Komatsu Hydraulic Mining Shovel PC4000 Repair Service Manuals
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Model:
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Mining Shovel PC4000, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Mining Shovel PC4000 Shop workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SMPC4000-8199 - Hydraulic Mining Shovel PC4000-6 Shop Manual.pdf
SMPC40008152 - Hydraulic Mining Shovel PC4000-6 Shop Manual.pdf
SMPC40008155 - Hydraulic Mining Shovel PC4000-6 Shop Manual.pdf
SMPC40008170 - Hydraulic Mining Shovel PC4000-6 Shop Manual.pdf
SMPC40008172 - Hydraulic Mining Shovel PC4000-6 Shop Manual.pdf
CEAWDPC4000 - Hydraulic Mining Shovel PC4000 General Assembly Procedure Manual (Z21854).pdf
FAMPC4000-05 - Hydraulic Mining Shovel PC4000 General Assembly Procedure.pdf
FAMPC4000-08205 - Hydraulic Mining Shovel PC4000-6 Field Assembly Manual.pdf
GZEAM08189 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
GZEAM08218-0 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
OM-PC4000-8224 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
OMPC40008152 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
OMPC40008155 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
OMPC40008170 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
OMPC40008172 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual.pdf
RRPC4000-6 - Hydraulic Mining Shovel PC4000-6 Remove & Replace Procedures.pdf
PRODUCT DETAILS:
Total Pages: 10,121 pages
File Format: PDF
Language: English
MAIN SECTIONS
CEAWDPC4000 - Hydraulic Mining Shovel PC4000 General Assembly Procedure Manual (Z21854)...2
COVER...2
GENERAL CONTENT...4
1. OVERVIEWS...6
1.1 OVERVIEW SUPERSTRUCTURE...6
1.2 OVERVIEW ENGINE HOUSE...8
2. GENERAL...10
2.1 DELIVERY OF THE EXCAVATOR...10
2.2 ASSEMBLING OF THE EXCAVATOR...10
2.3 TRANSPORTATION AND LIFTING...12
2.4 MANPOWER/ASSEMBLY TIME...14
2.5 ASSEMBLY SITE REQUIREMENTS...16
2.6 SPACE AND PLACING REQUIREMENTS...18
2.7 PREPARATION FOR ASSEMBLY...18
2.8 BASIC MEASUREMENTS AND WEIGHTS...20
2.9 TRANSPORT DIMENSIONS AND WEIGHTS...22
3. ASSEMBLY SEQUENCE...24
3.1 ASSEMBLY OF UNDERCARRIAGE...26
3.2 ASSEMBLY OF SUPERSTRUCTURE ONTO THE UNDERCARRIAGE...30
3.3 ASSEMBLY OF ENGINE HOUSE...32
3.4 MOUNTING OF BOOM...34
3.5 MOUNTING OF HYDRAULIC OIL TANK...36
3.6 MOUNTING OF HYDRAULIC OIL COOLER...38
3.7 MOUNTING OF FUEL TANK...40
3.8 MOUNTING OF HYDRAULIC ACCESS LADDER...42
3.9 MOUNTING OF CAB BASE...44
3.10 MOUNTING OF COUNTERWEIGHT...46
3.11 MOUNTING OF HANDRAILS, STEPS AND GRATINGS...48
3.12 MOUNTING OF CAB WITH SUPPORT FRAME...50
3.13 MOUNTING OF BUCKET CYLINDERS...52
3.14 FILLING UP HYDRAULIC TANK AND FUEL TANK...52
3.15 MOUNTING OF STICK...54
3.16 PRE-CHECKS PRIOR TO START-UP...54
3.17 MOUNTING OF STICK CYLINDERS TO THE STICK...56
3.18 ASSEMBLY OF BULLCLAM BUCKET TO THE STICK...58
3.19 MOUNTING OF THE PIN SEALS...62
3.20 CONNECTION OF THE CABLE HARNESSES TO THE TERMINAL RAILS IN THE SWITCH BOX "X2"...64
3.21 PUTTING THE CENTRAL LUBRICATION SYSTEM INTO OPERATION...66
3.22 STANDARD APPLICATION TORQUE CHART...68
FAMPC4000-05 - Hydraulic Mining Shovel PC4000 General Assembly Procedure...72
COVER...72
GENERAL CONTENT...74
1. Overviews...76
1.1 Overview Superstructure (Z22586)...76
1.2 Overview Engine House (Z21446)...78
2. General...80
2.1 Delivery of the Excavator...80
2.2 Assembling of the Excavator...80
2.3 Transportation and Lifting...82
2.4 Manpower / Assembly Time...84
2.5 Assembly Site Requirements...86
2.6 Space and Placing Requirements...90
2.7 Preparation for Assembly...90
2.8 Basic Measurements (Z23038)...92
2.9 Transport Dimensions and Weights (as example)...92
3. Assembly Sequence...94
3.1. Assembly of Undercarriage (Z21859)...94
3.1.1. Mounting of travel gear breather filters (Z21860)...96
3.1.2 Track tensioning system (Z23037)...98
3.2. Assembly of Superstructure onto the Undercarriage (Z23863)...100
3.3 Assembly of engine house (Z21863)...102
3.4 Mounting of Boom (Z21864)...104
3.5. Mounting of Hydraulic Oil Tank (Z23039)...106
3.6. Mounting of Hydraulic Oil Cooler (Z21866)...108
3.7. Mounting of Fuel Tank (Z21867)...110
3.8 Mounting of hydraulic access ladder (Z21871)...112
3.9. Mounting of Cab Base (Z21868)...114
3.10 Mounting of Counterweight (Z21869)...116
3.11 Mounting of Handrails, Steps and Gratings (Z23033)...118
3.12 Mounting of Cable transfer to the Operators Cab (Z22937)...120
3.13 Mounting of Cab with Support Frame (Z22938; Z22939)...124
3.13.1 Mounting of the Cab air cleaner (Cab support to Cab) (Z22940)...126
3.14 Mounting of Bucket Cylinders (Z21873)...128
3.15 Mounting of Stick (Bullclam bucket) (Z21874)...130
3.15.1 Mounting of Stick (Backhoe attachment) (Z23034)...132
3.16 Filling up hydraulic oil tank (Z21585)...134
3.17 Bleed air from all hydraulic pumps and check the Oil Level in all four Main Pump Housings (Z21693; Z22513)...136
3.18 Filling up fuel tank...138
3.19 Pre-checks for initial Start-up...140
3.20 Mounting of stick cylinders to the stick (Z21875)...144
3.21 Assembly of Bullclam Bucket to the Stick (Z21876)...146
3.22 Mounting of the Pin Seals (Z22042)...150
3.22.1 Mounting of the Pin Seals (Backhoe) (Z23035)...152
3.23 Connection of the cable harnesses to the terminal rails in the switch box "X2" (Z21879)...154
3.24 Putting the Central Lubrication System into operation (Z21880)...158
3.25 Metric standard thread...160
FAMPC4000-08205 - Hydraulic Mining Shovel PC4000-6 Field Assembly Manual...166
2 SAFETY...174
2.1 SAFETY INFORMATION...175
2.2 OVERVIEW...176
2.2.1 NORMAL OPERATIONS...176
2.2.2 REGULAR MAINTENANCE...176
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR...176
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR...176
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB...177
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR...178
2.4.1 UNDERSTANDING THE MACHINE...178
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR...178
2.4.3 PREPARATIONS FOR SAFE OPERATION...178
2.4.4 FIRE PREVENTION...180
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE...182
2.4.6 BURN PREVENTION...184
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS...184
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...185
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)...186
2.4.10 PRECAUTIONS AT JOBSITE...187
2.4.11 STARTING ENGINE...192
2.4.12 OPERATION...193
2.5 PRECAUTION FOR MAINTENANCE...199
2.5.1 GENERAL PRECAUTIONS...199
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE...207
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID...208
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS...212
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM...212
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS...212
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...212
2.7 SPECIAL SAFETY EQUIPMENT...213
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB...214
2.7.2 OBJECT HANDLING...214
2.7.3 LIGHTING...214
2.7.4 WARNING BEACON...214
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...214
2.8 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLY...222
2.8.1 WHEN ASSEMBLING THE EXCAVATOR...222
2.8.2 WHEN DISASSEMBLING THE EXCAVATOR...222
2.8.3 WHEN TRANSPORTING THE DISASSEMBLED EXCAVATOR...223
3 GENERAL...224
3.1 GENERAL...225
3.1.1 DELIVERY OF THE EXCAVATOR...225
3.1.2 ASSEMBLING THE EXCAVATOR...225
3.1.3 LIFTING AND TRANSPORTATION...225
3.1.4 PACKING LIST OF A TYPICAL FACE SHOVEL MACHINE...226
3.1.5 PACKING LIST OF A TYPICAL BACKHOE MACHINE...227
3.1.6 ELECTRICAL ENERGY...228
3.1.7 ELECTROMAGNETIC COMPATIBILITY (EMC)...228
3.1.8 MONITORING SYSTEM OF THE MACHINE...228
3.2 ASSEMBLY SITE REQUIREMENTS...229
3.2.1 CONFIGURATION OF COMPONENTS ON ERECTION SITE (EXAMPLE)...229
3.2.2 REQUIRED CRANES...231
3.2.3 MANPOWER / ASSEMBLY TIME...231
3.2.4 TOOLS AND EQUIPMENT FOR ASSEMBLY...232
3.2.5 STANDARD APPLICATION TORQUE CHART...235
3.2.6 PREPARATIONS FOR ASSEMBLY...238
3.2.7 BASIC DIMENSIONS...239
3.3 GENERAL INSTALLATION PROCEDURES FOR HYDRAULIC HOSE LINES...240
4 ASSEMBLY SEQUENCE...242
4.1 ASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES...243
4.1.1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINE’S STABILITY...244
4.2 ASSEMBLY SEQUENCE OF BACKHOE MACHINES...245
4.2.1 ASSEMBLY SEQUENCE UNDER CONSIDERATION OF THE MACHINE’S STABILITY...246
4.3 ASSEMBLY OF UNDERCARRIAGE...247
4.3.1 ASSEMBLY OF TRACKS...248
4.3.2 ATTACH CARBODY TO SIDE FRAME...249
4.3.3 DETERMINING THE TIGHTENING TORQUE...256
4.3.4 SPECIAL HYDRAULIC TORQUE WRENCH...260
4.3.5 CLOSING THE TRACKS...261
4.3.6 CONNECT HYDRAULIC LINES TO THE TRAVEL MOTORS...262
4.3.7 MOUNTING OF TRAVEL GEAR PROTECTION...265
4.3.8 MOUNTING OF TRAVEL MOTOR PROTECTION HOOD...267
4.3.9 HYDRAULIC TRACK TENSIONING SYSTEM...269
4.4 MOUNTING SUPERSTRUCTURE PLATFORM ONTO UNDERCARRIAGE...271
4.5 ASSEMBLY OF MACHINERY HOUSE ROOF...275
4.5.1 MOUNTING OF THE EXHAUST SYSTEM...277
4.5.2 MOUNTING OF THE AIR INTAKE SYSTEM...280
4.6 MOUNTING MACHINERY HOUSE ONTO THE SUPERSTRUCTURE PLATFORM...283
4.7 MOUNTING OF BATTERY BOX AND HYDRAULIC ACCESS LADDER...285
4.8 CONNECTING ENGINE OIL RESERVE SYSTEM...291
4.9 PRE-ASSEMBLY OF FACE SHOVEL BOOM...295
4.9.1 ATTACHMENT POINTS FOR SAFETY HARNESS ON BOOM...299
4.9.2 GENERAL INSTALLATION INSTRUCTIONS FOR ATTACHMENT PINS...301
4.9.3 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM...303
4.9.4 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME...307
4.10 PRE-ASSEMBLY OF BACKHOE BOOM...309
4.10.1 ATTACH BOOM CYLINDERS AND STICK CYLINDERS TO THE BOOM...311
4.10.2 ATTACH BOOM TO SUPERSTRUCTRE A-FRAME...315
4.11 MOUNTING OF COUNTERWEIGHT...317
4.12 MOUNTING OF THE FUEL TANK...319
4.12.1 CONNECTING FUEL SYSTEM HOSE LINES...321
4.13 ATTACHING THE CAB BASE...325
4.13.1 MAKING OF ELECTRICAL CABLE CONNECTIONS...327
4.13.2 CONNECT CAB HEATER HOSES TO CAB BASE...329
4.14 ATTACHING THE CAB WITH SUPPORT FRAME TO THE CAB BASE...331
4.14.1 CONNECTING THE AIR CONDITIONER HOSES OF THE CAB...333
4.14.2 INSTALL ORBCOMM ANTENNA...335
4.15 CONNECTING HYDRAULIC LINES BETWEEN MACHINERY HOUSE AND SUPERSTRUCTURE...337
4.15.1 CONNECTING HIGH PRESSURE LINES OF THE MAIN PUMPS...339
4.16 ATTACHING THE HYDRAULIC OIL RESERVOIR...341
4.17 ATTACHING THE HYDRAULIC OIL COOLER...343
4.17.1 CONNECTING THE HYDRAULIC HOSE LINES OF THE OIL COOLER CIRCUIT...345
4.17.2 CONNECTING THE HOSE LINES OF OIL COOLER FAN MOTORS...347
4.17.3 CONNECTING THE HOSE LINES OF PTO OIL COOLING CIRCUIT...349
4.17.4 CONNECTING THE RETURN OIL HOSE LINE OF RADIATOR FAN MOTOR...351
4.17.5 CONNECTING THE HOSE LINES FROM RETURN OIL MANIFOLD TO BACK-PRESSURE PIPE...353
4.18 CONNECTING SWING GEAR HYDRAULIC LINES...355
4.18.1 CONNECTING THE RETURN AND LEAKAGE OIL HOSE LINES...356
4.18.2 CONNECTING THE SWING BRAKE PRESSURE HOSES AND PILOT OIL HOSES...357
4.19 CONNECTING THE RETURN AND PRESSURE OIL HOSES FROM VALVE BLOCK...359
4.20 CONNECTING THE HOSE LINES OF THE TRANSFER PUMP...365
4.21 CONNECTING HYDRAULIC LINES TO THE ROTARY JOINT...367
