available Instruction Messages…………………………………………………….. 674
17.4 Flow charts (1-4) of KOMTRAX Plus main screens……………………………………………………. 677
17.5 KOMTRAX Plus service level……………………………………………………………………… 682
17.5.1 Explanation of the button symbols (Service Level)……………………………………………. 684
17.5.2 Service Menu Select Screen………………………………………………………………… 685
17.5.3 Real Time Menu Select Screen………………………………………………………………. 686
17.5.3.1 Real Time Menu, option: 01 Motor 1……………………………………………………. 687
17.5.3.2 Real Time Menu, option: 02 Motor 2……………………………………………………. 687
17.5.3.3 Real Time Menu, option: 03 PTO 1……………………………………………………… 688
17.5.3.4 Real Time Menu, option: 04 PTO 2……………………………………………………… 688
17.5.3.5 Real Time Menu, option: 05 Hydraulic………………………………………………….. 689
17.5.3.6 Real Time Menu, option: 06 Slew………………………………………………………. 690
17.5.3.7 Real Time Menu, option: 07 Electrical Equipment………………………………………… 691
17.5.3.8 Real Time Menu, option: 08 Emergency Stop……………………………………………… 692
17.5.3.9 Real Time Menu, option: 09 Heater…………………………………………………….. 693
17.5.3.10 Real Time Menu, option: 10 Manual Switch……………………………………………… 694
17.5.3.11 Real Time Menu, option: 11 Central lUBE System 1………………………………………. 695
17.5.3.12 Real Time Menu, option: 12 Slew Ring Gear Lube System………………………………….. 696
17.5.3.13 Real Time Menu, option: 13 Central Lube System 2………………………………………. 697
17.5.3.14 Real Time Menu, option: 14 Cable Drum………………………………………………… 698
17.5.3.15 Real Time Menu, option: 15 Windscreen Wiper…………………………………………… 699
17.5.3.16 Real Time Menu, option: 16 Ladder……………………………………………………. 700
17.5.3.17 Real Time Menu, option: 17 Service Arm……………………………………………….. 701
17.5.3.18 Real Time Menu, option: 18 Pilot Control……………………………………………… 702
17.5.3.19 Real Time Menu, option: 19 Other Items……………………………………………….. 703
17.5.3.20 Real Time Menu, option: 20 Output Signals…………………………………………….. 704
17.5.3.21 Output signals with deactivated MTC evaluation………………………………………… 707
17.5.4 PM-Clinic……………………………………………………………………………….. 709
17.5.4.1 General……………………………………………………………………………. 709
17.5.4.2 Power Check………………………………………………………………………… 710
17.5.5 Serial/GCC no. setting……………………………………………………………………. 711
17.5.6 Memory Clear…………………………………………………………………………….. 712
17.5.6.1 Input Memory Clear ID……………………………………………………………….. 712
17.5.6.2 Memory Clear screen…………………………………………………………………. 713
17.5.7 Failure History………………………………………………………………………….. 714
17.5.8 Maintenance Monitor………………………………………………………………………. 715
17.5.9 Snapshot………………………………………………………………………………… 716
17.5.10 Settings……………………………………………………………………………….. 717
17.5.10.1 Central Lubrication System (CLS 1), screen 1/12……………………………………….. 717
17.5.10.2 Swing Lubrication System (SLS), screen 2/12…………………………………………… 718
17.5.10.3 Central Lubrication System (CLS 2), screen 3/12……………………………………….. 719
17.5.10.4 Qmin – Qmax setting, screen 4/12…………………………………………………….. 720
17.5.10.5 Other Settings 1/2, screen 5/12……………………………………………………… 720
17.5.10.6 Other Settings 2/2, screen 6/12……………………………………………………… 722
17.5.10.7 Shutdown Bypass ON/OFF……………………………………………………………… 725
17.6 Interface-Connection KOMTRAX Plus controller……………………………………………………… 728
17.6.1 KOMTRAX Plus controller…………………………………………………………………… 729
17.7 Wiring of the KOMTRAX Plus controller……………………………………………………………. 730
17.8 MTC control system global layout………………………………………………………………… 734
17.8.1 MTC (Master Turbo Controller)……………………………………………………………… 736
17.8.1.1 MTC flowchart………………………………………………………………………. 736
17.8.1.2 MTC features……………………………………………………………………….. 736
17.8.1.3 MTC firmware and software……………………………………………………………. 737
17.8.1.4 View onto the MTC unit and its connectors……………………………………………… 738
17.9 Global layout of the internal CAN bus……………………………………………………………. 740
17.9.1 General information on a CAN bus system…………………………………………………….. 740
17.9.1.1 General CAN bus description………………………………………………………….. 741
17.9.1.2 CAN bus troubleshooting……………………………………………………………… 741
17.9.1.3 Can bus wiring……………………………………………………………………… 742
17.9.1.4 CAN bus end resistor………………………………………………………………… 744
17.10 The nodes in the CAN bus system………………………………………………………………… 746
17.10.1 Global layout…………………………………………………………………………… 746
17.10.2 Introduction……………………………………………………………………………. 748
17.10.2.1 ICN-V features…………………………………………………………………….. 748
17.10.2.2 ICN-D features…………………………………………………………………….. 750
17.10.3 Node DIP-switches……………………………………………………………………….. 751
17.10.4 Node box……………………………………………………………………………….. 752
17.10.5 Node locations on the machine…………………………………………………………….. 754
17.10.5.1 Node & location chart………………………………………………………………. 755
17.10.5.2 Exemplary view onto the CAN bus control components in a cab base………………………… 756
18 Lubrication system………………………………………………………………………………….. 759
18.1 General overview (SLS & CLS 1 / 2)………………………………………………………………. 760
18.1.1 General description………………………………………………………………………. 761
18.2 Basic function of the lubrication systems………………………………………………………… 762
18.3 Central lubrication system (CLS 1 & 2)…………………………………………………………… 764
18.3.1 General information on the CLS (CLS 1 / 2)………………………………………………….. 766
18.3.1.1 Manual lube activation………………………………………………………………. 766
18.4 Swing circle lubrication system (SLS)……………………………………………………………. 768
18.4.1 General information on the SLS…………………………………………………………….. 770
18.4.1.1 Manual lube activation………………………………………………………………. 770
18.5 Lubrication cycle……………………………………………………………………………… 771
18.5.1 Operation and control…………………………………………………………………….. 771
18.5.2 Lubrication cycle – components…………………………………………………………….. 772
18.5.3 Lubrication cycle – processing…………………………………………………………….. 774
18.5.4 Time segments & switch points of a lubrication cycle…………………………………………. 775
18.5.5 Lubrication modes………………………………………………………………………… 776
18.5.5.1 Automatic lubrication mode…………………………………………………………… 776
18.5.5.2 Manual lubrication mode……………………………………………………………… 776
18.5.5.3 VHMS service mode…………………………………………………………………… 776
18.6 Hydraulically driven lube pump………………………………………………………………….. 778
18.6.1 Adjustment of lube pump speed & working pressure…………………………………………….. 780
18.6.1.1 Stroke speed adjustment……………………………………………………………… 781
18.6.1.2 Working pressure adjustment………………………………………………………….. 782
18.7 Lubricant injectors……………………………………………………………………………. 784
18.7.1 Tightening torques for fittings at grease injectors………………………………………….. 785
18.7.2 Injector type description…………………………………………………………………. 786
18.7.3 Adjustment of the lubricant output…………………………………………………………. 786
18.7.4 Operation principle of lubricant injectors………………………………………………….. 788
18.7.4.1 Function description………………………………………………………………… 789
18.7.5 Connection of one or more injectors………………………………………………………… 790
18.8 Vent valve……………………………………………………………………………………. 792
18.8.1 Description……………………………………………………………………………… 793
18.9 End-line switch……………………………………………………………………………….. 794
18.9.1 Description……………………………………………………………………………… 795
18.9.2 CLS end-line switch adjustment…………………………………………………………….. 796
18.9.3 SLS end-line switch adjustment…………………………………………………………….. 798
18.10 In-line filter……………………………………………………………………………….. 800
18.10.1 Description…………………………………………………………………………….. 801
18.10.2 Maintenance procedure……………………………………………………………………. 801
18.11 Lubricant level sensor………………………………………………………………………… 802
18.11.1 Description…………………………………………………………………………….. 803
18.11.1.1 LEDs at the sonar sensor……………………………………………………………. 804
18.11.2 Binary type lubricant level sensor………………………………………………………… 806
18.11.3 Description…………………………………………………………………………….. 807
18.11.3.1 Adjustment………………………………………………………………………… 807
18.12 Commissioning………………………………………………………………………………… 808
18.12.1 Commissioning of the CLS 1 & CLS 2 lubrication systems………………………………………. 808
18.12.2 Fine adjustment…………………………………………………………………………. 809
18.12.3 Commissioning of the SLS lubrication system………………………………………………… 810
19 Deep temperature equipment (option)…………………………………………………………………… 813
19.1 General information……………………………………………………………………………. 814
19.1.1 Introduction…………………………………………………………………………….. 814
19.1.2 Deep temperature components overview……………………………………………………….. 814
19.1.3 Power supply preconditions for preheating…………………………………………………… 815
19.1.4 Power requirements for preheating systems…………………………………………………… 816
19.2 Preheating procedure…………………………………………………………………………… 817
19.2.1 Global flow chart of the preheating procedure……………………………………………….. 817
19.2.2 Starting the preheating procedure………………………………………………………….. 818
19.2.3 Preheating of operator’s cab and Diesel engine [coolant system]……………………………….. 819
19.2.4 Preheating of lubricants and superstructure (Diesel) [electric system]…………………………. 820
19.3 Constant heating of travel motors (TTT equipment below-40°C only)…………………………………… 821
19.4 Component location…………………………………………………………………………….. 822
19.4.1 Electric heating elements for hydraulic & batteries [electric machine]…………………………. 822
19.4.2 Electric heating elements for hydraulics [Diesel machine]…………………………………….. 824
19.4.3 Electric heating elements for engines & batteries [Diesel machine]…………………………….. 826
19.5 Components of TT equipment……………………………………………………………………… 828
19.5.1 Preheating components on a Diesel machine…………………………………………………… 828
19.5.2 Preheating components on an electric machine………………………………………………… 829
19.5.3 Exemplary Wiring Diagrams for preheating systems…………………………………………….. 830
19.5.3.1 Wiring diagram “Hydraulic Oil Tank Preheating” part 1 of 3………………………………. 830
19.5.3.2 Wiring diagram “Hydraulic Oil Tank Preheating” part 2 of 3………………………………. 831
19.5.3.3 Wiring diagram “Hydraulic Oil Tank Preheating” part 3 of 3………………………………. 832
19.5.3.4 Wiring diagram “Suction Oil Manifold Preheating”……………………………………….. 833
19.5.3.5 Wiring diagram “PTO Preheating”………………………………………………………. 834
19.5.3.6 Wiring diagram “Battery heater pads”………………………………………………….. 835
20 Cable drum (optional equipment)………………………………………………………………………. 837
20.1 General layout………………………………………………………………………………… 838
20.1.1 Long type cable drum……………………………………………………………………… 838
20.1.2 short type cable drum…………………………………………………………………….. 839
20.1.2.1 Parts installed in the undercarriage………………………………………………….. 840
20.2 Service switch………………………………………………………………………………… 841
20.3 Drive system………………………………………………………………………………….. 842
20.3.1 Drive motor……………………………………………………………………………… 843