4.21.1 CONNECTING THE PILOT OIL LINE, RETURN OIL LINE AND LEAKAGE OIL LINE TO THE ROTARY JOINT...369
4.22 ATTACHING THE HANDRAILS, CATWALKS AND STEPS...371
4.23 MOUNTING OF THE FIRE EXTINGUISHING TANK ASSEMBLIES...373
4.24 CENTRAL REFILLING SYSTEM...377
4.24.1 CONNECTING THE REFILLING LINES...378
4.25 CONNECTING THE GREASE LINES OF THE AUTOMATIC LUBRICATION SYSTEMS...383
4.26 MOUNTING THE CAN-NODE BOXES ONTO THE MACHINERY HOUSE ROOF...385
4.26.1 CONNECTING THE CABLES TO THE CAN-NODES...386
4.27 PRE-CHECKS PRIOR TO INITIAL START UP...387
4.28 FILLING AND BLEEDING THE HYDRAULIC SYSTEM...389
4.28.1 FILLING THE HYDRAULIC SYSTEM...390
4.28.2 BLEEDING THE HYDRAULIC SYSTEM...391
4.28.3 BLEEDING THE GEAR PUMP FOR PTO GEAR LUBRICATION...394
4.29 ASSEMBLY FACE SHOVEL ATTACHMENT...395
4.29.1 ATTACHING THE BUCKET CYLINDERS TO THE BOOM...396
4.29.2 ATTACHING THE STICK TO THE BOOM...398
4.29.3 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM...399
4.29.4 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS...399
4.29.5 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS...402
4.29.6 CONNECTING HOSE LINES FROM STICK TO BUCKET CYLINDERS...404
4.29.7 CONNECTING STICK CYLINDERS TO THE STICK...405
4.30 BLEEDING HYDRAULIC CIRCUITS...407
4.30.1 BLEEDING THE SWING PARKING BRAKE CIRCUIT...408
4.30.2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT...408
4.30.3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT...410
4.30.4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER...411
4.30.5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS...411
4.30.6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS...412
4.31 ATTACHING FACE SHOVEL TO THE STICK...413
4.31.1 ATTACHING BUCKET BACK WALL TO THE STICK...414
4.31.2 CONNECTING HOSE LINES FROM STICK TO BUCKET CLAM CYLINDERS...416
4.31.3 ATTACHING THE CLAM SHELL TO BUCKET BACK WALL...418
4.31.4 CONNECTING GREASE LINES OF THE FACE SHOVEL ATTACHMENT...420
4.31.5 CONNECTING GREASE LINES ON THE BUCKET...422
4.31.6 BLEEDING HYDRAULIC CIRCUIT OF BUCKET CLAM CYLINDERS...422
4.32 ASSEMBLY BACKHOE ATTACHMENT...423
4.32.1 CONNECTING HOSE LINES FROM DISTRIBUTOR MANIFOLD TO BOOM...424
4.32.2 CONNECTING HOSE LINES FROM BOOM TO BOOM CYLINDERS...425
4.32.3 CONNECTING HOSE LINES FROM BOOM TO STICK CYLINDERS...426
4.32.4 ATTACHING THE STICK TO THE BOOM...428
4.32.5 CONNECTING HOSE LINES FROM BOOM TO BUCKET CYLINDERS...432
4.33 BLEEDING HYDRAULIC CIRCUITS...433
4.33.1 BLEEDING THE SWING PARKING BRAKE CIRCUIT...434
4.33.2 BLEEDING THE TRAVEL PARKING BRAKE CIRCUIT...434
4.33.3 BLEEDING THE HYDRAULIC TRACK TENSIONING CIRCUIT...436
4.33.4 BLEEDING HYDRAULIC CIRCUIT OF ACCESS LADDER...437
4.33.5 BLEEDING HYDRAULIC CIRCUIT OF ATTACHMENT CYLINDERS...437
4.33.6 BLEEDING HYDRAULIC CIRCUIT OF SWING MOTORS...438
4.34 ATTACHING BACKHOE BUCKET TO THE STICK...439
4.34.1 CONNECTING GREASE LINES OF THE BACKHOE ATTACHMENT...444
4.35 BLEEDING HYDRAULIC CIRCUITS OF THE TRAVEL MOTORS...445
5 FINAL CHECKS AND ADJUSTMENTS...446
5.0.1 COMMISSIONING CHECK LIST...448
5.0.2 ADJUSTMENT OF AUTOMATIC LUBRICATION SYSTEMS...448
5.0.3 MAIN PUMP ADJUSTMENT IN RELATION TO ALTITUDE AT THE MINE SITE...450
5.0.4 PRESSURE COMPENSATION OF SEALED COMPONENTS...450
5.0.5 PLACING THE FIRE DETECTION AND SUPPRESSION SYSTEM IN SERVICE...451
5.0.6 COMMISSIONING OF THE AIR CONDITIONING...469
5.1 PERFORM THE PM-CLINIC PROCEDURE ACCORDING TO THE PM-CLINIC MANUAL...473
5.1.1 VISUAL INSPECTION...474
5.1.2 TRAVELLING INSTRUCTIONS...474
5.2 HANDLING OF DOCUMENTATION AFTER ASSEMBLY AND COMMISSIONING...475
6 DISASSEMBLY OF THE MACHINE...476
6.0.1 DISASSEMBLY SEQUENCE OF FACE SHOVEL MACHINES...477
6.0.2 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE...478
6.0.3 DISASSEMBLY SEQUENCE OF BACKHOE MACHINES...479
6.0.4 SAFETY PRECAUTIONS FOR DISASSEMBLING THE MACHINE...480
6.0.5 DISPOSAL OF WASTE MATERIAL...481
GZEAM08189 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual...501
COVER...501
1. INTRODUCTION...503
1.1 CONTENTS OF THE BINDER...504
1.2 DIVISION OF THE BINDER...505
1.3 DESIGNATED USE OF THE SHOVEL...506
1.4 DELIVERY OF THE SHOVEL...507
1.5 EXPLANATION OF ABBREVIATIONS...508
1.6 TABLE OF CONTENTS...509
2. SAFETY...515
2.1 SAFETY INSTRUCTIONS...516
2.1.1 WARNINGS AND SYMBOLS...516
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC MINING SHOVEL...516
2.1.3 ORGANIZATIONAL MEASURES...517
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...519
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES...520
2.1.6 WARNING OF SPECIAL DANGERS...523
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING...525
2.1.8 SPECIAL SAFETY EQUIPMENT...525
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...529
3. OPERATION...537
3.1 FOREWORD...538
3.2 CONSTRUCTION OF THE SHOVEL...539
3.2.1 OVERALL VIEW...539
3.2.2 SUPERSTRUCTURE...540
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER...550
3.2.4 EMERGENCY ESCAPE LADDER...554
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM...556
3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)...558
3.2.7 UNDERCARRIAGE...569
3.2.8 WORKING ATTACHMENT...570
3.2.9 DIESEL ENGINE TYPE SDA 16V160...572
3.2.10 ENGINE OIL MANAGEMENT SYSTEM...574
3.3 OPERATOR’S CAB - CONTROLS...578
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT...578
3.3.2 SAFETY CIRCUIT FOR CONTROLS...579
3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT...582
3.3.4 SAFETY CIRCUIT FOR CONTROLS...583
3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK...585
3.3.6 OPERATOR’S CONSOLE...587
3.3.7 INTERFACE PANEL FOR DIAGNOSTICS...595
3.3.8 CONTROL MODULE FOR AUXILIARY CAB HEATER...597
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR...598
3.4.1 SEQUENCE OF DISPLAYS...599
3.4.2 OPENING SCREEN...599
3.4.3 MAIN GAUGE SCREENS 1 TO 3...600
3.4.4 FUEL CONSUMPTION SCREEN...607
3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR...608
3.4.6 MAIN SCREEN - CHANGE >TIME >SMR >DATE...608
3.4.7 MAINTENANCE MONITOR...609
3.4.8 SETTINGS FOR OPERATOR...610
3.4.9 AUTOMATIC MESSAGES...615
3.4.10 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM...619
3.4.11 TABLE OF AVAILABLE INSTRUCTION MESSAGES...629
3.5 CAMERA SYSTEM WITH MONITORS...632
3.5.1 LOCATION OF MONITORS AND CONTROL UNITS...633
3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING...640
3.6.1 AUXILIARY HEATER FOR OPERATOR’S CAB...645
3.7 POWER HOUSE...646
3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES...647
3.7.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES...649
3.7.3 CENTRAL CONTROL AND FILTER PANEL...651
3.8 ELECTRICAL EQUIPMENT IN CAB BASE...654
3.8.1 STANDARD COMPONENTS IN CAB BASE...655
3.8.2 SWITCH BOARD (X2) IN CAB BASE...657
3.8.3 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE...667
3.9 CHECKS BEFORE STARTING THE ENGINE...674
3.10 STARTING THE ENGINE...680
3.10.1 STARTING PROCEDURE...683
3.10.2 ENGINE WARM-UP...691
3.10.3 HYDRAULIC OIL WARM-UP...691
3.11 MOVING THE SHOVEL...693
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS...693
3.11.2 TRAVELLING INSTRUCTIONS...696
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE...697
3.12.1 SLEWING THE SUPERSTRUCTURE...697
3.12.2 BRAKING THE SUPERSTRUCTURE...699
3.12.3 SLEW PARKING BRAKE...700
3.13 WORKING WITH THE ATTACHMENT...702
3.13.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM...702
3.13.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM...703
3.13.3 BOTTOM DUMP BUCKET...704
3.13.4 DROP BALL OPERATION...705
3.13.5 COMBINED OPERATION CYCLES...708
3.14 WORKING INSTRUCTIONS...710
3.14.1 STABILITY OF THE SHOVEL...710
3.14.2 SHOVEL OPERATION...710
3.15 PARKING THE SHOVEL...713
3.16 STOPPING THE ENGINE...714
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM...717
3.17 OPERATION OF THE LUBRICATION SYSTEM...718
3.17.1 CENTRAL LUBRICATION SYSTEM ”CLS”...718
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”...720
3.18 FIRE DETECTION AND SUPPRESSION SYSTEMS...722
3.18.1 HIGH LEVEL ALARM ”FIRE”...727
3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE...727
3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEMS...727
3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S...729
3.18.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER...731
3.19 TRANSFER PUMP FOR HYDRAULIC OIL...732
3.19.1 OPERATING THE TRANSFER PUMP...733
3.19.2 FUNCTIONS OF THE TRANSFER PUMP...735
3.20 CENTRAL REFILLING SYSTEM...738
3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM...739
3.20.2 OPERATING THE HYDRAULIC SERVICE ARM...741
3.20.3 RECEIVER PANEL WITH MONITOR BOX...743
3.20.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUB...749
3.21 WORK ON THE LOADER ATTACHMENT...752
3.22 TRANSPORTATION AND LIFTING OF THE SHOVEL...753
3.22.1 DISASSEMBLING OF THE SHOVEL...753
3.22.2 TRANSPORTATION AND LIFTING...753
3.23 RETRIEVAL PROCEDURE...754
3.24 SHOVEL STORAGE...755
3.24.1 PREPARING FOR STORAGE...755
3.24.2 ONE MONTH REPETITIVE SERVICE PERIOD...756
3.24.3 SIX MONTH REPETITIVE SERVICE PERIOD...756
3.24.4 PREPARING FOR OPERATION...757
3.25 TROUBLE SHOOTING...758
3.25.1 ENGINE...758
3.25.2 HYDRAULIC SYSTEM...759
3.25.3 FINAL DRIVES AND SWING MACHINERY...760
3.25.4 CRAWLER TRACKS...760
4. MAINTENANCE...761
4.1 FOREWORD...762
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE...763
4.3 FLUIDS AND LUBRICANTS...765
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES...765
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES...766
4.4 FILLING CAPACITIES...768
4.5 STANDARD TORQUE LIST...769
4.6 LUBRICATION AND MAINTENANCE SCHEDULE...770
4.6.1 INITIAL SERVICING...770
4.6.2 PERIODIC SERVICING INTERVALS...770
4.6.3 PERIODIC SERVICING SCHEDULE...771
4.6.4 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES...776
4.6.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...777
4.6.6 EXTENDED SERVICE INTERVALS FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM...781
4.6.7 MAINTENANCE OF THE ENGINE...783
4.7 WHEN NECESSARY...784
4.7.1 ENGINE AIR CLEANER SERVICE...785
4.7.2 SWING CIRCLE TOOTHING LUBRICATION...789
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS...791
4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...795
4.8 EVERY 10 OPERATING HOURS OR DAILY...796
4.8.1 WALK-AROUND INSPECTION...797
4.8.2 AIR CLEANER - CLEAN PRE-CLEANER...807
4.8.3 RADIATOR - CHECK COOLANT LEVEL...809
4.8.4 TRACK GROUPS - CLEAN...809
4.8.5 FUEL SYSTEM WATER SEPARATOR - DRAIN WATER...811
4.9 EVERY 50 OPERATING HOURS OR WEEKLY...812
4.9.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...813
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S" - CHECK OIL L...817
4.9.3 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL...819
4.9.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN" - CHECK OIL LEVELS...821
4.9.5 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL...823
4.9.6 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR - CHECK OIL LEVEL...825
4.9.7 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR...827
4.9.8 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY...829
4.10 EVERY 250 OPERATING HOURS OR MONTHLY...830
4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION...831
4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE...833
4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE...833
4.10.4 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...833
4.10.5 RADIATOR FAN BEARING HOUSING - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...833
4.10.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER...835
4.10.7 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT...839
4.10.8 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL...843
4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL...845
4.11 EVERY 500 OPERATING HOURS OR MONTHLY...846
4.11.1 BATTERIES - CHECK FLUID LEVEL...847
4.11.2 FLEXIBLE DRIVE COUPLING - CHECK OIL LEVEL...849
4.11.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS - CHECK OIL LEVEL...851
4.11.4 FUEL TANK - DRAIN CONDENSATION...853
4.11.5 CRAWLER TRACK - INSPECTION...855
4.11.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR - CHECK FOR CORRECT CONNECTION...861
4.11.7 GROUND CABLE OF OPERATOR’S CAB - CHECK FOR CORRECT CONNECTION...863
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH...864
4.12.1 HIGH STRENGTH BOLT CONNECTIONS...865
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE...913
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...927
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE...929
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK ACCUMULATORS...931
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE...933
4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES...935
4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES...937
4.13 EVERY 2000 OPERATING HOURS OR YEARLY...938
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER...939
4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION...951
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR...952
4.14.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL...953
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S"- CHANGE OIL...961
4.14.3 FINAL DRIVE HOUSINGS - CHANGE OIL...965
4.14.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN"- CHANGE OIL...967
4.14.5 FINAL DRIVE HOUSINGS - CHANGE OIL...971
4.14.6 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL...973
4.15 FIRE PREVENTION...974
4.16 WELD REPAIRS...976
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE...979
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT...981
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...983
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE...984
GZEAM08218-0 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual...991
1 FOREWORD...993
1.1 BEFORE READING THIS MANUAL...994
1.2 DIRECTIONS OF THE MACHINE...995
1.3 SPECIFICATION AND SERIAL PLATE...996
1.3.1 PRODUCT IDENTIFICATION NUMBER...996
1.4 DIVISION OF THE BINDER...997
1.5 DESIGNATED USE OF THE SHOVEL...998
1.6 DELIVERY OF THE SHOVEL...999
1.6.1 SPARE PARTS...999
1.6.2 SERVICE...999
1.7 EXPLANATION OF ABBREVIATIONS...1000
1.8 CONTENTS...1001
2 SAFETY...1007
2.1 SAFETY INFORMATION...1008
2.2 OVERVIEW...1009
2.2.1 NORMAL OPERATIONS...1009
2.2.2 REGULAR MAINTENANCE...1009
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR...1009
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR...1009
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB...1010
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR...1011
2.4.1 UNDERSTANDING THE MACHINE...1011
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR...1011
2.4.2.1 ENSURING SAFE OPERATION...1011
2.4.3 PREPARATIONS FOR SAFE OPERATION...1011
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT...1011
2.4.3.2 INSPECTING THE MACHINE...1011
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT...1012
2.4.3.4 KEEP MACHINE CLEAN...1012
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT...1012
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT...1013
2.4.3.7 IF A PROBLEM IS FOUND...1013
2.4.4 FIRE PREVENTION...1013
2.4.4.1 PRECAUTIONS TO PREVENT FIRE...1013
2.4.4.2 ACTION IF FIRE OCCURS...1014
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB...1015
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE...1015
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE...1015
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE...1015
2.4.5.3 NO PEOPLE ON THE ATTACHMENT...1015
2.4.5.4 WORKING IN HIGH PLACES...1015
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK...1016
2.4.5.6 LEAVING THE MACHINE...1016
2.4.6 BURN PREVENTION...1017
2.4.6.1 Hot coolant...1017
2.4.6.2 Hot oil...1017
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS...1017
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...1018
2.4.8.1 UNAUTHORIZED MODIFICATION...1018
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...1018
2.4.9 PRECAUTIONS AT JOBSITE...1020
2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT...1021
2.4.9.2 CAMERA SYSTEM WITH MONITORS...1021
2.4.9.3 ENSURE GOOD VISIBILITY...1021
2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS...1021
2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS...1022
2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES...1022
2.4.9.7 WORKING ON LOOSE GROUND...1023
2.4.9.8 GAS, DUST, STEAM AND SMOKE...1023
2.4.9.9 VENTILATION OF ENCLOSED AREAS...1024
2.4.10 STARTING ENGINE...1025
2.4.10.1 WARNING TAG...1025
2.4.10.2 CHECKS BEFORE STARTING ENGINE...1025
2.4.10.3 PRECAUTION WHEN STARTING ENGINE...1025
2.4.10.4 PRECAUTION IN COLD AREAS...1026
2.4.11 OPERATION...1026
2.4.11.1 CHECKS BEFORE OPERATION...1026
2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE...1027
2.4.11.3 PRECAUTIONS WHEN travelling...1028
2.4.11.4 TRAVELLING ON SLOPES...1029
2.4.11.5 OPERATIONS ON SLOPES...1030
2.4.11.6 PROHIBITED OPERATIONS...1030
2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES...1031
2.4.11.8 PARKING THE MACHINE...1031
2.4.11.9 TRANSPORTATION...1031
2.5 PRECAUTION FOR MAINTENANCE...1032
2.5.1 GENERAL PRECAUTIONS...1032
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...1033
2.5.1.2 STOP ENGINE FOR MAINTENANCE...1034
2.5.1.3 WARNING TAG...1035
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY...1036
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS...1036
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING...1037
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS...1037
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT...1038
2.5.1.9 NOISE...1038
2.5.1.10 WHEN USING A HAMMER...1038
2.5.1.11 PROPER TOOLS...1039
2.5.1.12 ACCUMULATOR...1039
2.5.1.13 PERSONNEL...1039
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE...1040
2.5.2.1 PRECAUTION WHEN WELDING...1040
2.5.2.2 BATTERY HANDLING...1040
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID...1041
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE...1041
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES...1042
2.5.3.3 REPLACEMENT OF HOSE LINES...1042
2.5.3.4 INSPECTION OF HOSE LINES...1042
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...1043
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE...1043
2.5.3.7 AIR CONDITIONING MAINTENANCE...1043
2.5.3.8 COMPRESSED AIR...1044
2.5.3.9 WASTE MATERIALS...1044
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS...1045
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM...1045
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS...1045
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...1045
2.7 SPECIAL SAFETY EQUIPMENT...1046
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB...1047
2.7.2 OBJECT HANDLING...1047
2.7.3 LIGHTING...1047
2.7.4 WARNING BEACON...1047
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...1047
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...1047
2.7.5.2 INSTRUCTIONS FOR USE...1049
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL...1051
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1),...1051
2.7.5.5 INSTRUCTIONS FOR USE...1053
2.8 SAFETY WARNING SIGNS...1055
2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS...1056
3 OPERATION...1069
3.1 FOREWORD...1070
3.2 CONSTRUCTION OF THE SHOVEL...1071
3.2.1 OVERALL VIEW...1071
3.2.2 SUPERSTRUCTURE...1072
3.2.2.1 Machinery House...1076
3.2.2.2 Main Hydraulic Oil Reservoir...1078
3.2.2.3 Hydraulic Oil Cooler...1079
3.2.2.4 Fuel Tank...1080
3.2.2.5 Counterweight...1081
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER...1082
3.2.3.1 Operating the hydraulic Access Ladder...1083
3.2.4 EMERGENCY ESCAPE LADDER...1086
3.2.5 BOOM ACCESS LADDER AND WALKWAY...1088
3.2.6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM...1090
3.2.6.1 Emergency Engine Shutdown System actuated from Ground Man (special equipment)...1091
3.2.6.2 Operator Warning System (special equipment)...1091
3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)...1092
3.2.7.1 Operator’s Cab - Emergency Escape Hammer and Storage Box for Operation Manual...1097
3.2.7.2 Operator’s Seat Adjustment...1099
3.2.7.3 Co-driver’s Seat and Refrigerator Box...1100
3.2.8 UNDERCARRIAGE...1101
3.2.9 WORKING ATTACHMENT...1102
3.2.9.1 Loader attachment with bottom dump bucket...1102
3.2.9.2 Loader attachment with backhoe bucket...1103
3.2.10 DIESEL ENGINE TYPE SDA 16V160E-2...1104
3.2.11 ENGINE OIL MANAGEMENT SYSTEM...1106
3.2.11.1 Oil Burning System "Centinel" combined with Oil Supply System "Reserve"...1108
3.2.11.2 Eliminator Engine Oil Filtration System...1109
3.3 OPERATOR’S CAB - CONTROLS...1110
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT...1110
3.3.1.1 HYDRAULIC CONTROL SYSTEM...1111
3.3.2 SAFETY CIRCUIT FOR CONTROLS...1111
3.3.2.1 EURO Control Pattern...1113
3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT...1114
3.3.3.1 HYDRAULIC CONTROL SYSTEM...1115
3.3.4 SAFETY CIRCUIT FOR CONTROLS...1115
3.3.4.1 EURO Control Pattern...1117
3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK...1117
3.3.6 OPERATOR’S CONSOLE...1119
3.3.6.1 Switch Board...1121
3.3.7 INTERFACE PANEL FOR DIAGNOSTICS...1127
3.3.8 CONTROL MODULE FOR AUXILIARY CAB HEATER...1129
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR (KOMTRAX PLUS)...1130
3.4.1 SEQUENCE OF DISPLAYS...1131
3.4.2 OPENING SCREEN...1131
3.4.3 MAIN GAUGE SCREENS 1 TO 3...1132
3.4.3.1 Main Gauge Screen 1...1133
3.4.3.2 Main Gauge Screen 2...1135
3.4.3.3 Main Gauge Screen 3...1135
3.4.3.4 Color Definition...1137
3.4.3.5 Automatic Shutdown of the Machine...1137
3.4.4 FUEL CONSUMPTION SCREEN...1139
3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR...1140
3.4.6 MAIN SCREEN - CHANGE >TIME >SMR >DATE...1140
3.4.7 MAINTENANCE MONITOR...1141
3.4.7.1 Maintenance confirmation through Service Personnel...1141
3.4.8 SETTINGS FOR OPERATOR...1142
3.4.8.1 Settings for Operator...1143
3.4.8.2 User ID Screen...1143
3.4.8.3 Reset Truck Counter 1...1143
3.4.8.4 Screen Adjustment...1144
3.4.8.5 Date Adjustment Screen...1146
3.4.8.6 Clock Adjustment Screen...1146
3.4.8.7 Language Selection Screen...1146
3.4.9 AUTOMATIC MESSAGES...1147
3.4.9.1 Automatic Messages...1148
3.4.9.2 Automatic Messages...1149
3.4.9.3 Automatic Messages...1150