20.4 Drum Body…………………………………………………………………………………….. 844
20.4.1 Slip ring assembly……………………………………………………………………….. 845
20.4.2 Checks and adjustments……………………………………………………………………. 845
20.5 High voltage interlock system…………………………………………………………………… 846
20.6 Cable guide drive mechanism…………………………………………………………………….. 848
20.6.1 Proximity switches on the cable guide drive mechanism………………………………………… 850
20.6.2 Checks and adjustments……………………………………………………………………. 852
20.7 Travel motion control………………………………………………………………………….. 856
20.8 Arrangement of the Slew Angle Sensor…………………………………………………………….. 858
20.8.1 Slew Angle Sensor 60B059 in the Wiring Diagram………………………………………………. 859
40 TROUBLESHOOTING ……………………………………………………………………………………….. 861
TOC………………………………………………………………………………………………….. 863
1 SAFETY……………………………………………………………………………………………… 883
1.1 SAFETY INFORMATION……………………………………………………………………………… 884
1.2 OVERVIEW………………………………………………………………………………………. 885
1.2.1 NORMAL OPERATIONS…………………………………………………………………………. 885
1.2.2 REGULAR MAINTENANCE……………………………………………………………………….. 885
1.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR……………………………………………………… 885
1.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR……. 885
1.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB………………………………………………………… 886
1.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR……………………………………………. 887
1.4.1 UNDERSTANDING THE MACHINE………………………………………………………………….. 887
1.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR………………………………………… 887
1.4.2.1 ENSURING SAFE OPERATION………………………………………………………………. 887
1.4.3 PREPARATIONS FOR SAFE OPERATION…………………………………………………………….. 887
1.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT………………………………………….. 887
1.4.3.2 INSPECTING THE MACHINE……………………………………………………………….. 887
1.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT………………………………………. 888
1.4.3.4 KEEP MACHINE CLEAN…………………………………………………………………… 888
1.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT………………………………………………. 888
1.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT…………………………………………….. 889
1.4.3.7 IF A PROBLEM IS FOUND………………………………………………………………… 889
1.4.4 FIRE PREVENTION…………………………………………………………………………… 889
1.4.4.1 PRECAUTIONS TO PREVENT FIRE…………………………………………………………… 889
1.4.4.2 ACTION IF FIRE OCCURS………………………………………………………………… 890
1.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB…………………………………………………….. 891
1.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE……………………………………………….. 891
1.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE……………………………….. 891
1.4.5.2 NO JUMPING ON OR OFF THE MACHINE………………………………………………………. 891
1.4.5.3 NO PEOPLE ON THE ATTACHMENT…………………………………………………………… 891
1.4.5.4 WORKING IN HIGH PLACES……………………………………………………………….. 891
1.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK……………………………………………………… 892
1.4.5.6 LEAVING THE MACHINE………………………………………………………………….. 892
1.4.6 BURN PREVENTION…………………………………………………………………………… 893
1.4.6.1 Hot coolant…………………………………………………………………………. 893
1.4.6.2 Hot oil…………………………………………………………………………….. 893
1.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS…………………………………………………………. 893
1.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…………………………………………………. 894
1.4.8.1 UNAUTHORIZED MODIFICATION…………………………………………………………….. 894
1.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS………………………………………….. 894
1.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)…………………………………………………………. 895
1.4.10 PRECAUTIONS AT JOBSITE……………………………………………………………………. 896
1.4.10.1 VISIBILITY FROM OPERATOR’S SEAT………………………………………………………. 897
1.4.10.2 CAMERA SYSTEM WITH MONITORS………………………………………………………….. 897
1.4.10.3 ENSURE GOOD VISIBILITY………………………………………………………………. 897
1.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS………………………………………………… 897
1.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS…………………………………………….. 898
1.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES………………………………………………… 898
1.4.10.7 WORKING ON LOOSE GROUND……………………………………………………………… 899
1.4.10.8 GAS, DUST, STEAM AND SMOKE…………………………………………………………… 899
1.4.10.9 VENTILATION OF ENCLOSED AREAS………………………………………………………… 900
1.4.11 STARTING motor…………………………………………………………………………… 901
1.4.11.1 WARNING TAG………………………………………………………………………… 901
1.4.11.2 CHECKS BEFORE STARTING motor…………………………………………………………. 901
1.4.11.3 PRECAUTION WHEN STARTING motor……………………………………………………….. 901
1.4.11.4 PRECAUTION IN COLD AREAS…………………………………………………………….. 902
1.4.12 OPERATION……………………………………………………………………………….. 902
1.4.12.1 CHECKS BEFORE OPERATION……………………………………………………………… 902
1.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE………………………………………. 903
1.4.12.3 PRECAUTIONS WHEN travelling………………………………………………………….. 904
1.4.12.4 TRAVELLING ON SLOPES………………………………………………………………… 905
1.4.12.5 OPERATIONS ON SLOPES………………………………………………………………… 906
1.4.12.6 PROHIBITED OPERATIONS……………………………………………………………….. 906
1.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES………………………………………….. 907
1.4.12.8 PARKING THE MACHINE…………………………………………………………………. 907
1.4.12.9 TRANSPORTATION……………………………………………………………………… 907
1.5 PRECAUTION FOR MAINTENANCE………………………………………………………………………. 908
1.5.1 GENERAL PRECAUTIONS……………………………………………………………………….. 908
1.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL – BASIC RESPONSIBILITIES…………………………. 909
1.5.1.2 STOP motor FOR MAINTENANCE……………………………………………………………. 910
1.5.1.3 WARNING TAG…………………………………………………………………………. 911
1.5.1.4 KEEP WORKPLACE CLEAN AND TIDY…………………………………………………………. 912
1.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS………………………………………………… 912
1.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING………………………………….. 913
1.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS…………………………………………….. 913
1.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT………………………………….. 914
1.5.1.9 NOISE………………………………………………………………………………. 914
1.5.1.10 WHEN USING A HAMMER…………………………………………………………………. 914
1.5.1.11 PROPER TOOLS……………………………………………………………………….. 915
1.5.1.12 ACCUMULATOR………………………………………………………………………… 915
1.5.1.13 PERSONNEL………………………………………………………………………….. 915
1.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE…………………………………………………… 916
1.5.2.1 PRECAUTION WHEN WELDING………………………………………………………………. 916
1.5.2.2 BATTERY HANDLING…………………………………………………………………….. 916
1.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID………………………………………………………… 917
1.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE……………………………………………………. 917
1.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES…………………………………………………. 918
1.5.3.3 REPLACEMENT OF HOSE LINES…………………………………………………………….. 918
1.5.3.4 INSPECTION OF HOSE LINES……………………………………………………………… 918
1.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…………………………………………… 919
1.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE………………………………………………………….. 919
1.5.3.7 AIR CONDITIONING MAINTENANCE………………………………………………………….. 919
1.5.3.8 COMPRESSED AIR………………………………………………………………………. 920
1.5.3.9 WASTE MATERIALS……………………………………………………………………… 920
1.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS……………………………………. 921
1.6.1 INSPECTION OF THE HYDRAULIC SYSTEM………………………………………………………….. 921
1.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS………………………………… 921
1.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR……………………………………………….. 921
1.7 SPECIAL SAFETY EQUIPMENT………………………………………………………………………… 922
1.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB……………………………………… 923
1.7.2 OBJECT HANDLING…………………………………………………………………………… 923
1.7.3 LIGHTING…………………………………………………………………………………. 923
1.7.4 WARNING BEACON……………………………………………………………………………. 923
1.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)…………………………………… 923
1.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)……………………………… 923
1.7.5.2 INSTRUCTIONS FOR USE…………………………………………………………………. 925
1.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL………………………………………… 927
1.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1),….. 927
1.7.5.5 INSTRUCTIONS FOR USE…………………………………………………………………. 929
2 Introduction & General Information for Troubleshooting…………………………………………………… 931
2.1 Overview………………………………………………………………………………………. 932
2.1.1 General advice when using troubleshooting charts……………………………………………… 932
2.2 General Precautions…………………………………………………………………………….. 933
2.3 Preparations For Work…………………………………………………………………………… 934
2.4 Precautions During Work…………………………………………………………………………. 934
2.5 Precautions When Carrying Out Any Operation……………………………………………………….. 935
2.5.1 Precautions when carrying out removal work…………………………………………………… 935
2.5.2 Precautions when carrying out installation work………………………………………………. 935
2.5.3 Precautions when completing the operation……………………………………………………. 936
2.6 Fundamental Requirements for Trouble shooting……………………………………………………… 937
2.6.1 Technical documentation……………………………………………………………………. 937
2.6.2 Tools……………………………………………………………………………………. 937
2.6.2.1 Reference Guide for Deutsch Removal Tools………………………………………………. 941
2.6.3 Personnel………………………………………………………………………………… 942
2.7 Points To Remember When Trouble- shooting…………………………………………………………. 942
2.8 Sequence Of Events In Troubleshooting…………………………………………………………….. 944
2.9 Checks Before Troubleshooting……………………………………………………………………. 945
2.10 Handling Of Electric Equipment And Hydraulic Components……………………………………………. 946
2.10.1 Points to remember when handling electric equipment………………………………………….. 946
2.10.2 Points To Remember When Handling Hydraulic Equipment…………………………………………. 949
2.11 General working procedures……………………………………………………………………… 951
2.11.1 Air Bleeding of Various Hydraulic Parts…………………………………………………….. 951
2.11.2 Air bleeding from the hydraulic pumps………………………………………………………. 951
2.11.3 Air bleeding from hydraulic cylinders………………………………………………………. 951
2.12 Cylinder bypass test…………………………………………………………………………… 952
2.13 Information about MTC & Nodes…………………………………………………………………… 953
2.13.1 Outline of the MTC and its connector locations………………………………………………. 953
2.13.1.1 View onto the MTC connectors* LH & RH…………………………………………………. 953
2.13.1.2 General description of the MTC……………………………………………………….. 953
2.13.1.3 Information about the LED indications at the MTC……………………………………….. 954
2.13.2 Information about the ICN-D node…………………………………………………………… 954
2.13.2.1 View onto an ICN-D node without wiring………………………………………………… 955