3.4.10 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM...1151
3.4.11 TABLE OF AVAILABLE INSTRUCTION MESSAGES...1163
3.5 CAMERA SYSTEM WITH MONITORS...1166
3.5.1 LOCATION OF MONITORS AND CONTROL UNITS...1167
3.5.1.1 Operating the Monitors...1169
3.5.1.2 Ajustments of the Monitor...1169
3.5.1.3 Arrangement of the Cameras...1173
3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING...1174
3.6.1 Digital Display...1174
3.6.2 AUXILIARY HEATER FOR OPERATOR’S CAB...1179
3.7 POWER HOUSE...1180
3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES...1181
3.7.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES...1183
3.7.3 CENTRAL CONTROL AND FILTER PANEL...1185
3.8 ELECTRICAL EQUIPMENT IN CAB BASE...1186
3.8.1 STANDARD COMPONENTS IN CAB BASE...1187
3.8.2 LOW VOLTAGE SWITCH BOARD IN CAB BASE...1191
3.8.2.1 Checking diagnostic fault codes of the engine electronic controlled fuel system QUANTUM and of the engine monitoring system CENSE...1193
3.8.3 MASTER TURBO CONTROLLER MTC - LED INDICATIONS...1195
3.8.4 BINARY FAULT CODE LIST...1202
3.8.4.1 Combination Message 308 Trouble Can-Bus or Can Hardware...1204
3.8.5 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS...1204
3.8.6 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE...1207
3.9 CHECKS BEFORE STARTING THE ENGINE...1214
3.9.0.1 Coolant Level...1217
3.9.0.2 Machinery House Doors...1219
3.9.0.3 Operator’s Seat Adjustment...1219
3.10 STARTING THE ENGINE...1220
3.10.1 STARTING PROCEDURE...1223
3.10.2 ENGINE WARM-UP...1231
3.10.3 HYDRAULIC OIL WARM-UP...1231
3.10.4 JUMP START WITH BOOSTER BATTERIES...1231
3.11 MOVING THE SHOVEL...1233
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS...1233
3.11.1.1 TRAVEL ALARM / BACK-UP ALARM...1235
3.11.2 TRAVELLING INSTRUCTIONS...1235
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE...1236
3.12.1 SLEWING THE SUPERSTRUCTURE...1236
3.12.1.1 MACHINES WITH "EURO" CONTROL...1236
3.12.1.2 MACHINES WITH "KMG" CONTROL...1237
3.12.2 BRAKING THE SUPERSTRUCTURE...1237
3.12.3 SLEW PARKING BRAKE...1238
3.12.3.1 Hydraulic Slew Brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System...1239
3.12.3.2 IMPORTANT INSTRUCTIONS FOR SLEWING THE SUPERSTRUCTURE...1239
3.13 WORKING WITH THE ATTACHMENT...1240
3.13.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM...1240
3.13.1.1 Backhoe...1240
3.13.1.2 FACE SHOVEL...1240
3.13.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM...1241
3.13.2.1 Backhoe...1241
3.13.2.2 FACE SHOVEL...1241
3.13.3 BOTTOM DUMP BUCKET...1242
3.13.3.1 Operating the bucket clam...1242
3.13.3.2 OPERATING THE BUCKET CLAM...1242
3.13.4 DROP BALL OPERATION...1243
3.13.4.1 SAFETY INSTRUCTIONS...1243
3.13.4.2 SAFETY DEVICES (SPECIAL EQUIPMENT)...1245
3.13.4.3 WORKING HINTS...1245
3.13.5 COMBINED OPERATION CYCLES...1246
3.14 WORKING INSTRUCTIONS...1248
3.14.1 STABILITY OF THE SHOVEL...1248
3.14.2 SHOVEL OPERATION...1248
3.15 PARKING THE SHOVEL...1251
3.15.0.1 CLEANING THE TRACK GROUPS...1251
3.16 STOPPING THE ENGINE...1252
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM...1255
3.17 OPERATION OF THE LUBRICATION SYSTEM...1256
3.17.1 CENTRAL LUBRICATION SYSTEM ”CLS”...1256
3.17.1.1 Manual actuation of the central lubrication system...1256
3.17.1.2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM...1257
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”...1257
3.17.2.1 Manual actuation of the swing circle lubrication system...1258
3.17.2.2 SWING CIRCLE LUBRICATION SYSTEM ”SLS”...1259
3.17.2.3 ADJUSTMENTS OF THE SWING CIRCLELUBRICATION SYSTEM...1259
3.18 FIRE DETECTION AND SUPPRESSION SYSTEMS...1260
3.18.0.1 FIRE DETECTION AND SUPPRESSION SYSTEMS...1261
3.18.1 HIGH LEVEL ALARM ”FIRE”...1265
3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE...1265
3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEMS...1265
3.18.3.1 MANUAL ACTUATION...1265
3.18.3.2 AUTOMATIC ACTUATION...1265
3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEMS...1267
3.18.5 EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF...1269
3.19 TRANSFER PUMP FOR HYDRAULIC OIL...1270
3.19.1 OPERATING THE TRANSFER PUMP...1271
3.19.2 FUNCTIONS OF THE TRANSFER PUMP...1273
3.20 CENTRAL REFILLING SYSTEM...1276
3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM...1277
3.20.1.1 Operation of the hydraulic Service Arm...1277
3.20.2 OPERATING THE HYDRAULIC SERVICE ARM...1279
3.20.3 RECEIVER PANEL WITH MONITOR BOX...1281
3.20.3.1 Refilling Procedure...1283
3.20.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM...1285
3.20.4.1 Refilling the Grease Containers of the Automatic Lubrication Systems...1287
3.21 WORK ON THE LOADER ATTACHMENT...1288
3.21.0.1 OBSERVE THE FOLLOWING INSTRUCTIONS...1288
3.22 TRANSPORTATION AND LIFTING OF THE SHOVEL...1289
3.22.1 DISASSEMBLING OF THE SHOVEL...1289
3.22.2 TRANSPORTATION AND LIFTING...1289
3.23 RETRIEVAL PROCEDURE...1290
3.24 SHOVEL STORAGE...1291
3.24.0.1 GENERAL...1291
3.24.1 PREPARING FOR STORAGE...1291
3.24.2 ONE MONTH REPETITIVE SERVICE PERIOD...1291
3.24.3 SIX MONTH REPETITIVE SERVICE PERIOD...1291
3.24.4 PREPARING FOR OPERATION...1292
3.25 TROUBLE SHOOTING...1293
3.25.0.1 GENERAL...1293
3.25.1 ENGINE...1293
3.25.2 HYDRAULIC SYSTEM...1294
3.25.3 FINAL DRIVES AND SWING MACHINERY...1295
3.25.4 CRAWLER TRACKS...1295
4 MAINTENANCE...1297
4.1 FOREWORD...1298
4.1.0.1 DEFINITIONS...1298
4.1.0.2 GENERAL RECOMMENDATIONS...1298
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE...1299
4.3 FLUIDS AND LUBRICANTS...1300
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES...1300
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES...1301
4.4 FILLING CAPACITIES...1303
4.5 STANDARD TORQUE LIST...1304
4.6 LUBRICATION AND MAINTENANCE SCHEDULE...1305
4.6.1 INITIAL SERVICING...1305
4.6.1.1 AFTER THE FIRST 250 OPERATING HOURS...1305
4.6.1.2 AFTER THE FIRST 250 AND 1000 OPERATING HOURS...1305
4.6.2 PERIODIC SERVICING INTERVALS...1305
4.6.3 PERIODIC SERVICING SCHEDULE...1306
4.6.3.1 Lubrication Chart...1310
4.7 SAFETY CRITICAL PARTS...1312
4.7.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES...1312
4.7.2 INSPECTION OF HOSE LINES...1312
4.7.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS...1312
4.8 EXTENDED SERVICE INTERVALS...1315
4.8.1 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM...1315
4.8.1.1 Servicing Intervals...1319
4.8.2 MAINTENANCE OF THE ENGINE...1319
4.9 ENGINE FUEL FILTER LOCATION...1320
4.9.1 fuel line connections on the engine...1321
4.10 WHEN NECESSARY...1322
4.10.1 ENGINE AIR CLEANER SERVICE...1323
4.10.1.1 General Service Tips...1325
4.10.2 SWING CIRCLE TOOTHING LUBRICATION...1327
4.10.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS...1329
4.10.3.1 CLEAN OR REPLACE FILTER ELEMENTS...1331
4.10.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...1333
4.11 EVERY 10 OPERATING HOURS OR DAILY...1334
4.11.1 WALK-AROUND INSPECTION...1335
4.11.1.1 WORKING ATTACHMENT - INITIAL CHECKS FOR PROPER LUBRICATION...1339
4.11.1.2 CHECK GREASE INJECTORS...1341
4.11.1.3 CORRECTIVE ACTIONS...1341
4.11.1.4 CHECK GREASE INJECTORS...1343
4.11.2 AIR CLEANER - CLEAN PRE-CLEANER...1345
4.11.2.1 Clean dust cups of pre-cleaners...1345
4.11.3 RADIATOR - CHECK COOLANT LEVEL...1347
4.11.4 TRACK GROUPS - CLEAN...1347
4.11.5 FUEL SYSTEM WATER SEPARATOR - DRAIN WATER...1349
4.11.6 BOOM - CHECK LADDER AND WALKWAY...1351
4.12 EVERY 50 OPERATING HOURS OR WEEKLY...1352
4.12.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...1353
4.12.1.1 Swing gears manufactured by "L&S"...1353
4.12.1.2 Swing gears manufactured by SIEBENHAAR...1355
4.12.1.3 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S" - CHECK OIL LEVELS...1357
4.12.1.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN" - CHECK OIL LEVELS...1361
4.12.2 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR - CHECK OIL LEVEL...1365
4.12.2.1 CHECK OIL LEVEL OF PTO GEAR...1365
4.12.2.2 CHECK OIL LEVEL OF OIL COLLECTOR RESERVOIR (4)...1365
4.12.3 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR...1367
4.12.4 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY...1369
4.13 EVERY 250 OPERATING HOURS OR MONTHLY...1370
4.13.1 AIR CONDITIONING...1371
4.13.2 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION...1371
4.13.3 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL...1375
4.13.4 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE...1377
4.13.5 SIGNAL HORN COMPRESSOR - LUBRICATE...1377
4.13.6 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...1377
4.13.7 RADIATOR FAN BEARING HOUSING - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...1377
4.13.8 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER...1379
4.13.9 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT...1383
4.13.9.1 Clean and inspect filter element (2) as follows:...1383
4.13.9.2 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT (Heavy duty version, special equipment)...1385
4.13.9.3 Clean pre-cleaner dust bowl...1385
4.13.9.4 Clean and inspect main filter element...1385
4.13.10 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL...1387
4.14 EVERY 500 OPERATING HOURS OR MONTHLY...1388
4.14.1 BATTERIES - CHECK FLUID LEVEL...1389
4.14.2 FLEXIBLE DRIVE COUPLING - CHECK OIL LEVEL...1391
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS - CHECK OIL LEVEL...1393
4.14.3.1 CHECK OIL LEVEL OF ALL MAIN PUMP DRIVE SHAFT HOUSINGS...1393
4.14.4 FUEL TANK - DRAIN CONDENSATION...1395
4.14.4.1 DRAIN CONDENSATION AS FOLLOWS...1395
4.14.5 CRAWLER TRACK - INSPECTION...1397
4.14.5.1 CHECK ADJUSTING RANGE OF GUIDE WHEELS...1397
4.14.5.2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS...1399
4.14.5.3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS...1401
4.14.5.4 Bleeding the System...1401
4.14.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR - CHECK FOR CORRECT CONNECTION...1403
4.14.7 GROUND CABLE OF OPERATOR’S CAB - CHECK FOR CORRECT CONNECTION...1405
4.15 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH...1406
4.15.1 HIGH STRENGTH BOLT CONNECTIONS...1407
4.15.2 HYDRAULIC SYSTEM - FILTER SERVICE...1457
4.15.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...1471
4.15.3.1 Oil drain plugs, illustration...1471
4.15.3.2 PTO (PUMP DISTRIBUTOR GEAR)...1471
4.15.3.3 SWING GEARS AND TRAVEL GEARS...1471
4.15.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE...1473
4.15.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK ACCUMULATORS...1475
4.15.6 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES...1477
4.15.7 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES...1479
4.16 EVERY 2000 OPERATING HOURS OR YEARLY...1480
4.16.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER...1481
4.16.2 FILLING THE HYDRAULIC SYSTEM...1491
4.16.3 BLEEDING THE HYDRAULIC SYSTEM...1493
4.16.4 GEAR PUMP FOR PTO GEAR LUBRICATION...1495
4.16.5 EMERGENCY ESCAPE LADDER - INSPECTION...1497
4.17 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR...1498
4.17.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL...1499
4.17.1.1 Swing gears manufactured by "L&S"...1499
4.17.1.2 "SWING GEARS MANUFACTURED BY “SIEBENHAAR”...1503
4.17.1.3 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S"- CHANGE OIL...1507
4.17.1.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN"- CHANGE OIL...1513
4.17.2 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL...1519
4.18 FIRE PREVENTION...1520
4.18.1 PRECAUTIONS...1521
4.19 WELD REPAIRS...1522
4.19.1 GENERAL PROTECTIVE MEASURES...1523
4.19.1.1 WELD REPAIRS ON MAJOR COMPONENTS OF THE SHOVEL...1523
4.19.1.2 COUNTERWEIGHT...1523
4.19.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE...1525
4.19.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT...1527
4.19.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...1529
4.19.5 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE...1531
OM-PC4000-8224 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual...1539
1 FOREWORD...1541
1.1 BEFORE READING THIS MANUAL...1542
1.2 DIRECTIONS OF THE MACHINE...1543
1.3 SPECIFICATION AND SERIAL PLATE...1544
1.3.1 PRODUCT IDENTIFICATION NUMBER...1544
1.4 DIVISION OF THE BINDER...1545
1.5 DESIGNATED USE OF THE SHOVEL...1546
1.6 DELIVERY OF THE SHOVEL...1547
1.6.1 SPARE PARTS...1547
1.6.2 SERVICE...1547
1.7 EXPLANATION OF ABBREVIATIONS...1548
1.8 CONTENTS...1549
2 SAFETY...1555
2.1 SAFETY INFORMATION...1556
2.2 OVERVIEW...1557
2.2.1 NORMAL OPERATIONS...1557
2.2.2 REGULAR MAINTENANCE...1557
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR...1557
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR...1557
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB...1558
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR...1559
2.4.1 UNDERSTANDING THE MACHINE...1559
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR...1559
2.4.2.1 ENSURING SAFE OPERATION...1559
2.4.3 PREPARATIONS FOR SAFE OPERATION...1559
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT...1559
2.4.3.2 INSPECTING THE MACHINE...1559
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT...1560
2.4.3.4 KEEP MACHINE CLEAN...1560
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT...1560
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT...1561
2.4.3.7 IF A PROBLEM IS FOUND...1561
2.4.4 FIRE PREVENTION...1561
2.4.4.1 PRECAUTIONS TO PREVENT FIRE...1561
2.4.4.2 ACTION IF FIRE OCCURS...1562
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB...1563
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE...1563
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE...1563
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE...1563
2.4.5.3 NO PEOPLE ON THE ATTACHMENT...1563
2.4.5.4 WORKING IN HIGH PLACES...1563
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK...1564
2.4.5.6 LEAVING THE MACHINE...1564
2.4.6 BURN PREVENTION...1565
2.4.6.1 Hot coolant...1565
2.4.6.2 Hot oil...1565
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS...1565
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...1566
2.4.8.1 UNAUTHORIZED MODIFICATION...1566
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...1566
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)...1567
2.4.10 PRECAUTIONS AT JOBSITE...1568
2.4.10.1 VISIBILITY FROM OPERATOR’S SEAT...1569
2.4.10.2 CAMERA SYSTEM WITH MONITORS...1569
2.4.10.3 ENSURE GOOD VISIBILITY...1569
2.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS...1569
2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS...1570
2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES...1570
2.4.10.7 WORKING ON LOOSE GROUND...1571
2.4.10.8 GAS, DUST, STEAM AND SMOKE...1571
2.4.10.9 VENTILATION OF ENCLOSED AREAS...1572
2.4.11 STARTING ENGINE...1573
2.4.11.1 WARNING TAG...1573
2.4.11.2 CHECKS BEFORE STARTING ENGINE...1573
2.4.11.3 PRECAUTION WHEN STARTING ENGINE...1573
2.4.11.4 PRECAUTION IN COLD AREAS...1574
2.4.12 OPERATION...1574
2.4.12.1 CHECKS BEFORE OPERATION...1574
2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE...1575
2.4.12.3 PRECAUTIONS WHEN travelling...1576
2.4.12.4 TRAVELLING ON SLOPES...1577
2.4.12.5 OPERATIONS ON SLOPES...1578
2.4.12.6 PROHIBITED OPERATIONS...1578
2.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES...1579
2.4.12.8 PARKING THE MACHINE...1579
2.4.12.9 TRANSPORTATION...1579
2.5 PRECAUTION FOR MAINTENANCE...1580
2.5.1 GENERAL PRECAUTIONS...1580
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...1581
2.5.1.2 STOP ENGINE FOR MAINTENANCE...1582
2.5.1.3 WARNING TAG...1583
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY...1584
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS...1584
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING...1585
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS...1585
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT...1586
2.5.1.9 NOISE...1586
2.5.1.10 WHEN USING A HAMMER...1586
2.5.1.11 PROPER TOOLS...1587
2.5.1.12 ACCUMULATOR...1587
2.5.1.13 PERSONNEL...1587
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE...1588
2.5.2.1 PRECAUTION WHEN WELDING...1588
2.5.2.2 BATTERY HANDLING...1588
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID...1589
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE...1589
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES...1590
2.5.3.3 REPLACEMENT OF HOSE LINES...1590
2.5.3.4 INSPECTION OF HOSE LINES...1590
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...1591
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE...1591
2.5.3.7 AIR CONDITIONING MAINTENANCE...1591
2.5.3.8 COMPRESSED AIR...1592
2.5.3.9 WASTE MATERIALS...1592
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS...1593
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM...1593
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS...1593
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...1593
2.7 SPECIAL SAFETY EQUIPMENT...1594
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB...1595
2.7.2 OBJECT HANDLING...1595
2.7.3 LIGHTING...1595
2.7.4 WARNING BEACON...1595
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...1595
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...1595
2.7.5.2 INSTRUCTIONS FOR USE...1597
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL...1599
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1),...1599
2.7.5.5 INSTRUCTIONS FOR USE...1601
2.8 SAFETY WARNING SIGNS...1603
2.8.1 LOCATION AND DESCRIPTION OF THE SIGNS...1604
3 OPERATION...1617
3.1 FOREWORD...1618
3.2 CONSTRUCTION OF THE SHOVEL...1619
3.2.1 OVERALL VIEW...1619
3.2.2 SUPERSTRUCTURE...1620
3.2.2.1 Machinery House...1624
3.2.2.2 Main Hydraulic Oil Reservoir...1626
3.2.2.3 Hydraulic Oil Cooler...1627
3.2.2.4 Fuel Tank...1628
3.2.2.5 Counterweight...1629
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER...1630
3.2.3.1 Operating the hydraulic Access Ladder...1631
3.2.4 EMERGENCY ESCAPE LADDER...1634
3.2.5 BOOM ACCESS LADDER AND WALKWAY...1636
3.2.6 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM...1638
3.2.6.1 Emergency Engine Shutdown System actuated from Ground Man (special equipment)...1639
3.2.6.2 Operator Warning System (special equipment)...1639
3.2.7 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)...1640
3.2.7.1 Operator’s Cab - Emergency Escape Hammer and Storage Box for Operation Manual...1645
3.2.7.2 Operator’s Seat Adjustment...1647
3.2.7.3 Co-driver’s Seat and Refrigerator Box...1648
3.2.8 UNDERCARRIAGE...1649
3.2.9 WORKING ATTACHMENT...1650
3.2.9.1 Loader attachment with bottom dump bucket...1650
3.2.9.2 Loader attachment with backhoe bucket...1651
3.2.10 DIESEL ENGINE TYPE SDA 16V160E-2...1652
3.2.11 ENGINE OIL MANAGEMENT SYSTEM...1654
3.2.11.1 Oil Burning System "Centinel" combined with Oil Supply System "Reserve"...1656
3.2.11.2 Eliminator Engine Oil Filtration System...1657
3.3 OPERATOR’S CAB - CONTROLS...1658
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT...1658
3.3.1.1 HYDRAULIC CONTROL SYSTEM...1659
3.3.2 SAFETY CIRCUIT FOR CONTROLS...1659
3.3.2.1 EURO Control Pattern...1661
3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT...1662
3.3.3.1 HYDRAULIC CONTROL SYSTEM...1663
3.3.4 SAFETY CIRCUIT FOR CONTROLS...1663
3.3.4.1 EURO Control Pattern...1665
3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK...1665
3.3.6 OPERATOR’S CONSOLE...1667
3.3.6.1 Switch Board...1669
3.3.7 INTERFACE PANEL FOR DIAGNOSTICS...1675
3.3.8 CONTROL MODULE FOR AUXILIARY CAB HEATER...1677
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR (KOMTRAX PLUS)...1678
3.4.1 SEQUENCE OF DISPLAYS...1679
3.4.2 OPENING SCREEN...1679
3.4.3 MAIN GAUGE SCREENS 1 TO 3...1680
3.4.3.1 Main Gauge Screen 1...1681
3.4.3.2 Main Gauge Screen 2...1683
3.4.3.3 Main Gauge Screen 3...1683
3.4.3.4 Color Definition...1685
3.4.3.5 Automatic Shutdown of the Machine...1685
3.4.4 FUEL CONSUMPTION SCREEN...1687
3.4.5 FAILURE MESSAGE HISTORY SCREEN FOR OPERATOR...1688
3.4.6 MAIN SCREEN - CHANGE >TIME >SMR >DATE...1688
3.4.7 MAINTENANCE MONITOR...1689
3.4.7.1 Maintenance confirmation through Service Personnel...1689
3.4.8 SETTINGS FOR OPERATOR...1690
3.4.8.1 Settings for Operator...1691
3.4.8.2 User ID Screen...1691
3.4.8.3 Reset Truck Counter 1...1691
3.4.8.4 Screen Adjustment...1692
3.4.8.5 Date Adjustment Screen...1694
3.4.8.6 Clock Adjustment Screen...1694
3.4.8.7 Language Selection Screen...1694
3.4.9 AUTOMATIC MESSAGES...1695
3.4.9.1 Automatic Messages...1696
3.4.9.2 Automatic Messages...1697
3.4.9.3 Automatic Messages...1698
3.4.10 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM...1699
3.4.11 TABLE OF AVAILABLE INSTRUCTION MESSAGES...1711
3.5 CAMERA SYSTEM WITH MONITORS...1714
3.5.1 LOCATION OF MONITORS AND CONTROL UNITS...1715
3.5.1.1 Operating the Monitors...1717
3.5.1.2 Ajustments of the Monitor...1717
3.5.1.3 Arrangement of the Cameras...1721
3.6 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING...1722
3.6.1 Digital Display...1722
3.6.2 AUXILIARY HEATER FOR OPERATOR’S CAB...1727
3.7 POWER HOUSE...1728
3.7.1 EMERGENCY ENGINE SHUTDOWN SWITCHES...1729
3.7.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES...1731
3.7.3 CENTRAL CONTROL AND FILTER PANEL...1733
3.8 ELECTRICAL EQUIPMENT IN CAB BASE...1734
3.8.1 STANDARD COMPONENTS IN CAB BASE...1735
3.8.2 LOW VOLTAGE SWITCH BOARD IN CAB BASE...1739
3.8.2.1 Checking diagnostic fault codes of the engine electronic controlled fuel system QUANTUM and of the engine monitoring system CENSE...1741
3.8.3 MASTER TURBO CONTROLLER MTC - LED INDICATIONS...1743
3.8.4 BINARY FAULT CODE LIST...1750
3.8.4.1 Combination Message 308 Trouble Can-Bus or Can Hardware...1752
3.8.5 TABLE OF LOCATION NUMBERS FOR ELECTRICAL COMPONENTS...1752
3.8.6 COMPONENTS OF ELECTRICAL PREHEATING SYSTEM IN CAB BASE...1755
3.9 CHECKS BEFORE STARTING THE ENGINE...1762
3.9.0.1 Coolant Level...1765
3.9.0.2 Machinery House Doors...1767
3.9.0.3 Operator’s Seat Adjustment...1767
3.10 STARTING THE ENGINE...1768
3.10.1 STARTING PROCEDURE...1771
3.10.2 ENGINE WARM-UP...1779
3.10.3 HYDRAULIC OIL WARM-UP...1779
3.10.4 JUMP START WITH BOOSTER BATTERIES...1779
3.11 MOVING THE SHOVEL...1781
3.11.1 TRAVEL CONTROL WITH FOOT PEDALS...1781
3.11.1.1 TRAVEL ALARM / BACK-UP ALARM...1783