2.13.2.2 View onto the Status LEDs at the ICN-D node……………………………………………. 956
2.13.2.3 General information on the LED control………………………………………………… 956
2.13.3 Information about the ICN-V node…………………………………………………………… 958
2.13.3.1 View onto an ICN-V node……………………………………………………………… 958
2.13.3.2 View onto an open ICN-V node and its DIP-switches………………………………………. 959
2.13.4 DIP switches at the ICN-D and ICN-V nodes…………………………………………………… 960
2.14 Basics about “How to crimp”…………………………………………………………………….. 961
2.14.1 Stripping a wire for use with the HDT 48 crimp tool………………………………………….. 961
2.14.2 View onto the Deutsch crimp tool HDT 48…………………………………………………….. 961
2.14.3 Adjustment of the wire size at the Deutsch crimp tool HDT 48………………………………….. 962
2.14.3.1 Wire cross section units in mm2 and AWG……………………………………………….. 962
2.14.4 Crimping instructions (for Deutsch crimp tool HDT 48)………………………………………… 963
2.15 Cable Shielding……………………………………………………………………………….. 964
3 Mounting Locations and Connector Types…………………………………………………………………. 965
3.1 Component Location (exemplarily)…………………………………………………………………. 966
3.1.1 Side View onto the Excavator……………………………………………………………….. 966
3.1.2 Side view onto the Superstructure…………………………………………………………… 968
3.1.3 Top View onto the Superstructure……………………………………………………………. 970
3.1.4 Side View onto the Machine House……………………………………………………………. 972
3.2 Slip ring unit & Rotary joint……………………………………………………………………. 974
3.2.1 Slip Ring Unit in Detail…………………………………………………………………… 976
3.3 General Layout of the Cable Drum…………………………………………………………………. 978
3.3.1 Proximity Switches on the Cable Guide Drive………………………………………………….. 979
3.4 Capacitors…………………………………………………………………………………….. 980
3.5 High Voltage Switch Cabinet – View 1……………………………………………………………… 982
3.5.1 High Voltage Switch Cabinet – View 2………………………………………………………… 984
3.6 Cab Support……………………………………………………………………………………. 986
3.6.1 Low voltage switch board – location 11 – view 1………………………………………………. 988
3.6.2 Low voltage switch board – location 11 – view 2………………………………………………. 990
3.6.3 Switch cabinet for power breakers…………………………………………………………… 992
3.7 Mounting plate for instruments…………………………………………………………………… 994
3.8 Medium Voltage Switch Board – Location 12 – view 1…………………………………………………. 996
3.8.1 Medium Voltage Switch Board – Location 12 – view 2……………………………………………. 998
3.9 Arrangement of the Slew Angle Sensor………………………………………………………………1000
3.9.1 Slew Angle Sensor 60B059 in the Wiring Diagram………………………………………………..1001
3.10 Location of the Control Blocks…………………………………………………………………..1002
3.11 Control and filter panels – location of components…………………………………………………1004
3.12 Location of the Suction Oil tank with strainers……………………………………………………1006
3.13 Arrangement of the Remote Control Valves………………………………………………………….1008
3.14 Hydraulic Oil Tank – Location of the Electrical Components………………………………………….1010
3.15 General Overview on SLS & CLS1/2…………………………………………………………………1012
3.16 Batteries, Battery Main Switches & Safety Switch for Maintenance…………………………………….1014
3.17 Hydraulically operated access ladder……………………………………………………………..1016
3.18 Service arm……………………………………………………………………………………1018
3.19 Connector Types Overview………………………………………………………………………..1020
3.19.1 Connector (10-pole) for ICN-D nodes (Phoenix Contact)…………………………………………1023
3.19.2 Connector for ICN-V nodes (55 pins)…………………………………………………………1024
4 Standard Value Table for Electrical Components…………………………………………………………..1025
5 References for Troubleshooting (CAN Bus & Node Outputs)…………………………………………………..1043
5.1 CAN-Bus Trouble or Node Output Trouble…………………………………………………………….1044
5.1.1 Trouble CAN-BUS or CAN-Hardware (G00308)……………………………………………………..1045
5.1.2 Trouble output short-circuit (G00043)………………………………………………………..1046
5.2 Sequence of the CAN nodes at the CAN bus…………………………………………………………..1048
5.3 Troubleshooting for Relay Monitored Node Outputs……………………………………………………1049
5.3.1 Relay Check……………………………………………………………………………….1049
G00107 – Trouble slew parking brake control 56K250a…………………………………………………….1050
View onto the CoDeSys HMI Visualization screen for message G00107…………………………………….1052
Wiring Diagram (56K250a & 56K250b) for message G00107……………………………………………….1053
5.3.2 Output Check………………………………………………………………………………1054
G00108 – Trouble slew parking brake control Output to 56K250a……………………………………………1055
View onto the CoDeSys HMI Visualization screen for message G00108…………………………………….1057
Wiring Diagram (56K250a & 56K250b) for message G00108……………………………………………….1058
6 Tables for Testing and Troubleshooting………………………………………………………………….1059
6.1 Index of Tables in this section…………………………………………………………………..1060
6.2 Test Value Table for Temperature Sensors (PT100) g Centigrade – Volt………………………………….1061
6.3 Test Value Table for Temperature Sensors (PT100) g Centigrade – Ohm…………………………………..1062
6.4 Table of G-Codes………………………………………………………………………………..1063
6.4.1 Monitoring-codes without readout…………………………………………………………….1070
6.5 Table of Instruction Messages…………………………………………………………………….1071
6.6 Table of Binary Codes……………………………………………………………………………1074
6.6.1 Table of Add-On Binary Codes for G00308………………………………………………………1076
6.7 Binary Output Signals on the KOMTRAX Plus Monitor…………………………………………………..1077
6.8 Tables of Symptom Codes………………………………………………………………………….1080
6.8.1 Symptoms of the E-Motors and Related parts……………………………………………………1080
6.8.2 Symptoms of the Hydraulic System…………………………………………………………….1080
6.8.3 Symptoms of the Mechanical System……………………………………………………………1081
6.8.4 SYMPTOMS OF ADDITIONAL SYSTEMS………………………………………………………………1081
6.9 Power Supply……………………………………………………………………………………1082
6.10 Cable colour identification……………………………………………………………………..1082
7 Troubleshooting by Trouble Code………………………………………………………………………..1083
G00001 – Trouble Shut-Off (gate) valve………………………………………………………………..1084
View onto the gap of proximity switch 40B031……………………………………………………….1086
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR………………………….1087
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor…………………………………1087
Wiring Diagram (40B031) for message G00001 (Trouble Shut-Off (gate) valve)…………………………….1088
G00003 – Trouble pump controller……………………………………………………………………..1089
G00005 – Low hydraulic oil level……………………………………………………………………..1098
Wiring Diagram, oil level label, and defined position of the attachment (G00005)……………………….1100
G00007 – Trouble hydraulic oil level………………………………………………………………….1101
Hydraulic oil level at defined position of the attachment……………………………………………1102
Wiring Diagram for 40B004 (message G00007)…………………………………………………………1103
G00012 (Sonar) – Central lubrication system grease level too low…………………………………………1104
G00013 (Sonar) – Slew ring gear lubr. system grease level too low………………………………………..1104
Wiring Diagram (62B108 / 62B109 / 62B173) for G00012 / G00013 / G00202 (sonar)…………………………1108
Wiring Diagram (junction box for sonar sensors) for G00012 / G00013 / G00202…………………………..1109
G00012 (Binary) – Central lubrication system grease level too low………………………………………..1110
G00013 (Binary) – Slew ring gear lubr. system grease level too low……………………………………….1110
Wiring Diagram (binary grease level sensors) for G00012 / G00013 / G00202……………………………..1113
Wiring Diagram (junction box for binary sensors) for G00012 / G00013 / G00202………………………….1114
G00020 – Trouble Shut-Off (gate) valve (Start blocked)………………………………………………….1115
View onto the gap of proximity switch 40B031 (G00020)……………………………………………….1117
Wiring Diagram (40B031) for message G00020 (Main gate valve closed)…………………………………..1118
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR………………………….1119
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor…………………………………1119
G00033 – Trouble KOMTRAX Plus controller………………………………………………………………1120
G00034 – Trouble KOMTRAX Plus Display…………………………………………………………………1121
G00035 – Trouble totally loss gear oil (PTO 1)…………………………………………………………1122
G00036 – Trouble totally loss gear oil (PTO 2)…………………………………………………………1122
Location of sensors 57B175-1/-2 at PTO-1/-2 (G00035 & G00036)………………………………………..1124
Input signal (analog) of the gear oil sensors 57B175-1/-2 on the REAL TIME MONITOR……………………..1125
View onto the setting for SHUTDOWN BYPASS on the KOMTRAX Plus monitor…………………………………1125
Exemplary Wiring Diagram (57B175-1/-2) for messages G00035 & G00036…………………………………..1126
G00043 – Trouble output short-circuit…………………………………………………………………1127
G00046 – Reverse travel cut out bypassed by horn……………………………………………………….1128
G00047 – Travel cut out by cable drum…………………………………………………………………1129
Temperature sensor 91B979 and module 91B980 for message G00047……………………………………….1130
Cable drum temperature on the REAL TIME MONITOR for message G00047……………………………………1131
G00048 – Trouble emergency safety circuit……………………………………………………………..1132
Wiring Diagram (11K044a) for message G00048………………………………………………………..1133
G00049 – Trouble cab heating 1……………………………………………………………………….1134
Wiring Diagram for cab heater 1 – location 20 – below operator’s seat…………………………………1135
Wiring Diagram for cab heater 1 – location 12 (LV board) – overheating protection control……………….1136
Wiring Diagram for cab heater 1 – location 12 – blower control & after-run…………………………….1137
Wiring Diagram for cab heating – location 12 – 3 step heater regulation……………………………….1138
G00050 – Trouble cab heating 2……………………………………………………………………….1139
Wiring Diagram for cab heater 2 – location 20 – at the cab wall………………………………………1140
Wiring Diagram for cab heater 2 – location 12 (LV board) – overheating protection control……………….1141
Wiring Diagram for cab heater 2 – location 12 – blower control & after-run…………………………….1142
Wiring Diagram for cab heater 1 & 2 – location 12 – 3 step heater regulation…………………………..1143
G00053 – Reset emergency safety circuit……………………………………………………………….1144
G00054 – Monitoring idle position cut off……………………………………………………………..1145
Wiring Diagram (11K032) for message G00054…………………………………………………………1146
Input signal (analog) of relay 11K032 on the REAL TIME MONITOR (G00054)……………………………….1147
Exemplary view onto the KOMTRAX Plus Failure History (G00054)………………………………………..1147
G00055 – Trouble monitoring cable drum motor temperature………………………………………………..1148
Wiring Diagram (91B979 & 91B980) for message G00055…………………………………………………1149
G00059 – Fire in the switch cabinet…………………………………………………………………..1150
Wiring Diagram 1 (temperature sensors) for message G00059……………………………………………1152