3.11.2 TRAVELLING INSTRUCTIONS...1783
3.11.2.1 TRAVELLING LONG DISTANCES...1785
3.12 SLEWING AND BRAKING THE SUPERSTRUCTURE...1786
3.12.1 SLEWING THE SUPERSTRUCTURE...1786
3.12.1.1 MACHINES WITH "EURO" CONTROL...1786
3.12.1.2 MACHINES WITH "KMG" CONTROL...1787
3.12.2 BRAKING THE SUPERSTRUCTURE...1787
3.12.3 SLEW PARKING BRAKE...1788
3.12.3.1 Hydraulic Slew Brake actuated by hydraulic access Ladder and Service Arm of Central Refilling System...1789
3.12.3.2 IMPORTANT INSTRUCTIONS FOR SLEWING THE SUPERSTRUCTURE...1789
3.13 WORKING WITH THE ATTACHMENT...1790
3.13.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM...1790
3.13.1.1 Backhoe...1790
3.13.1.2 FACE SHOVEL...1790
3.13.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM...1791
3.13.2.1 Backhoe...1791
3.13.2.2 FACE SHOVEL...1791
3.13.3 BOTTOM DUMP BUCKET...1792
3.13.3.1 Operating the bucket clam...1792
3.13.3.2 OPERATING THE BUCKET CLAM...1792
3.13.4 DROP BALL OPERATION...1793
3.13.4.1 SAFETY INSTRUCTIONS...1793
3.13.4.2 SAFETY DEVICES (SPECIAL EQUIPMENT)...1795
3.13.4.3 WORKING HINTS...1795
3.13.5 COMBINED OPERATION CYCLES...1796
3.14 WORKING INSTRUCTIONS...1798
3.14.1 STABILITY OF THE SHOVEL...1798
3.14.2 SHOVEL OPERATION...1798
3.15 PARKING THE SHOVEL...1801
3.15.0.1 CLEANING THE TRACK GROUPS...1801
3.16 STOPPING THE ENGINE...1802
3.16.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM...1805
3.17 OPERATION OF THE LUBRICATION SYSTEM...1806
3.17.1 CENTRAL LUBRICATION SYSTEM ”CLS”...1806
3.17.1.1 Manual actuation of the central lubrication system...1806
3.17.1.2 ADJUSTMENTS OF THE CENTRAL LUBRICATION SYSTEM...1807
3.17.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”...1807
3.17.2.1 Manual actuation of the swing circle lubrication system...1808
3.17.2.2 SWING CIRCLE LUBRICATION SYSTEM ”SLS”...1809
3.17.2.3 ADJUSTMENTS OF THE SWING CIRCLELUBRICATION SYSTEM...1809
3.18 FIRE DETECTION AND SUPPRESSION SYSTEMS...1810
3.18.0.1 FIRE DETECTION AND SUPPRESSION SYSTEMS...1811
3.18.1 HIGH LEVEL ALARM ”FIRE”...1815
3.18.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE...1815
3.18.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEMS...1815
3.18.3.1 MANUAL ACTUATION...1815
3.18.3.2 AUTOMATIC ACTUATION...1815
3.18.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEMS...1817
3.18.5 EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF...1819
3.19 TRANSFER PUMP FOR HYDRAULIC OIL...1820
3.19.1 OPERATING THE TRANSFER PUMP...1821
3.19.2 FUNCTIONS OF THE TRANSFER PUMP...1823
3.20 CENTRAL REFILLING SYSTEM...1826
3.20.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM...1827
3.20.1.1 Operation of the hydraulic Service Arm...1827
3.20.2 OPERATING THE HYDRAULIC SERVICE ARM...1829
3.20.3 RECEIVER PANEL WITH MONITOR BOX...1831
3.20.3.1 Refilling Procedure...1833
3.20.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM...1835
3.20.4.1 Refilling the Grease Containers of the Automatic Lubrication Systems...1837
3.21 WORK ON THE LOADER ATTACHMENT...1838
3.21.0.1 OBSERVE THE FOLLOWING INSTRUCTIONS...1838
3.22 TRANSPORTATION AND LIFTING OF THE SHOVEL...1839
3.22.1 DISASSEMBLING OF THE SHOVEL...1839
3.22.2 TRANSPORTATION AND LIFTING...1839
3.23 RETRIEVAL PROCEDURE...1840
3.24 SHOVEL STORAGE...1841
3.24.0.1 GENERAL...1841
3.24.1 PREPARING FOR STORAGE...1841
3.24.2 ONE MONTH REPETITIVE SERVICE PERIOD...1841
3.24.3 SIX MONTH REPETITIVE SERVICE PERIOD...1841
3.24.4 PREPARING FOR OPERATION...1842
3.25 TROUBLE SHOOTING...1843
3.25.0.1 GENERAL...1843
3.25.1 ENGINE...1843
3.25.2 HYDRAULIC SYSTEM...1844
3.25.3 FINAL DRIVES AND SWING MACHINERY...1845
3.25.4 CRAWLER TRACKS...1845
4 MAINTENANCE...1847
4.1 FOREWORD...1848
4.1.0.1 DEFINITIONS...1848
4.1.0.2 GENERAL RECOMMENDATIONS...1848
4.2 SAFETY PRECAUTIONS FOR MAINTENANCE...1849
4.3 FLUIDS AND LUBRICANTS...1850
4.3.1 LUBRICANTS FOR OPERATION IN COLD AND ARCTIC CLIMATES...1850
4.3.2 FLUIDS AND LUBRICANTS FOR MODERATE AND HOT CLIMATES...1851
4.4 FILLING CAPACITIES...1853
4.5 STANDARD TORQUE LIST...1854
4.6 LUBRICATION AND MAINTENANCE SCHEDULE...1855
4.6.1 INITIAL SERVICING...1855
4.6.1.1 AFTER THE FIRST 250 OPERATING HOURS...1855
4.6.1.2 AFTER THE FIRST 250 AND 1000 OPERATING HOURS...1855
4.6.2 PERIODIC SERVICING INTERVALS...1855
4.6.3 PERIODIC SERVICING SCHEDULE...1856
4.6.3.1 Lubrication Chart...1860
4.7 SAFETY CRITICAL PARTS...1862
4.7.1 REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE LINES...1862
4.7.2 INSPECTION OF HOSE LINES...1862
4.7.3 PERIODIC REPLACEMENT OF FURTHER SAFETY CRITICAL PARTS...1862
4.8 EXTENDED SERVICE INTERVALS...1865
4.8.1 FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM...1865
4.8.1.1 Servicing Intervals...1869
4.8.2 MAINTENANCE OF THE ENGINE...1869
4.9 ENGINE FUEL FILTER LOCATION...1870
4.9.1 fuel line connections on the engine...1871
4.10 WHEN NECESSARY...1872
4.10.1 ENGINE AIR CLEANER SERVICE...1873
4.10.1.1 General Service Tips...1875
4.10.2 SWING CIRCLE TOOTHING LUBRICATION...1877
4.10.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS...1879
4.10.3.1 CLEAN OR REPLACE FILTER ELEMENTS...1881
4.10.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...1883
4.11 EVERY 10 OPERATING HOURS OR DAILY...1884
4.11.1 WALK-AROUND INSPECTION...1885
4.11.1.1 WORKING ATTACHMENT - INITIAL CHECKS FOR PROPER LUBRICATION...1889
4.11.1.2 CHECK GREASE INJECTORS...1891
4.11.1.3 CORRECTIVE ACTIONS...1891
4.11.1.4 CHECK GREASE INJECTORS...1893
4.11.2 AIR CLEANER - CLEAN PRE-CLEANER...1895
4.11.2.1 Clean dust cups of pre-cleaners...1895
4.11.3 RADIATOR - CHECK COOLANT LEVEL...1897
4.11.4 TRACK GROUPS - CLEAN...1897
4.11.5 FUEL SYSTEM WATER SEPARATOR - DRAIN WATER...1899
4.11.6 BOOM - CHECK LADDER AND WALKWAY...1901
4.12 EVERY 50 OPERATING HOURS OR WEEKLY...1902
4.12.1 SWING GEARS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...1903
4.12.1.1 Swing gears manufactured by "L&S"...1903
4.12.1.2 Swing gears manufactured by SIEBENHAAR...1905
4.12.1.3 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S" - CHECK OIL LEVELS...1907
4.12.1.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN" - CHECK OIL LEVELS...1911
4.12.2 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR - CHECK OIL LEVEL...1915
4.12.2.1 CHECK OIL LEVEL OF PTO GEAR...1915
4.12.2.2 CHECK OIL LEVEL OF OIL COLLECTOR RESERVOIR (4)...1915
4.12.3 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR...1917
4.12.4 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY...1919
4.13 EVERY 250 OPERATING HOURS OR MONTHLY...1920
4.13.1 AIR CONDITIONING...1921
4.13.2 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION...1921
4.13.3 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL...1925
4.13.4 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE...1927
4.13.5 SIGNAL HORN COMPRESSOR - LUBRICATE...1927
4.13.6 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...1927
4.13.7 RADIATOR FAN BEARING HOUSING - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...1927
4.13.8 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER...1929
4.13.9 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT...1933
4.13.9.1 Clean and inspect filter element (2) as follows:...1933
4.13.9.2 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT (Heavy duty version, special equipment)...1935
4.13.9.3 Clean pre-cleaner dust bowl...1935
4.13.9.4 Clean and inspect main filter element...1935
4.13.10 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL...1937
4.14 EVERY 500 OPERATING HOURS OR MONTHLY...1938
4.14.1 BATTERIES - CHECK FLUID LEVEL...1939
4.14.2 FLEXIBLE DRIVE COUPLING - CHECK OIL LEVEL...1941
4.14.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS - CHECK OIL LEVEL...1943
4.14.3.1 CHECK OIL LEVEL OF ALL MAIN PUMP DRIVE SHAFT HOUSINGS...1943
4.14.4 FUEL TANK - DRAIN CONDENSATION...1945
4.14.4.1 DRAIN CONDENSATION AS FOLLOWS...1945
4.14.5 CRAWLER TRACK - INSPECTION...1947
4.14.5.1 CHECK ADJUSTING RANGE OF GUIDE WHEELS...1947
4.14.5.2 CHECK ADJUSTING RANGE FOR GUIDE WHEELS...1949
4.14.5.3 CHECK ADJUSTING RANGE FOR GUIDE WHEELS...1951
4.14.5.4 Bleeding the System...1951
4.14.6 GROUND CABLES OF ENGINE, STARTER MOTORS AND ALTERNATOR - CHECK FOR CORRECT CONNECTION...1953
4.14.7 GROUND CABLE OF OPERATOR’S CAB - CHECK FOR CORRECT CONNECTION...1955
4.15 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH...1956
4.15.1 HIGH STRENGTH BOLT CONNECTIONS...1957
4.15.2 HYDRAULIC SYSTEM - FILTER SERVICE...2007
4.15.3 PTO (PUMP DISTRIBUTOR GEAR), SWING GEARS AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...2021
4.15.3.1 Oil drain plugs, illustration...2021
4.15.3.2 PTO (PUMP DISTRIBUTOR GEAR)...2021
4.15.3.3 SWING GEARS AND TRAVEL GEARS...2021
4.15.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE...2023
4.15.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK ACCUMULATORS...2025
4.15.6 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES...2027
4.15.7 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES...2029
4.16 EVERY 2000 OPERATING HOURS OR YEARLY...2030
4.16.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER...2031
4.16.2 FILLING THE HYDRAULIC SYSTEM...2041
4.16.3 BLEEDING THE HYDRAULIC SYSTEM...2043
4.16.4 GEAR PUMP FOR PTO GEAR LUBRICATION...2045
4.16.5 EMERGENCY ESCAPE LADDER - INSPECTION...2047
4.17 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR...2048
4.17.1 SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL...2049
4.17.1.1 Swing gears manufactured by "L&S"...2049
4.17.1.2 "SWING GEARS MANUFACTURED BY “SIEBENHAAR”...2053
4.17.1.3 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "L&S"- CHANGE OIL...2057
4.17.1.4 TRAVEL GEARS AND MOTOR ADAPTER HOUSINGS MANUFACTURED BY "ZOLLERN"- CHANGE OIL...2063
4.17.2 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL...2069
4.18 FIRE PREVENTION...2070
4.18.1 PRECAUTIONS...2071
4.19 WELD REPAIRS...2072
4.19.1 GENERAL PROTECTIVE MEASURES...2073
4.19.1.1 WELD REPAIRS ON MAJOR COMPONENTS OF THE SHOVEL...2073
4.19.1.2 COUNTERWEIGHT...2073
4.19.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE...2075
4.19.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT...2077
4.19.4 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...2079
4.19.5 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE...2081
OMPC40008152 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual...2089
COVER...2089
1. INTRODUCTION...2091
1.1 CONTENTS OF THE BINDER...2092
1.2 DIVISION OF THE BINDER...2093
1.3 DESIGNATED USE OF THE EXCAVATOR...2094
1.4 DELIVERY OF THE EXCAVATOR...2095
1.5 EXPLANATION OF ABBREVATIONS...2096
1.6 TABLE OF CONTENTS...2097
2. SAFETY...2103
2.1 SAFETY INSTRUCTIONS...2104
2.1.1 WARNINGS AND SYMBOLS...2104
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC EXCAVATOR...2104
2.1.3 ORGANIZATIONAL MEASURES...2105
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...2107
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES...2108
2.1.6 WARNING OF SPECIAL DANGERS...2111
2.1.7 TRANSPORTING AND TOWING - RECOMMISSIONING...2113
2.1.8 SPECIAL SAFETY EQUIPMENT...2113
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...2117
3. OPERATION...2125
3.1 FOREWORD...2126
3.2 CONSTRUCTION OF THE EXCAVATOR...2127
3.2.1 OVERALL VIEW...2127
3.2.2 SUPERSTRUCTURE...2128
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER...2136
3.2.4 EMERGENCY ESCAPE LADDER...2140
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN AND OPERATOR WARNING SYSTEM...2142
3.2.6 OPERATOR'S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)...2144
3.2.7 UNDERCARRIAGE...2151
3.2.8 WORKING ATTACHMENT...2152
3.2.9 DIESEL ENGINE TYPE SDA 16V160...2154
3.3 OPERATOR'S CAB - CONTROLS...2160
3.3.1 HYDRAULIC CONTROL SYSTEM...2161
3.3.2 SAFETY CIRCUIT FOR CONTROLS...2161
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS - HEALTH MONITOR...2172
3.4.1 INITIALIZATION SCREEN NO. 0.0...2172
3.4.2 OPERATOR INFORMATION SCREEN NO. 1.1...2172
3.4.3 STANDARD MONITOR 1 (NO. 1.2)...2173
3.4.4 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM...2187
3.4.5 TABLE OF AVAILABLE INSTRUCTION MESSAGES...2199
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING...2202
3.5.1 A - HEATING...2202
3.5.2 B - COOLING...2203
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING...2203
3.6 POWER HOUSE...2204
3.6.1 EMERGENY SHUTDOWN SWITCHES AND BATTERY MAIN SWITCHES...2205
3.6.2 CENTRAL CONTROL AND FILTER PANEL...2207
3.7 ELECTRICAL EQUIPMENT IN CAB BASE...2208
3.7.1 SWITCH BOARD (X2) IN CAB BASE...2211
3.8 CHECKS BEFORE STARTING THE ENGINE...2220
3.9 STARTING THE ENGINE...2226
3.9.1 STARTING PROCEDURE...2229
3.9.2 ENGINE WARM-UP...2233
3.9.3 HYDRAULIC OIL WARM-UP...2233
3.10 MOVING THE EXCAVATOR...2235
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS...2235
3.10.2 TRAVELLING INSTRUCTIONS...2238
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE...2239
3.11.1 SLEWING THE SUPERSTRUCTURE...2239
3.11.2 BRAKING THE SUPERSTRUCTURE...2241
3.11.3 SLEW PARKING BRAKE...2242
3.12 WORKING WITH THE ATTACHMENT...2244
3.12.1 MACHINES EQUIPPED WITH "EURO" CONTROL SYSTEM...2244
3.12.2 MACHINES EQUIPPED WITH "KMG" CONTROL SYSTEM...2245
3.12.3 BOTTOM DUMP BUCKET...2246
3.12.4 DROP BALL OPERATION...2247
3.12.5 COMBINED OPERATION CYCLES...2250
3.13 WORKING INSTRUCTIONS...2252
3.13.1 STABILITY OF THE EXCAVATOR...2252
3.12.2 EXCAVATOR OPERATION...2252
3.14 PARKING THE EXCAVATOR...2255
3.15 STOPPING THE ENGINE...2256
3.16 OPERATION OF THE LUBRICATION SYSTEM...2260
3.16.1 CENTRAL LUBRICATION SYSTEM "CLS"...2260
3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM "SLS"...2262
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM...2264
3.17.1 HIGH LEVEL ALARM "FIRE"...2267
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE...2267
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM...2267
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE SUPPRESSION SYSTEM...2269
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER HOUSE ROOF...2271
3.18 CENTRAL REFILLING SYSTEM...2272
3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM...2273
3.18.2 OPERATING THE HYDRAULIC SERVICE ARM...2275
3.18.3 RECEIVER PANEL WITH MONITOR BOX...2277
3.18.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUBRICATION SYSTEM...2283
3.19 WORK ON THE LOADER ATTACHMENT...2286
3.20 TRANSPORTATION AND LIFTING OF THE EXCAVATOR...2287
3.20.1 DISASSEMBLING OF THE EXCAVATOR...2287
3.20.2 TRANSPORTATION AND LIFTING...2287
3.21 RETRIEVAL PROCEDURE...2288
3.22 EXCAVATOR STORAGE...2289
3.22.1 PREPARING FOR STORAGE...2289
3.22.2 ONE MONTH REPETITIVE SERVICE PERIOD...2290
3.22.3 SIX MONTH REPETITIVE SERVICE PERIOD...2290
3.22.4 PREPARING FOR OPERATION...2291
3.23 TROUBLE SHOOTING...2292
3.23.1 ENGINE...2292
3.23.2 HYDRAULIC SYSTEM...2293
3.23.3 FINAL DRIVES AND SWING MACHINERY...2294
3.23.4 CRAWLER TRACKS...2294
4. MAINTENANCE...2295
4.1 FOREWORD...2296
4.2 PRECAUTIONS FOR MAINTENANCE...2297
4.3 FUEL AND LUBRICANTS...2299
4.4 FILLING CAPACITIES...2301
4.5 STANDARD TORQUE LIST...2302
4.6 LUBRICATION AND MAINTENANCE SCHEDULE...2303
4.6.1 INITIAL SERVICING...2303
4.6.2 PERIODIC SERVICING INTERVALS...2303
4.6.3 PERIODIC SERVICING SCHEDULE...2304
4.6.4 EXTENDED SERVICE INTERVALS OF ENGINE OIL RESERVE SYSTEM...2311
4.6.5 MAINTENANCE OF THE ENGINE...2311
4.7 WHEN NECESSARY...2312
4.7.1 ENGINE AIR CLEANER SERVICE...2313
4.7.2 SWING CIRCLE TOOTHING LUBRICATION...2317
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS...2319
4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...2323
4.8 EVERY 10 OPERATING HOURS OR DAILY...2324
4.8.1 VISUAL INSPECTIONS...2325
4.8.2 AIR CLEANER - CLEAN PRE-CLEANER...2335
4.8.3 RADIATOR - CHECK COOLANT LEVEL...2337
4.8.4 TRACK GROUPS - CLEAN...2337
4.9 EVERY 50 OPERATING HOURS OR WEEKLY...2338
4.9.1 SWING MACHINERY, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...2339
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...2345
4.9.3 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL...2347
4.9.4 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR - CHECK OIL LEVEL...2349
4.9.5 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR...2351
4.9.6 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY...2353
4.10 EVERY 250 OPERATING HOURS OR MONTHLY...2354
4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION...2355
4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE...2357
4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE...2357
4.10.4 HYDRAULIC OIL COOLER FAN BEARINGS - CHECK OIL LEVEL...2357
4.10.5 RADIATOR FAN BEARING - CHECK OIL LEVEL...2357
4.10.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER...2359
4.10.7 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT...2363
4.11 EVERY 500 OPERATING HOURS OR MONTHLY...2364
4.11.1 BATTERIES - CHECK FLUID LEVEL...2365
4.11.2 FLEXIBLE DRIVE COUPLING - CHECK OIL LEVEL...2367
4.11.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS - CHECK OIL LEVEL...2369
4.11.4 FUEL TANK - DRAIN CONDENSATION...2371
4.11.5 CRAWLER TRACK - INSPECTION...2373
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH...2378
4.12.1 HIGH STRENGTH BOLT CONNECTIONS...2379
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE...2421
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING MACHINERY AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...2433
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE...2435
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK ACCUMULATORS...2437
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE...2439
4.13 EVERY 2000 OPERATING HOURS OR YEARLY...2440
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER...2441
4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION...2453
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR...2454
4.14.1 SWING MACHINERY, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL...2455
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL...2465
4.14.3 FINAL DRIVE HOUSINGS - CHANGE OIL...2469
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL...2471
4.15 FIRE PREVENTION...2472
4.16 REPAIR WELDINGS...2474
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE...2477
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT...2479
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...2481
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE...2481
OMPC40008155 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual...2483
COVER...2483
1. INTRODUCTION...2485
1.1 CONTENTS OF THE BINDER...2486
1.2 DIVISION OF THE BINDER...2487
1.3 DESIGNATED USE OF THE SHOVEL...2488
1.4 DELIVERY OF THE SHOVEL...2489
1.5 EXPLANATION OF ABBREVATIONS...2490
1.6 TABLE OF CONTENTS...2491
2. SAFETY...2497
2.1 SAFETY INSTRUCTIONS...2498
2.1.1 WARNINGS AND SYMBOLS...2498
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC MINING SHOVEL...2498
2.1.3 ORGANIZATIONAL MEASURES...2499
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...2501
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES...2502
2.1.6 WARNING OF SPECIAL DANGERS...2505
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING...2507
2.1.8 SPECIAL SAFETY EQUIPMENT...2507
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...2511
3. OPERATION...2519
3.1 FOREWORD...2520
3.2 CONSTRUCTION OF THE SHOVEL...2521
3.2.1 OVERALL VIEW...2521
3.2.2 SUPERSTRUCTURE...2522
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER...2530
3.2.4 EMERGENCY ESCAPE LADDER...2534
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN AND OPERATOR WARNING SYSTEM...2536
3.2.6 OPERATOR’S CAB...2538
3.2.7 UNDERCARRIAGE...2545
3.2.8 WORKING ATTACHMENT...2546
3.2.9 DIESEL ENGINE TYPE SDA 16V160...2548
3.2.10 ENGINE OIL MANAGEMENT SYSTEM...2550
3.3 OPERATOR’S CAB - CONTROLS...2554
3.3.1 HYDRAULIC CONTROL SYSTEM...2555
3.3.2 SAFETY CIRCUIT FOR CONTROLS...2555
3.3.3 CONTROL PANEL...2559
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR...2566
3.4.1 INITIALIZATION SCREEN NO. 0.0...2566
3.4.2 OPERATOR INFORMATION SCREEN NO. 1.1...2566
3.4.3 STANDARD MONITOR 1 (NO. 1.2)...2567
3.4.4 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM...2581
3.4.5 TABLE OF AVAILABLE INSTRUCTION MESSAGES...2593
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING...2596
3.5.1 A - HEATING...2596
3.5.2 B - COOLING...2597
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING...2597
3.6 POWER HOUSE...2598
3.6.1 EMERGENCY SHUTDOWN SWITCHES AND BATTERY MAIN SWITCHES...2599
3.6.2 CENTRAL CONTROL AND FILTER PANEL...2601
3.7 ELECTRICAL EQUIPMENT IN CAB BASE...2602
3.7.1 STANDARD COMPONENTS IN CAB BASE...2603
3.7.2 SWITCH BOARD (X2) IN CAB BASE...2605
3.7.3 COMPONENTS OF ELECTRICAL PRE-HEATING SYSTEM LOCATED IN THE CAB BASE...2613
3.8 CHECKS BEFORE STARTING THE ENGINE...2618
3.9 STARTING THE ENGINE...2624
3.9.1 STARTING PROCEDURE...2627
3.9.2 ENGINE WARM-UP...2631
3.9.3 HYDRAULIC OIL WARM-UP...2631
3.10 MOVING THE SHOVEL...2633
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS...2633
3.10.2 TRAVELLING INSTRUCTIONS...2636
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE...2637
3.11.1 SLEWING THE SUPERSTRUCTURE...2637
3.11.2 BRAKING THE SUPERSTRUCTURE...2639
3.11.3 SLEW PARKING BRAKE...2640
3.12 WORKING WITH THE ATTACHMENT...2642
3.12.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM...2642
3.12.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM...2643
3.12.3 BOTTOM DUMP BUCKET...2644
3.12.4 DROP BALL OPERATION...2645
3.12.5 COMBINED OPERATION CYCLES...2648
3.13 WORKING INSTRUCTIONS...2650
3.13.1 STABILITY OF THE SHOVEL...2650
3.13.2 SHOVEL OPERATION...2650
3.14 PARKING THE SHOVEL...2653
3.15 STOPPING THE ENGINE...2654
3.16 OPERATION OF THE LUBRICATION SYSTEM...2658
3.16.1 CENTRAL LUBRICATION SYSTEM ”CLS”...2658
3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”...2660
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM...2662
3.17.1 HIGH LEVEL ALARM ”FIRE”...2665
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE...2665
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM...2665
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S...2667
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER...2669
3.18 CENTRAL REFILLING SYSTEM...2670
3.18.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM...2671