Wiring Diagram 2 (activation unit in the cab) for message G00059……………………………………..1153
Wiring Diagram 3 (12K403a & 12K403b) for message G00059……………………………………………..1154
Wiring Diagram 4 (pilot line interruption) for message G00059………………………………………..1155
G00060 – Fire in the power house……………………………………………………………………..1156
Wiring Diagram 1 (fire warning system) for message G00060……………………………………………1157
Wiring Diagram 2 (fire warning system) for message G00060……………………………………………1158
Wiring Diagram 3 (fire warning system) for message G00060……………………………………………1159
G00063 – Trouble monitoring hydraulic oil temp…………………………………………………………1160
Wiring Diagram (59B015) and REAL TIME MONITOR for message G00063……………………………………..1161
G00064 – Trouble monitoring hydraulic oil level………………………………………………………..1162
Wiring Diagram (40B004) for message G00064…………………………………………………………1164
G00065 – Very low hydraulic oil level…………………………………………………………………1165
View onto the hydraulic oil level label……………………………………………………………1165
G00066 – Trouble hydraulic oil temperature…………………………………………………………….1166
Hydraulic oil temperature table…………………………………………………………………..1167
Wiring Diagram (57K506a-1/57K506b-1 & 57K506a-2/57K506b-2) and location for G00066……………………..1168
G00067 – Trouble battery voltage too high……………………………………………………………..1169
Wiring Diagram (11T080) and component location at the X2 board……………………………………….1170
Wiring Diagram (13T002 & 13T004) for message G00067…………………………………………………1171
Input signal of 11T080 on the REAL TIME MONITOR for message G00067……………………………………1172
G00068 – Trouble gear lubrication (PTO 2)……………………………………………………………..1172
G00069 – Trouble monitoring oil temperature gear (PTO 1)………………………………………………..1173
Input signal of 57B049-1 on the REAL TIME MONITOR (G00069)…………………………………………..1174
Gear oil temperature (PTO 1 & PTO 2) on the Main Gauge Screen………………………………………..1174
Wiring Diagram (57B049-1 & 57B049-2) and component location (G00069 & G00083)………………………….1175
G00070 – Trouble oil temperature gear (PTO 1)………………………………………………………….1176
Location of the PTO gear oil level dipstick & temperature sensor 57B049-1/-2…………………………..1179
G00071 – Trouble gear lubrication (PTO 1)……………………………………………………………..1180
Wiring Diagram (57B017-1 & 57B017-2) for messages G00071 & G00068…………………………………….1181
Input signal of 57B017-1 on the REAL TIME MONITOR for message G00071………………………………….1181
G00081 – Trouble lubrication system…………………………………………………………………..1182
Operation cycles of the lubrication systems………………………………………………………..1184
Wiring Diagram (11K050) for message G00081…………………………………………………………1185
G00083 – Trouble monitoring oil temperature gear (PTO 2)………………………………………………..1186
G00084 – Trouble oil temperature gear (PTO 2)………………………………………………………….1186
G00086 – SHUTDOWN…………………………………………………………………………………..1186
G00090 – Trouble power supply………………………………………………………………………..1187
Wiring Diagram (stabilized power supply) for messages G00090 & G00099…………………………………1188
Wiring Diagram (battery chargers) for messages G00090 & G00099……………………………………….1189
G00091 – Pilot control cut out……………………………………………………………………….1190
View onto the lock lever and the cover of 20S105 (G00091)……………………………………………1191
G00092 – Emergency shut-down at access ladder………………………………………………………….1192
G00093 – Emergency shut-down at valve block……………………………………………………………1192
G00094 – Emergency shut-down at hydraulic control panel…………………………………………………1192
G00095 – Emergency shut-down in cabin…………………………………………………………………1192
Wiring Diagram (emergency switches) for G00092~G00095 & G00097……………………………………….1194
G00096 – Pilot control cut out……………………………………………………………………….1195
Wiring Diagram (20S094) for message G00096…………………………………………………………1196
G00097 – Emergency shut-down at counterweight………………………………………………………….1196
G00099 – Trouble power supply………………………………………………………………………..1196
G00100 – Maintenance Safety Switch……………………………………………………………………1197
Wiring Diagram (50S058) for message G00100…………………………………………………………1198
G00103 – Faulty switch 20M004………………………………………………………………………..1199
Wiring Diagram 1 (windscreen wiper) for message G00103………………………………………………1201
Wiring Diagram 2 (windscreen wiper) for message G00103………………………………………………1202
G00107 – Trouble slew parking brake control 56K250a…………………………………………………….1203
View onto the CoDeSys HMI Visualization screen for message G00107…………………………………….1205
Wiring Diagram (56K250a & 56K250b) for message G00107……………………………………………….1206
G00108 – Trouble slew parking brake control Output to 56K250a……………………………………………1207
View onto the CoDeSys HMI Visualization screen for message G00108…………………………………….1209
Wiring Diagram (56K250a & 56K250b) for message G00108……………………………………………….1210
G00109 – Trouble slew parking brake control 56K250b…………………………………………………….1211
G00110 – Trouble slew parking brake control Output to 56K250b……………………………………………1211
G00111 – Trouble travel parking brake control 56K251a…………………………………………………..1212
56K251a & 56K251b (relay check) on the REAL TIME MONITOR (G00111 & G00113)…………………………….1212
G00112 – Trouble travel parking brake control Output to 56K251a………………………………………….1213
56K251a & 56K251b (output check) on the REAL TIME MONITOR (G00112 & G00114)……………………………1213
G00113 – Trouble travel parking brake control 56K251b…………………………………………………..1214
G00114 – Trouble travel parking brake control Output to 56K251b………………………………………….1214
G00115 – Trouble slew hydraulic brake control 56K252a…………………………………………………..1215
56K252a & 56K252b (relay check) on the REAL TIME MONITOR (G00115 & G00117)…………………………….1215
G00116 – Trouble slew hydraulic brake control Output to 56K252a………………………………………….1216
56K252a & 56K252b (output check) on the REAL TIME MONITOR (G00116 & G00118)……………………………1216
G00117 – Trouble slew hydraulic brake control 56K252b…………………………………………………..1217
G00118 – Trouble slew hydraulic brake control Output to 56K252b………………………………………….1217
G00119 – Trouble cable drum wind up control 91K257a…………………………………………………….1218
91K257a & 91K257b (relay check) on the REAL TIME MONITOR (G00119 & G00121)…………………………….1218
G00120 – Trouble cable drum wind up control Output to 91K257a……………………………………………1219
91K257a & 91K257b (output check) on the REAL TIME MONITOR (G00120 & G00122)……………………………1219
G00121 – Trouble cable drum wind up control 91K257b…………………………………………………….1220
G00122 – Trouble cable drum wind up control Output to 91K257b……………………………………………1220
G00123 – Trouble cable drum unwind control 91K258a……………………………………………………..1221
91K258a & 91K258b (relay check) on the REAL TIME MONITOR (G00123 & G00125)…………………………….1221
G00124 – Trouble cable drum wind up control Output to 91K258a……………………………………………1222
91K258a & 91K258b (output check) on the REAL TIME MONITOR (G00124 & G00126)……………………………1222
G00125 – Trouble cable drum unwind control 91K258b……………………………………………………..1223
G00126 – Trouble cable drum wind up control Output to 91K258b……………………………………………1223
G00127 – Trouble cable drum torque control 91K259a……………………………………………………..1224
91K259a & 91K259b (relay check) on the REAL TIME MONITOR (G00127 & G00129)…………………………….1224
G00128 – Trouble cable drum torque control Output to 91K259a…………………………………………….1225
91K259a & 91K259b (output check) on the REAL TIME MONITOR (G00128 & G00130)……………………………1225
G00129 – Trouble cable drum torque control 91K259b……………………………………………………..1226
G00130 – Trouble cable drum torque control Output to 91K259b…………………………………………….1226
G00139 – Trouble monitoring X1-2 pressure……………………………………………………………..1227
G00140 – Trouble monitoring X1-1 pressure……………………………………………………………..1227
Wiring Diagram (57B085-1 & 57B085-2) for messages G00139 & G00140…………………………………….1229
G00141 – Trouble monitoring X2 pressure……………………………………………………………….1230
Wiring Diagram (57B086) for message G00141…………………………………………………………1232
G00147 – Trouble monitoring gear lubrication (PTO 1)……………………………………………………1233
G00150 – Trouble monitoring gear lubrication (PTO 2)……………………………………………………1233
Wiring Diagram (57B017-1 & 57B017-2) for messages G00147 & G00150…………………………………….1236
G00151 – Trouble monitoring gear (PTO) oil filter 1…………………………………………………….1237
Wiring Diagram (57B027-1/-2) and location for messages G00151 & G00193………………………………..1240
G00154 – Trouble monitoring return oil filter………………………………………………………….1241
Wiring Diagram (40B163) for message G00154…………………………………………………………1243
G00155 – Trouble monitoring leak oil filter……………………………………………………………1244
Wiring Diagram (40B164) for message G00155…………………………………………………………1246
G00159 – Trouble monitoring breather filter……………………………………………………………1247
Wiring Diagram (40B024) for message G00159…………………………………………………………1249
G00161 – Trouble monitoring battery voltage……………………………………………………………1250
Wiring Diagram (11T080) and component location for message G00161…………………………………….1252
G00165 – Trouble breather filter hydraulic oil tank…………………………………………………….1253
Sight glass, hydraulic oil temperature information, and defined positions (G00165)……………………..1254
G00166 – Trouble oil filter gear (PTO 1)………………………………………………………………1256
Location of the PTO 1/2 gear oil filters with pressure sensors 57B027-1 & 57B027-2……………………..1257
G00169 – Trouble return oil filter hydraulic oil tank…………………………………………………..1258
G00170 – Trouble leak oil filter hydraulic oil tank…………………………………………………….1259
G00176 – Trouble battery voltage too low………………………………………………………………1260
Input signal of 11T080 on the REAL TIME MONITOR for message G00176……………………………………1261
Wiring Diagram (11T080) and component location at the X2 board……………………………………….1262
Wiring Diagram (13T002 & 13T004) for message G00176…………………………………………………1263
G00179 – Trouble control pressure X1-1………………………………………………………………..1264
View onto the valve cartridge block for X1 pressure adjustment……………………………………….1265
G00180 – Trouble pilot pressure X2 too low…………………………………………………………….1266
Valve cartridge block with X2 pressure sensor 57B086 & M1.2………………………………………….1267
G00181 – Trouble pilot pressure X2 too high……………………………………………………………1268
Control and filter panel 1 with X2 pressure sensor 57B086 & M3……………………………………….1269
G00182 – Trouble control pressure X1-2………………………………………………………………..1269
G00184 (Sonar) – Central lubrication system empty………………………………………………………1270
Grease level (sonar, CLS 1 & SLS & CLS 2) on the REAL TIME MONITOR……………………………………1271
G00184 (Binary) – Central lubrication system empty……………………………………………………..1272
G00185 – Trouble central lubrication system……………………………………………………………1274
Allocation of vent valves and end-of-line switches………………………………………………….1275
Action chart for lube cycles……………………………………………………………………..1276
View onto the vent valve (62Q507a – 62Q509a – 62Q642a)………………………………………………1277
Wiring Diagram (60B043/62B046/80B043) for messages G00185/G00188/G00203……………………………….1278
G00186 – Trouble central lubrication system……………………………………………………………1279
Allocation of vent valves………………………………………………………………………..1279
Action chart for lube cycles……………………………………………………………………..1280
View onto the vent valve (62Q507a – 62Q509a – 62Q642a)………………………………………………1281
G00187 – Slew ring gear lubrication system empty……………………………………………………….1282
G00188 – Trouble slew ring gear lubrication system……………………………………………………..1282
G00189 – Trouble slew ring gear lubrication system……………………………………………………..1282
G00191 – Trouble oil filter gear (PTO 2)………………………………………………………………1282
G00193 – Trouble monitoring gear (PTO) oil filter 2…………………………………………………….1282
G00201 – Attachment lubrication system empty…………………………………………………………..1282
G00202 (Sonar) – Attachment lubrication system grease level too low………………………………………1282
G00203 – Trouble attachment lubrication system…………………………………………………………1282
G00204 – Trouble attachment lubrication system…………………………………………………………1282
G00210 – Trouble electric motor 1 winding temperature…………………………………………………..1283
G00211 – Trouble electric motor 2 winding temperature…………………………………………………..1283
Wiring Diagram (motor winding temp. monitoring – motor 1) for G00210………………………………….1284
Wiring Diagram (motor winding temp. monitoring – motor 2) for G00211………………………………….1285
REAL TIME MONITOR for motor winding temperature, G00210 & G00211……………………………………..1286
G00212 – Trouble electric motor 1 bearing temperature…………………………………………………..1287
G00213 – Trouble electric motor 2 bearing temperature…………………………………………………..1287
REAL TIME MONITOR for motor bearing temperature, G00212 & G00213……………………………………..1288
Wiring Diagram (motor bearing temperature – motor 1 & 2), G00212 & G00213……………………………..1289
G00214 – Trouble transformer 1 temperature…………………………………………………………….1290
G00215 – Trouble transformer 2 temperature…………………………………………………………….1290
Wiring Diagram (temperature control for transformer A), message G00214………………………………..1291
REAL TIME MONITOR (net-line voltage & transformer temperature) for G00214 & 215………………………..1292
G00216 – Trouble software not compatible………………………………………………………………1293
G00218 – Switch off all motors for running transfer pump………………………………………………..1295
G00219 – Return oil tank empty……………………………………………………………………….1296
Sensor 40B068 (return oil level) on the REAL TIME MONITOR……………………………………………1296
G00220 – Trouble transfer pump motor overheated………………………………………………………..1297
Wiring Diagram (transfer pump) for message G00220…………………………………………………..1298
G00231 – Trouble pilot control lever 20S019……………………………………………………………1299
G00232 – Trouble pilot control lever 20S020……………………………………………………………1299
Wiring Diagram (20S019) for message G00231…………………………………………………………1300
Wiring Diagram (20S020) for message G00232…………………………………………………………1301
G00233 – Trouble pilot control 11Q045…………………………………………………………………1302
Wiring Diagram (11Q045) for message G00233…………………………………………………………1303
G00234 – Trouble pilot control 11K111a………………………………………………………………..1304
11K111a & 11K111b (relay check) on the REAL TIME MONITOR (G00234 & G00236)…………………………….1304
G00235 – Trouble pilot control Output to 11K111a……………………………………………………….1305
11K111a & 11K111b (output check) on the REAL TIME MONITOR (G00235 & G00237)……………………………1305
G00236 – Trouble pilot control 11K111b………………………………………………………………..1306
G00237 – Trouble pilot control Output to 11K111b……………………………………………………….1306
G00238 – Trouble supply by key switch 11Q044…………………………………………………………..1307
Input signal of 11Q044 on the REAL TIME MONITOR (G00238)…………………………………………….1307
Wiring Diagram (11Q044) for message G00238…………………………………………………………1308
G00239 – Trouble electrical matter……………………………………………………………………1309
Wiring Diagram (12K403a/b) for message G00239………………………………………………………1310
G00240 – Trouble hydraulic oil temperature…………………………………………………………….1311
Hydraulic Oil Temperature Table…………………………………………………………………..1312
G00241 – Motor 1 already running……………………………………………………………………..1313
G00244 – Motor shutdown from ground…………………………………………………………………..1314
Input signal of 54S007 & 54S008 on the REAL TIME MONITOR (G00244)…………………………………….1315
G00246 – Hydraulic oil temperature……………………………………………………………………1316
G00250 – Electric motor 2 already running……………………………………………………………..1316
G00252 – Emergency shut-down at access ladder………………………………………………………….1317
G00253 – Emergency shut-down at valve block……………………………………………………………1317
G00254 – Emergency shut-down at hydraulic control panel…………………………………………………1317
G00255 – Emergency shut-down in cabin…………………………………………………………………1317
Wiring Diagram (emergency switches) for G00252~G00255 & G00258 & G00355……………………………….1319
G00256 – Operator warning system……………………………………………………………………..1320
G00257 – Hydraulic oil temperature……………………………………………………………………1321
Hydraulic Oil Temperature Table…………………………………………………………………..1322
G00258 – Emergency shut-down at counterweight………………………………………………………….1323
G00261 – Maintenance Safety Switch……………………………………………………………………1323
Wiring Diagram (50S058 and safety line) for message G00261…………………………………………..1324
G00262 – Trouble screen at hydr. cooler entry clogged…………………………………………………..1325
40B166 and 40B165 on the REAL TIME MONITOR (05 Hydraulic)……………………………………………1325
Location of 40B166 and 40B165 at the hydraulic oil tank (G00262)……………………………………..1326
Wiring Diagram (40B166 & 40B165) for message G00262…………………………………………………1327
G00263 – Trouble monitoring motor 1 bearing temperature…………………………………………………1328
G00264 – Trouble monitoring motor 2 bearing temperature…………………………………………………1328
View onto the terminal box at motor side…………………………………………………………..1329
Wiring Diagram (motor bearing temperature – motor 1 & 2), G00263 & G00264……………………………..1330
G00265 – Trouble monitoring emergency voltage………………………………………………………….1331
Wiring Diagram (12T082) for message G00265…………………………………………………………1333
G00266 – Trouble emergency voltage too high……………………………………………………………1334
Wiring Diagram (12T082) for message G00266…………………………………………………………1335
Wiring Diagram (13T003) for message G00266…………………………………………………………1336
Input signal of 12T082 on the REAL TIME MONITOR for message G00266……………………………………1337
G00267 – Trouble emergency voltage too low…………………………………………………………….1338
Wiring Diagram (12T082) for message G00267…………………………………………………………1339
Wiring Diagram (13T003) for message G00267…………………………………………………………1340
Input signal of 12T082 on the REAL TIME MONITOR for message G00267……………………………………1341
G00274 – Trouble monitoring motor 1 winding temperature…………………………………………………1342
G00276 – Trouble monitoring motor 2 winding temperature…………………………………………………1342
View onto the terminal box at motor side…………………………………………………………..1343
Wiring Diagram (motor winding temp. monitoring – motor 1) for G00274………………………………….1344
Wiring Diagram (motor winding temp. monitoring – motor 2) for G00276………………………………….1345
G00277 – Trouble high voltage capacitor 1……………………………………………………………..1346
Wiring Diagram (capacitor pressure monitoring) for G00277 & G00303……………………………………1347
Capacitor pressure (motor 1) on the REAL TIME MONITOR for message G00277………………………………1347
G00278 – Earth fault tripped…………………………………………………………………………1348
G00281 – Ground leakage tripped………………………………………………………………………1349
Wiring Diagram (12F431) for message G00281…………………………………………………………1350
Wiring Diagram (continued) for message G00281………………………………………………………1351
G00285 – Trouble motor 1…………………………………………………………………………….1352
G00286 – Trouble motor 2…………………………………………………………………………….1352
Wiring Diagram (motor protection relays & node inputs) for message G00285/286………………………….1354
Wiring Diagram (motor protection relay motor 1) for message G00285……………………………………1355
Wiring Diagram (motor protection relay motor 2) for message G00286……………………………………1356
G00287 – Trouble 3 phase current rotation direction…………………………………………………….1357
Wiring Diagram (phase sequence monitoring) for message G00287………………………………………..1358
Phase sequence relay on the REAL TIME MONITOR for message G00287……………………………………..1359
G00288 – Trouble restart motor 1, temperature too high………………………………………………….1360
G00289 – Trouble restart motor 2, temperature too high………………………………………………….1360
G00290 – Trouble motor main relay 1…………………………………………………………………..1361
Wiring Diagram (32Q701-1/-2) for messages G00290 & G00306……………………………………………1362
Wiring Diagram (32Q701-1/-2 & nodes) for messages G00290 & G00306…………………………………….1363
Wiring Diagram (safety circuit) for messages G00290 & G00306…………………………………………1364
G00291 – Reverse travel cut out by cable drum………………………………………………………….1365
Wiring Diagram (91B904a, 91B911, 91B919) for message G00291………………………………………….1366
G00292 – Reverse travel left track cut out by cable drum………………………………………………..1367
G00293 – Reverse travel right track cut out by cable drum……………………………………………….1367
Wiring Diagram (diagonal cable pull) for messages G00292 & G00293…………………………………….1368
G00294 – Forward travel cut out by cable drum………………………………………………………….1369
Wiring Diagram (91B912 & 91B913, optional 91B914 & 91B915) for message G00294………………………….1370
Wiring Diagram (91B904b) for message G00294………………………………………………………..1371
G00295 – Trouble temperature cab base…………………………………………………………………1372
Cab base temperature on the REAL TIME MONITOR (G00295)………………………………………………1372
Wiring Diagram (10B001) for message G00295…………………………………………………………1373
G00296 – Trouble temperature high voltage cabinet………………………………………………………1374
HV-cabinet temperature on the REAL TIME MONITOR (G00296)…………………………………………….1374
G00301 – Trouble high voltage supply was interrupted……………………………………………………1375
Motor voltage (12T431-3) on the REAL TIME MONITOR (G00301)…………………………………………..1375
Wiring Diagram (12T431) for message G00301…………………………………………………………1376
Wiring Diagram (continued) for message G00301………………………………………………………1377
G00303 – Trouble high voltage capacitor 2……………………………………………………………..1378
G00304 – Start Motor 1 blocked……………………………………………………………………….1378
G00305 – Start Motor 2 blocked……………………………………………………………………….1378
G00306 – Trouble motor main relay 2…………………………………………………………………..1379
G00307 – Attention ! Cable drum !…………………………………………………………………….1379
G00308 – Trouble CAN-Bus or CAN-Hardware………………………………………………………………1380
G00309 – Trouble ladder up 56K253a……………………………………………………………………1383
56K253a & 56K253b (relay check) on the REAL TIME MONITOR (G00309 & G00311)…………………………….1383
G00310 – Trouble ladder up Output to 56K253a…………………………………………………………..1384
56K253a & 56K253b (output check) on the REAL TIME MONITOR (G00310 & G00312)……………………………1384
G00311 – Trouble ladder up redundant 56K253b…………………………………………………………..1385
G00312 – Trouble ladder up redundant Output to 56K253b………………………………………………….1385
G00313 – Trouble ladder down 56K254a………………………………………………………………….1386
56K254a & 56K254b (relay check) on the REAL TIME MONITOR (G00313 & G00315)…………………………….1386
G00314 – Trouble ladder down Output to 56K254a…………………………………………………………1387
56K254a & 56K254b (output check) on the REAL TIME MONITOR (G00314 & G00316)……………………………1387
G00315 – Trouble ladder down redundant 56K254b…………………………………………………………1388
G00316 – Trouble ladder down redundant Output to 56K254b………………………………………………..1388
G00317 – Trouble service arm up 56K255a……………………………………………………………….1389
56K255a & 56K255b (relay check) on the REAL TIME MONITOR (G00317 & G00319)…………………………….1389
G00318 – Trouble service arm up Output to 56K255a………………………………………………………1390
56K255a & 56K255b (output check) on the REAL TIME MONITOR (G00318 & G00320)……………………………1390
G00319 – Trouble service arm up redundant 56K255b………………………………………………………1391
G00320 – Trouble service arm up redundant Output to 56K255b……………………………………………..1391
G00321 – Trouble service arm down 56K256a……………………………………………………………..1392
56K256a & 56K256b (relay check) on the REAL TIME MONITOR (G00321 & G00323)…………………………….1392
G00322 – Trouble service arm down Output to 56K256a…………………………………………………….1393
56K256a & 56K256b (output check) on the REAL TIME MONITOR (G00322 & G00324)……………………………1393
G00323 – Trouble service arm down redundant 56K256b…………………………………………………….1394
G00324 – Trouble service arm down redundant Output to 56K256…………………………………………….1394
G00325 – Trouble service arm Input……………………………………………………………………1395
G00326 – Trouble ladder Input………………………………………………………………………..1395
G00327 – Trouble parking brake Input………………………………………………………………….1395
G00328 – Trouble start Input…………………………………………………………………………1395
G00329 – Protection switch tripped……………………………………………………………………1398
Additional protection switches on the REAL TIME MONITOR (G00329)……………………………………..1398
G00330 – Trouble pilot control 11Q111…………………………………………………………………1399
Wiring Diagram (11Q111/11K126) for message G00330…………………………………………………..1401
G00334 -Trouble cab heater contactor………………………………………………………………….1402
Wiring Diagram for cab heating – 3 step heater regulation……………………………………………1403
Wiring Diagram – additional cab heater at the cab wall………………………………………………1404
Wiring Diagram – additional cab heater at the cab wall………………………………………………1405
G00335 -Trouble cab heater safety relay……………………………………………………………….1406
Wiring Diagram (heater safety relays) for message G00335…………………………………………….1408
G00337 – Trouble motor on control 12K408a-1……………………………………………………………1409
12K408a-1/-2 & 12K408b-1/-2 (relay check) on the REAL TIME MONITOR……………………………………1409
G00338 – Trouble motor on control Output to 12K408a-1…………………………………………………..1410
12K408a-1/-2 & 12K408b-1/-2 (output check) on the REAL TIME MONITOR…………………………………..1410
G00339 – Trouble motor on control 12K408b-1……………………………………………………………1411
G00340 – Trouble motor on control Output to 12K408b-1…………………………………………………..1411
G00341 – Trouble motor on control 12K408a-2……………………………………………………………1411
G00342 – Trouble motor on control Output to 12K408a-2…………………………………………………..1411
G00343 – Trouble motor on control 12K408b-2……………………………………………………………1411
G00344 – Trouble motor on control Output to 12K408b-2…………………………………………………..1411
G00345 – E-Motor 2 running…………………………………………………………………………..1412
G00346 – E-Motor 2 standstill………………………………………………………………………..1412
G00347 – E-Motor 1 running…………………………………………………………………………..1413
G00348 – E-Motor 1 standstill………………………………………………………………………..1413
G00354 – Emergency shut-down cable drum……………………………………………………………….1413
G00355 – Emergency shut-down cable drum……………………………………………………………….1413
G00417 – Communication failure PLC [MTC] <=> KOMTRAX Plus controller……………………………………..1414
G00420 – Connector sel error…………………………………………………………………………1415
G00421 – Farm sys error……………………………………………………………………………..1416
G00423 – Application sys error……………………………………………………………………….1417
G00425 – Settings impossible to take over into the PLC [MTC]…………………………………………….1418
Wiring Diagram: KOMTRAX Plus monitor → KOMTRAX Plus controller → MTC………………………………….1419
G00491 – Communication failure MH800 <=> KOMTRAX Plus controller…………………………………………1420
Wiring Diagram overview: MH800 <=> KOMTRAX Plus controller…………………………………………..1421
8 Troubleshooting by Symptoms……………………………………………………………………………1423
8.1 Symptoms of the E-motors and related parts…………………………………………………………1424
SEM001 – Starting the E-motor(s) is not possible……………………………………………………….1424
Wiring Diagram (batteries and lock lever switch) for SEM001………………………………………….1425
SEM002 – Stopping the E-motor(s) is not possible……………………………………………………….1426
Wiring Diagram (motor stop switches) for SEM002…………………………………………………….1427
SEM003 – E-motor has excessive vibration………………………………………………………………1428
View onto the coupling for SEM003…………………………………………………………………1429
SEM004 – Abnormal noise coming from the E-motor(s)……………………………………………………..1430
SEM005 – E-motor lacks output (low power)……………………………………………………………..1431
View onto the PM CLINIC sheet (power check) for SEM005………………………………………………1432
SEM006 – Air-to-Air motor cooling system not sufficient…………………………………………………1433
Exemplary view onto the Air-to-Air motor cooling system for SEM006……………………………………1434
SEM007 – Motor shuts down during start………………………………………………………………..1435
Motor 1 – Signal flow from bottom to top (SEM007)…………………………………………………..1436
Motor 2 – Signal flow from bottom to top (SEM007)…………………………………………………..1437
Motor 1/2 – Signal flow from bottom to top continued (SEM007)………………………………………..1438
Wiring Diagram – Motor 1 & 2 and capacitors (SEM007)………………………………………………..1439
SEM008 – Substation main circuit breaker tripped……………………………………………………….1440
Net-line supply overview (SEM008)…………………………………………………………………1441
Electric energy consumption (SEM008)………………………………………………………………1442
Motor current overview (SEM008)…………………………………………………………………..1443
8.2 Symptoms of the Hydraulic System………………………………………………………………….1444
SHY001 – All the work equipment shows lack of power or slow movement (especially the “boom up” function)……..1444
SHY002 – No work equipment, travel or swing movement……………………………………………………1446
SHY003 – Work equipment has too much hydraulic drift……………………………………………………1447
SHY004 – Work equipment has big time lag………………………………………………………………1448
SHY005 – Machine deviates during travel movement……………………………………………………….1449
SHY006 – Machine does not swing………………………………………………………………………1450
SHY007 – Swing acceleration is poor…………………………………………………………………..1451
SHY008 – Excessive overrun when stopping swing…………………………………………………………1453
SHY009 – Floating system without function……………………………………………………………..1455
SHY010 – Abnormal noise coming from SRV or MRV…………………………………………………………1456
SHY011 – Track tensioning system without function………………………………………………………1457
Track tensioning – overview (SHY011)………………………………………………………………1458
SHY012 – Ladder does not move, or slow movement………………………………………………………..1459
SHY013 – The hydraulic driven grease pump does not move…………………………………………………1461
SHY014 – Trouble pump bearing lubrication……………………………………………………………..1463
SHY015 – Abnormal track chain movement during digging…………………………………………………..1464
SHY016 – Swing parking brake without function………………………………………………………….1465
SHY017 – Travel parking brake without function…………………………………………………………1466
8.3 Symptoms of the Mechanical System…………………………………………………………………1467
SME001 – Abnormal noise around the PTO / hydraulic pumps………………………………………………..1467
SME002 – There is a big shock when stopping swing………………………………………………………1469
SME003 – There is a big abnormal noise when moving/stopping swing………………………………………..1470
SME004 – Abnormal noise coming from a travel gearbox……………………………………………………1472
SME005 – Abnormal noise coming from the work equipment (lack of grease)…………………………………..1474
SME006 – Abnormal idler movement……………………………………………………………………..1476
SME007 – Leak at the PTO shaft seal…………………………………………………………………..1477
8.4 Symptoms of Additional Systems……………………………………………………………………1479
SAD001 – Air conditioner for the cabin does not work……………………………………………………1479
Exemplary view onto A/C test tools & A/C filling and service station………………………………….1480
Wiring Diagram – Cab heater control unit 20S026a (SAD001)……………………………………………1481
Wiring Diagram – Air conditioner cab (SAD001)………………………………………………………1482
SAD002 – Air conditioner LV cabinet does not work………………………………………………………1483
Exemplary view onto A/C test tools & A/C filling and service station………………………………….1484
Wiring Diagram – Compressor drive LV switch cabinet (SAD002)…………………………………………1485
Wiring Diagram – Air conditioner LV switch cabinet (SAD002)………………………………………….1486
SAD003 – Air conditioner HV cabinet does not work………………………………………………………1487
Exemplary view onto A/C test tools & A/C filling and service station………………………………….1488
Wiring Diagram – Compressor drive HV switch cabinet (SAD003)…………………………………………1489
Wiring Diagram – Air conditioner HV switch cabinet (SAD003)………………………………………….1490
50 DISASSEMBLY & ASSEMBLY ………………………………………………………………………………….1491
Overview………………………………………………………………………………………………1493
TOC
………………………………………………………………………………………………….1495
1 Introduction…………………………………………………………………………………………1505
1.1 Contents of the binder…………………………………………………………………………..1506
1.2 Foreword……………………………………………………………………………………….1507
1.2.1 Service…………………………………………………………………………………..1508
2 Safety………………………………………………………………………………………………1509
2.1 General information……………………………………………………………………………..1510
2.1.1 Method of using this manual…………………………………………………………………1510
2.2 Safety instructions……………………………………………………………………………..1512
2.2.1 General precautions………………………………………………………………………..1512
2.2.2 Preparations before work……………………………………………………………………1514
2.2.3 Precautions during work…………………………………………………………………….1515
2.2.3.1 Precautions with high pressure oil……………………………………………………..1517
2.2.4 Warning of special dangers………………………………………………………………….1518
2.2.4.1 Electrical energy…………………………………………………………………….1518
2.2.4.2 Gas, dust, steam and smoke…………………………………………………………….1519
2.2.4.3 Noise……………………………………………………………………………….1519
2.2.4.4 Oil, grease and other chemical substances……………………………………………….1519
2.2.4.5 Hydraulic, air conditioning and pneumatic equipment………………………………………1520
2.2.4.6 Heat………………………………………………………………………………..1520
2.2.4.7 Height………………………………………………………………………………1520
2.2.5 Special safety equipment……………………………………………………………………1523
2.2.5.1 Safety harness in conformity with EN 361 (European standard)………………………………1523
2.2.5.2 Instructions for use………………………………………………………………….1525
2.2.5.3 Recommendations for use of the holding hooks and hold-back hooks of the safety harness……….1527
2.2.5.4 Instructions for using the fall absorber………………………………………………..1529
2.2.6 Safety hints for hydraulic hose installation………………………………………………….1530
2.2.7 Safety hints for Lifting heavy parts…………………………………………………………1533
2.2.8 Safety hints for Wire ropes…………………………………………………………………1533
2.2.9 Safety hints for Sling accessory…………………………………………………………….1535
2.3 Grounding procedure of the high voltage system……………………………………………………..1536
2.4 Explanation of abbreviations……………………………………………………………………..1539
3 Superstructure……………………………………………………………………………………….1541
3.1 Superstructure overview………………………………………………………………………….1542
3.2 service crane (optional)…………………………………………………………………………1545
3.2.1 Removal of the service crane………………………………………………………………..1545
3.2.2 Replacement of the service crane…………………………………………………………….1547
3.3 Engine house roof……………………………………………………………………………….1548
3.3.1 Removal of the roof plates………………………………………………………………….1548
3.3.2 Replacement of the roof plates………………………………………………………………1554
3.3.3 front roof section…………………………………………………………………………1555
3.3.3.1 Removal of the front roof plates……………………………………………………….1555
3.3.3.2 Replacement of the front roof plates……………………………………………………1558
3.4 Batteries………………………………………………………………………………………1559
3.4.1 Removal of the batteries……………………………………………………………………1559
3.4.2 Replacement of the batteries………………………………………………………………..1561
3.5 Electric motors…………………………………………………………………………………1562
3.5.1 Removal of the front electric motor (Motor 1)…………………………………………………1562
3.5.2 Replacement of the front electric motor (motor 1)……………………………………………..1566
3.5.3 Removal of the rear electric motor (motor 2)………………………………………………….1568
3.5.4 Replacement of the rear electric motor (motor 2)………………………………………………1568
3.5.5 Final alignment of the electric motors……………………………………………………….1569
3.5.6 Capacitor assemblies……………………………………………………………………….1572
3.5.6.1 Removal of the capacitor assembly (Motor 1)……………………………………………..1573
3.5.6.2 Replacement of the capacitor assembly (Motor 1)………………………………………….1575
3.5.6.3 Removal of the capacitor assembly (Motor 2)……………………………………………..1575
3.5.6.4 Replacement of the capacitor assembly (Motor 2)………………………………………….1575
3.6 Flexible coupling……………………………………………………………………………….1576
3.6.1 Vulkan coupling assembly……………………………………………………………………1576
3.6.1.1 Removal of the Vulkan coupling…………………………………………………………1577
3.6.1.2 Replacement of the Vulkan coupling……………………………………………………..1579
3.7 PTO……………………………………………………………………………………………1580
3.7.1 Main pumps………………………………………………………………………………..1580
3.7.1.1 Removal of main pumps…………………………………………………………………1582
3.7.1.2 Replacement of main pumps……………………………………………………………..1585
3.7.2 PTO oil pumps (auxiliary pumps)……………………………………………………………..1587
3.7.2.1 Removal of the PTO oil pumps (auxiliary pumps)…………………………………………..1587
3.7.2.2 Replacement of the PTO oil pumps (auxiliary pumps)……………………………………….1587
3.7.3 Pump distributor gearbox (PTO)………………………………………………………………1588
3.7.3.1 Removal of the pump distributor gearbox (PTO)……………………………………………1590
3.7.3.2 Replacement of the pump distributor gearbox (PTO)………………………………………..1594
3.8 Hydraulics……………………………………………………………………………………..1595
3.8.1 Hydraulic cooler fan drive pumps…………………………………………………………….1595
3.8.1.1 Removal of the hydraulic cooler fan drive pumps………………………………………….1596
3.8.1.2 Replacement of the hydraulic cooler fan drive pumps………………………………………1598
3.8.2 Additional hydraulic oil cooler assembly……………………………………………………..1599
3.8.2.1 Removal of the Additional hydraulic oil cooler fan assembly……………………………….1602
3.8.2.2 Replacement of Additional hydraulic oil cooler fan assembly……………………………….1605
3.8.2.3 Removal of Additional hydraulic oil cooler fans and motors………………………………..1606
3.8.2.4 Replacement of Additional hydraulic oil cooler fans and motors…………………………….1607
3.8.2.5 Removal of the Additional hydraulic oil coolers………………………………………….1608
3.8.2.6 Replacement of the Additional hydraulic oil coolers………………………………………1611
3.8.2.7 Removal of the Additional hydraulic oil cooler assembly…………………………………..1612
3.8.2.8 Replacement of Additional hydraulic oil cooler assembly…………………………………..1614
3.8.3 Hydraulic oil cooler assembly……………………………………………………………….1616
3.8.3.1 Removal of the hydraulic oil cooler fan assemblies……………………………………….1620
3.8.3.2 Replacement of hydraulic oil cooler fan assemblies……………………………………….1624
3.8.3.3 Removal of the hydraulic oil cooler fan and motor………………………………………..1626
3.8.3.4 Replacement of hydraulic oil cooler fan and motor………………………………………..1628
3.8.3.5 Removal of the hydraulic oil coolers……………………………………………………1630
3.8.3.6 Replacement of the hydraulic oil coolers………………………………………………..1634
3.8.3.7 Removal of the hydraulic oil cooler assembly…………………………………………….1636
3.8.3.8 Replacement of the hydraulic oil cooler assembly…………………………………………1640
3.8.4 Pilot oil pump (gear pump)………………………………………………………………….1641
3.8.4.1 Removal of the pilot oil pump………………………………………………………….1641
3.8.4.2 Replacement of the pilot oil pump………………………………………………………1643
3.8.5 Main gate valve……………………………………………………………………………1644
3.8.5.1 Removal of the main gate valve…………………………………………………………1644
3.8.5.2 Replacement of the main gate valve……………………………………………………..1645
3.8.6 Hydraulic oil reservoir…………………………………………………………………….1646
3.8.6.1 Removal of the hydraulic oil reservoir………………………………………………….1648
3.8.6.2 Replacement of the hydraulic oil reservoir………………………………………………1651
3.8.7 Main control valve blocks…………………………………………………………………..1653
3.8.7.1 Removal of the main control valve blocks………………………………………………..1654
3.8.7.2 Replacement of the main control valve blocks…………………………………………….1657
3.8.8 Main relief valves (MRV)……………………………………………………………………1658
3.8.8.1 Removal of the MRV on the main control valve block……………………………………….1658
3.8.8.2 Replacement of the MRV on the main control valve block……………………………………1659
3.8.9 Service line relief valves (SRV)…………………………………………………………….1660
3.8.9.1 Removal of the SRV on the manifold……………………………………………………..1660
3.8.9.2 Replacement of the SRV on the manifold………………………………………………….1662
3.8.9.3 Removal of the SRV on the main control valve block……………………………………….1663
3.8.9.4 Replacement of the SRV on the main control valve blocks…………………………………..1665
3.8.10 Anti-cavitation valves (ACV)……………………………………………………………….1666
3.8.10.1 Removal of the ACV on the manifold…………………………………………………….1667
3.8.10.2 Replacement of the ACV on the manifold…………………………………………………1671
3.8.10.3 Removal of the ACV on the main control valve blocks……………………………………..1672
3.8.10.4 Replacement of the ACV on the main control valve blocks………………………………….1673
3.8.11 Throttle check valves……………………………………………………………………..1674
3.8.11.1 Removal of the throttle check valves on the manifold…………………………………….1678
3.8.11.2 Replacement of the throttle check valves on the manifold…………………………………1680
3.8.12 Manifold…………………………………………………………………………………1681
3.8.12.1 Removal of the manifold………………………………………………………………1681
3.8.12.2 Replacement of the manifold…………………………………………………………..1683
3.9 Slew system…………………………………………………………………………………….1685
3.9.1 Slew gear…………………………………………………………………………………1685
3.9.1.1 Removal of the Slew gear………………………………………………………………1688
3.9.1.2 Replacement of the slew gear…………………………………………………………..1691
3.9.2 Swing motor……………………………………………………………………………….1694
3.9.2.1 Removal of the swing motor…………………………………………………………….1695
3.9.2.2 Replacement of the swing motor…………………………………………………………1698
3.9.3 Slew parking brake…………………………………………………………………………1701
3.9.3.1 Removal/disassembly of the slew parking brake (L&S)………………………………………1703
3.9.3.2 Replacement/assembly of the slew parking brake (L&S)……………………………………..1706
3.9.3.3 Removal of the slew parking brake (Siebenhaar)…………………………………………..1709
3.9.3.4 replacement of the slew parking brake (Siebenhaar)……………………………………….1712
3.9.4 Dynamic slew brake…………………………………………………………………………1716
3.9.4.1 Removal of the slew brake valve………………………………………………………..1719
3.9.4.2 Replacement of the slew brake valve…………………………………………………….1721
3.9.5 swing circle………………………………………………………………………………1722
3.9.5.1 Removal of the swing circle……………………………………………………………1724
3.9.5.2 Replacement of the swing circle………………………………………………………..1727
3.10 Lubrication system……………………………………………………………………………..1732
3.10.1 Swing circle lubrication pinion (dummy wheel)………………………………………………..1732
3.10.1.1 Removal of the lubrication pinion assembly……………………………………………..1734
3.10.1.2 Replacement of the lubrication pinion assembly………………………………………….1736
3.10.2 Lubrication pump station…………………………………………………………………..1738
3.10.2.1 Removal of the lubrication pump station………………………………………………..1742
3.10.2.2 Replacement of the lubrication pump station…………………………………………….1744
3.10.2.3 Removal of the lubrication pump……………………………………………………….1745
3.10.2.4 Replacement of the lubricating pump……………………………………………………1747
3.11 Operator’s cab…………………………………………………………………………………1748
3.11.1 Removal of the operator’s cab………………………………………………………………1751
3.11.2 Replacement of the operator’s cab…………………………………………………………..1756
3.11.3 Viscous cab-mounts………………………………………………………………………..1758
3.11.3.1 Removal of the viscous cab-mounts……………………………………………………..1758
3.11.3.2 replacement of the viscous cab-mounts………………………………………………….1760
3.11.4 Front window (windscreen)………………………………………………………………….1762
3.11.4.1 Removal of the front window…………………………………………………………..1762
3.11.4.2 Replacement of the front window……………………………………………………….1763
3.11.5 Operator’s seat…………………………………………………………………………..1764
3.11.5.1 Removal of the operator’s seat………………………………………………………..1764
3.11.5.2 Replacement of the operator’s seat…………………………………………………….1765
3.11.6 ECS……………………………………………………………………………………..1766
3.11.6.1 Removal of the ECS text display……………………………………………………….1766
3.11.6.2 Replacement of the ECS text display……………………………………………………1766
3.12 Cab base (medium voltage switch cabinet)………………………………………………………….1767
3.12.1 Removal of the cab base……………………………………………………………………1767
3.12.2 Replacement of the cab base………………………………………………………………..1770
3.12.3 Pump controller…………………………………………………………………………..1773
3.12.3.1 Removal of the pump controller………………………………………………………..1773
3.12.3.2 Replacement of the pump controller…………………………………………………….1774
3.13 Access ladder………………………………………………………………………………….1776
3.13.1 Removal of the access ladder……………………………………………………………….1779
3.13.2 Replacement of the access ladder……………………………………………………………1783
3.13.3 Removal of the access ladder cylinder……………………………………………………….1785
3.13.4 Replacement of the access ladder cylinder……………………………………………………1787
3.14 Counterweight………………………………………………………………………………….1788
3.14.1 Removal of the counterweight……………………………………………………………….1788
3.14.2 Replacement of the counterweight……………………………………………………………1791
3.15 Superstructure lifting………………………………………………………………………….1792
3.15.1 Lift the superstructure (platform, PN 910 605 40 only)………………………………………..1792
3.15.2 Dump the superstructure (platform, PN 910 605 40 only)………………………………………..1795
3.15.3 Remove the superstructure from the undercarriage……………………………………………..1796
3.15.4 Install the superstructure onto the undercarriage…………………………………………….1801
3.16 High voltage switch cabinet……………………………………………………………………..1805
3.16.1 Removal of the high voltage switch cabinet…………………………………………………..1806
3.16.2 Replacement of the high voltage switch cabinet……………………………………………….1810
3.17 Slip ring unit…………………………………………………………………………………1812
3.17.1 Removal of the slip ring unit………………………………………………………………1813
3.17.2 Replacement of the slip ring unit…………………………………………………………..1817
4 Undercarriage………………………………………………………………………………………..1819
4.1 Undercarriage overview…………………………………………………………………………..1820
4.2 Travel system…………………………………………………………………………………..1822
4.2.1 Track group……………………………………………………………………………….1822
4.2.1.1 Changing of the track group……………………………………………………………1822
4.2.2 Sprocket………………………………………………………………………………….1827
4.2.2.1 Removal of the sprocket assembly……………………………………………………….1827
4.2.2.2 Replacement of the sprocket assembly……………………………………………………1832
4.2.3 Guide wheels (idlers)………………………………………………………………………1834
4.2.3.1 Removal of the guide wheel assembly…………………………………………………….1834
4.2.3.2 Replacement of the guide wheel assembly…………………………………………………1836
4.2.4 Track tensioning accumulators……………………………………………………………….1837
4.2.4.1 Removal of the low pressure accumulators………………………………………………..1837
4.2.4.2 Replacement of the low pressure accumulators…………………………………………….1839
4.2.4.3 Removal of the high pressure accumulators……………………………………………….1840
4.2.4.4 Replacement of the high pressure accumulators……………………………………………1841
4.2.5 Track tensioning valve block………………………………………………………………..1842
4.2.5.1 Removal of the track tensioning valve block……………………………………………..1842
4.2.5.2 Replacement of the track tensioning valve block………………………………………….1844
4.2.6 Track tensioning cylinders………………………………………………………………….1845
4.2.6.1 Removal of the track tensioning cylinders……………………………………………….1845
4.2.6.2 Replacement of the track tensioning cylinders……………………………………………1847
4.2.7 Substitute the Hydraulic hoses of the track tensioning system…………………………………..1849
4.2.7.1 Substitute the hydraulic hoses inside the car body……………………………………….1851
4.2.7.2 Substitute the hydraulic hose between car body and crawler frame…………………………..1851
4.2.7.3 Substitute the hydraulic hoses inside the crawler frame…………………………………..1853
4.2.7.4 Subsequent work………………………………………………………………………1854
4.2.8 Travel brake valve block (overspeed valve)……………………………………………………1855
4.2.8.1 Removal of the travel brake valve block…………………………………………………1858
4.2.8.2 Replacement of the travel brake valve block……………………………………………..1860
4.2.9 Travel motor………………………………………………………………………………1861
4.2.9.1 Removal of the travel motors…………………………………………………………..1861
4.2.9.2 Replacement of the travel motors……………………………………………………….1863
4.2.10 Travel parking brake………………………………………………………………………1864
4.2.10.1 Removal of the travel parking brake……………………………………………………1866
4.2.10.2 Replacement of the travel parking brake………………………………………………..1869
4.2.11 Travel gearbox……………………………………………………………………………1875
4.2.11.1 Removal of the travel gearbox…………………………………………………………1876
4.2.11.2 Replacement of the travel gearbox……………………………………………………..1879
4.2.12 Carrier roller……………………………………………………………………………1881
4.2.12.1 Removal of the carrier roller assembly…………………………………………………1881
4.2.12.2 Replacement of the carrier roller assembly……………………………………………..1884
4.2.13 Track roller……………………………………………………………………………..1885
4.2.13.1 Removal of the track roller assembly…………………………………………………..1885
4.2.13.2 Replacement of the track roller assembly……………………………………………….1887
4.3 Car body……………………………………………………………………………………….1888
4.3.1 Removal of the car body and the crawler carriers (type with mounting pins)……………………….1888
4.3.2 Replacement of the car body and the crawler carriers (type with mounting pins)……………………1892
4.3.3 Removal of the car body and the crawler carriers (type with bolted connection)……………………1896
4.3.4 Replacement of the car body and the crawler carriers (type with bolted connection)………………..1899
4.3.4.1 Tightening torque for the crawler carrier mounting bolts………………………………….1902
4.3.5 Rotary joint………………………………………………………………………………1906
4.3.5.1 Removal of the rotary joint……………………………………………………………1908
4.3.5.2 Replacement of the rotary joint………………………………………………………..1911
4.4 Cable drum assembly……………………………………………………………………………..1912
4.4.1 Removal of the cable drum assembly…………………………………………………………..1913
4.4.2 Replacement of the cable drum assembly……………………………………………………….1915
5 Attachment…………………………………………………………………………………………..1917
5.1 Face Shovel (FSA)……………………………………………………………………………….1918
5.1.1 FSA Overview………………………………………………………………………………1918
5.1.2 Using the installation tools for hydraulic cylinders…………………………………………..1919
5.1.3 Boom……………………………………………………………………………………..1920
5.1.3.1 Removal of the boom…………………………………………………………………..1920
5.1.3.2 Replacement of the boom……………………………………………………………….1925
5.1.3.3 Removal of the boom cylinders………………………………………………………….1930
5.1.3.4 Replacement of the boom cylinders………………………………………………………1935
5.1.4 Stick…………………………………………………………………………………….1938
5.1.4.1 Removal of the stick………………………………………………………………….1938
5.1.4.2 Replacement of the stick………………………………………………………………1942
5.1.4.3 Removal of the stick cylinders…………………………………………………………1946
5.1.4.4 Replacement of the stick cylinders……………………………………………………..1951
5.1.5 Bull clam bucket…………………………………………………………………………..1954
5.1.5.1 Removal of the bull clam bucket………………………………………………………..1956
5.1.5.2 Replacement of the bull clam bucket…………………………………………………….1960
5.1.5.3 Removal of the bucket cylinders………………………………………………………..1962
5.1.5.4 Replacement of the bucket cylinders…………………………………………………….1967
5.1.5.5 Removal of the clam cylinders………………………………………………………….1972
5.1.5.6 Replacement of the clam cylinders………………………………………………………1976
5.1.6 Ground engaging tools (GET)…………………………………………………………………1980
5.1.6.1 Removal and replacement of the GET……………………………………………………..1982
5.1.7 Hydraulic hoses at the face shovel attachment…………………………………………………1984
5.1.7.1 Substitute the boom arc hoses………………………………………………………….1984
5.1.7.2 Substitute the boom cylinder hoses……………………………………………………..1988
5.1.7.3 Substitute the stick arc hoses…………………………………………………………1992
5.1.7.4 Substitute the stick cylinder hoses…………………………………………………….1998
5.1.7.5 Substitute the bucket cylinder hoses……………………………………………………2002
5.1.7.6 Substitute the clam cylinder hoses……………………………………………………..2008
5.2 Metering valves (grease injectors) at the attachment………………………………………………..2016
5.2.1 Check the operation of the metering valves (grease injectors)…………………………………..2017
5.2.2 Removal of the metering valves (grease injectors)……………………………………………..2018
5.2.3 Replacement of the metering valves (grease injectors)………………………………………….2019
5.3 Cylinder bypass test…………………………………………………………………………….2020
6 Service information…………………………………………………………………………………..2023
6.1 Fluids and lubricants……………………………………………………………………………2024
6.2 Filling capacities………………………………………………………………………………2025
6.3 Work instructions……………………………………………………………………………….2026
6.3.1 Remove / install the crawler carrier…………………………………………………………2026
6.4 Weight tables…………………………………………………………………………………..2027
6.4.1 Superstructure…………………………………………………………………………….2027
6.4.1.1 Undercarriage………………………………………………………………………..2030
6.4.1.2 Face shovel attachment (FSA)…………………………………………………………..2031
6.5 Torque charts according to ISO……………………………………………………………………2032
6.5.1 Metric standard thread……………………………………………………………………..2032
6.5.2 Metric fine thread…………………………………………………………………………2033
6.5.3 SAE flange connections……………………………………………………………………..2034
6.6 Blind plugs…………………………………………………………………………………….2036
6.6.1 Dummy plates for SAE-flanges………………………………………………………………..2036
6.6.2 Classification of threads to the nominal width………………………………………………..2038
6.6.3 Plugs and fittings according to EN ISO 84 34-1………………………………………………..2039
6.7 Conversion table………………………………………………………………………………..2040
6.7.1 Method of using the conversion table…………………………………………………………2040
6.7.2 Millimeter – Inch & Kilogram – Pound…………………………………………………………2041
6.7.3 Liter – U.S. Gallon & Liter – U.K. Gallon…………………………………………………….2042
6.7.4 Nm- ft.lb…………………………………………………………………………………2043
6.7.5 Bar – PSI – kPa – MPa………………………………………………………………………2044
6.7.6 Basic Values in Ohm according to DIN 4376 / IEC 751……………………………………………2045
6.7.7 Temperature……………………………………………………………………………….2046
6.8 Tools………………………………………………………………………………………….2047
6.8.1 Standard tool case…………………………………………………………………………2047
6.8.2 Used special tools (overview)……………………………………………………………….2049

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