3.18.2 OPERATING THE HYDRAULIC SERVICE ARM...2673
3.18.3 RECEIVER PANEL WITH MONITOR BOX...2675
3.18.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUB...2681
3.19 WORK ON THE LOADER ATTACHMENT...2684
3.20 TRANSPORTATION AND LIFTING OF THE SHOVEL...2685
3.20.1 DISASSEMBLING OF THE SHOVEL...2685
3.20.2 TRANSPORTATION AND LIFTING...2685
3.21 RETRIEVAL PROCEDURE...2686
3.22 SHOVEL STORAGE...2687
3.22.1 PREPARING FOR STORAGE...2687
3.22.2 ONE MONTH REPETITIVE SERVICE PERIOD...2688
3.22.3 SIX MONTH REPETITIVE SERVICE PERIOD...2688
3.22.4 PREPARING FOR OPERATION...2689
3.23 TROUBLE SHOOTING...2690
3.23.1 ENGINE...2690
3.23.2 HYDRAULIC SYSTEM...2691
3.23.3 FINAL DRIVES AND SWING MACHINERY...2692
3.23.4 CRAWLER TRACKS...2692
4. MAINTENANCE...2693
4.1 FOREWORD...2694
4.2 PRECAUTIONS FOR MAINTENANCE...2695
4.3 FUEL AND LUBRICANTS...2697
4.4 FILLING CAPACITIES...2699
4.5 STANDARD TORQUE LIST...2700
4.6 LUBRICATION AND MAINTENANCE SCHEDULE...2701
4.6.1 INITIAL SERVICING...2701
4.6.2 PERIODIC SERVICING INTERVALS...2701
4.6.3 PERIODIC SERVICING SCHEDULE...2702
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM...2709
4.6.5 MAINTENANCE OF THE ENGINE...2711
4.7 WHEN NECESSARY...2712
4.7.1 ENGINE AIR CLEANER SERVICE...2713
4.7.2 SWING CIRCLE TOOTHING LUBRICATION...2717
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS...2719
4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...2723
4.8 EVERY 10 OPERATING HOURS OR DAILY...2724
4.8.1 WALK-AROUND INSPECTION...2725
4.8.2 AIR CLEANER - CLEAN PRE-CLEANER...2735
4.8.3 RADIATOR - CHECK COOLANT LEVEL...2737
4.8.4 TRACK GROUPS - CLEAN...2737
4.9 EVERY 50 OPERATING HOURS OR WEEKLY...2738
4.9.1 SWING MACHINERY AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...2739
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...2743
4.9.3 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL...2745
4.9.4 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR - CHECK OIL LEVEL...2747
4.9.5 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR...2749
4.9.6 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY...2751
4.10 EVERY 250 OPERATING HOURS OR MONTHLY...2752
4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION...2753
4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE...2755
4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE...2755
4.10.4 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...2755
4.10.5 RADIATOR FAN BEARING HOUSING - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...2755
4.10.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER...2757
4.10.7 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT...2761
4.10.8 WINDSHIELD WASHER RESERVOIR - CHECK FLUID LEVEL...2763
4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL...2765
4.11 EVERY 500 OPERATING HOURS OR MONTHLY...2766
4.11.1 BATTERIES - CHECK FLUID LEVEL...2767
4.11.2 FLEXIBLE DRIVE COUPLING - CHECK OIL LEVEL...2769
4.11.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS - CHECK OIL LEVEL...2771
4.11.4 FUEL TANK - DRAIN CONDENSATION...2773
4.11.5 CRAWLER TRACK - INSPECTION...2775
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH...2780
4.12.1 HIGH STRENGTH BOLT CONNECTIONS...2781
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE...2821
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING MACHINERY AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...2833
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE...2835
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK ACCUMULATORS...2837
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE...2839
4.13 EVERY 2000 OPERATING HOURS OR YEARLY...2840
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER...2841
4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION...2853
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR...2854
4.14.1 SWING MACHINERY AND MOTOR ADAPTER HOUSING - CHANGE OIL...2855
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL...2863
4.14.3 FINAL DRIVE HOUSINGS - CHANGE OIL...2867
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL...2869
4.15 FIRE PREVENTION...2870
4.16 REPAIR WELDINGS...2872
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE...2875
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT...2877
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...2879
4.16.4 AFTER FINISHING THE REPAIR WELDINGS ON THE SUPERSTRUCTURE...2880
OMPC40008170 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual...2881
COVER...2881
1. INTRODUCTION...2883
1.1 CONTENTS OF THE BINDER...2884
1.2 DIVISION OF THE BINDER...2885
1.3 DESIGNATED USE OF THE SHOVEL...2886
1.4 DELIVERY OF THE SHOVEL...2887
1.5 EXPLANATION OF ABBREVIATIONS...2888
1.6 TABLE OF CONTENTS...2889
2. SAFETY...2895
2.1 SAFETY INSTRUCTIONS...2896
2.1.1 WARNINGS AND SYMBOLS...2896
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC MINING SHOVEL...2896
2.1.3 ORGANIZATIONAL MEASURES...2897
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...2899
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES...2900
2.1.6 WARNING OF SPECIAL DANGERS...2903
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING...2905
2.1.8 SPECIAL SAFETY EQUIPMENT...2905
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...2909
3. OPERATION...2917
3.1 FOREWORD...2918
3.2 CONSTRUCTION OF THE SHOVEL...2919
3.2.1 OVERALL VIEW...2919
3.2.2 SUPERSTRUCTURE...2920
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER...2930
3.2.4 EMERGENCY ESCAPE LADDER...2934
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM...2936
3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)...2938
3.2.7 UNDERCARRIAGE...2949
3.2.8 WORKING ATTACHMENT...2950
3.2.9 DIESEL ENGINE TYPE SDA 16V160...2952
3.2.10 ENGINE OIL MANAGEMENT SYSTEM...2954
3.3 OPERATOR’S CAB - CONTROLS...2958
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT...2958
3.3.2 SAFETY CIRCUIT FOR CONTROLS...2959
3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT...2962
3.3.4 SAFETY CIRCUIT FOR CONTROLS...2963
3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK...2965
3.3.6 OPERATOR’S CONSOLE...2967
3.3.7 INTERFACE PANEL FOR DIAGNOSTICS AND CONTROLS FOR HEATING AND AIR CONDITIONING...2973
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR...2976
3.4.1 INITIALIZATION SCREEN NO. 0.0...2976
3.4.2 OPERATOR INFORMATION SCREEN NO. 1.1...2976
3.4.3 STANDARD MONITOR 1 (NO. 1.2)...2977
3.4.4 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM...2991
3.4.5 TABLE OF AVAILABLE INSTRUCTION MESSAGES...3000
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING...3002
3.5.1 A - HEATING...3003
3.5.2 B - COOLING...3003
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING...3003
3.5.4 AUXILIARY HEATER FOR OPERATOR’S CAB...3005
3.6 POWER HOUSE...3006
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES...3007
3.6.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES...3009
3.6.3 CENTRAL CONTROL AND FILTER PANEL...3011
3.7 ELECTRICAL EQUIPMENT IN CAB BASE...3014
3.7.1 STANDARD COMPONENTS IN CAB BASE...3015
3.7.2 SWITCH BOARD (X2) IN CAB BASE...3017
3.7.3 COMPONENTS OF ELECTRICAL PRE-HEATING SYSTEM LOCATED IN THE CAB BASE...3027
3.8 CHECKS BEFORE STARTING THE ENGINE...3034
3.9 STARTING THE ENGINE...3040
3.9.1 STARTING PROCEDURE...3043
3.9.2 ENGINE WARM-UP...3047
3.9.3 HYDRAULIC OIL WARM-UP...3047
3.10 MOVING THE SHOVEL...3049
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS...3049
3.10.2 TRAVELLING INSTRUCTIONS...3052
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE...3053
3.11.1 SLEWING THE SUPERSTRUCTURE...3053
3.11.2 BRAKING THE SUPERSTRUCTURE...3055
3.11.3 SLEW PARKING BRAKE...3056
3.12 WORKING WITH THE ATTACHMENT...3058
3.12.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM...3058
3.12.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM...3059
3.12.3 BOTTOM DUMP BUCKET...3060
3.12.4 DROP BALL OPERATION...3061
3.12.5 COMBINED OPERATION CYCLES...3064
3.13 WORKING INSTRUCTIONS...3066
3.13.1 STABILITY OF THE SHOVEL...3066
3.13.2 SHOVEL OPERATION...3066
3.14 PARKING THE SHOVEL...3069
3.15 STOPPING THE ENGINE...3070
3.15.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM...3073
3.16 OPERATION OF THE LUBRICATION SYSTEM...3074
3.16.1 CENTRAL LUBRICATION SYSTEM ”CLS”...3074
3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”...3076
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM...3078
3.17.1 HIGH LEVEL ALARM ”FIRE”...3081
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE...3081
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM...3081
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S...3083
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER...3085
3.18 TRANSFER PUMP FOR HYDRAULIC OIL...3086
3.18.1 OPERATING THE TRANSFER PUMP...3087
3.18.2 FUNCTIONS OF THE TRANSFER PUMP...3089
3.19 CENTRAL REFILLING SYSTEM...3092
3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM...3093
3.19.2 OPERATING THE HYDRAULIC SERVICE ARM...3095
3.19.3 RECEIVER PANEL WITH MONITOR BOX...3097
3.19.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUB...3103
3.20 WORK ON THE LOADER ATTACHMENT...3106
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL...3107
3.21.1 DISASSEMBLING OF THE SHOVEL...3107
3.21.2 TRANSPORTATION AND LIFTING...3107
3.22 RETRIEVAL PROCEDURE...3108
3.23 SHOVEL STORAGE...3109
3.23.1 PREPARING FOR STORAGE...3109
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD...3110
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD...3110
3.23.4 PREPARING FOR OPERATION...3111
3.24 TROUBLE SHOOTING...3112
3.24.1 ENGINE...3112
3.24.2 HYDRAULIC SYSTEM...3113
3.24.3 FINAL DRIVES AND SWING MACHINERY...3114
3.24.4 CRAWLER TRACKS...3114
4. MAINTENANCE...3115
4.1 FOREWORD...3116
4.2 PRECAUTIONS FOR MAINTENANCE...3117
4.3 FUEL AND LUBRICANTS...3119
4.4 FILLING CAPACITIES...3121
4.5 STANDARD TORQUE LIST...3122
4.6 LUBRICATION AND MAINTENANCE SCHEDULE...3123
4.6.1 INITIAL SERVICING...3123
4.6.2 PERIODIC SERVICING INTERVALS...3123
4.6.3 PERIODIC SERVICING SCHEDULE...3124
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM...3131
4.6.5 MAINTENANCE OF THE ENGINE...3133
4.7 WHEN NECESSARY...3134
4.7.1 ENGINE AIR CLEANER SERVICE...3135
4.7.2 SWING CIRCLE TOOTHING LUBRICATION...3139
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS...3141
4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...3145
4.8 EVERY 10 OPERATING HOURS OR DAILY...3146
4.8.1 WALK-AROUND INSPECTION...3147
4.8.2 AIR CLEANER - CLEAN PRE-CLEANER...3157
4.8.3 RADIATOR - CHECK COOLANT LEVEL...3159
4.8.4 TRACK GROUPS - CLEAN...3159
4.8.5 FUEL SYSTEM WATER SEPARATOR - DRAIN WATER...3161
4.9 EVERY 50 OPERATING HOURS OR WEEKLY...3162
4.9.1 SWING MACHINERY AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...3163
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...3167
4.9.3 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL...3169
4.9.4 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR - CHECK OIL LEVEL...3171
4.9.5 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR...3173
4.9.6 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY...3175
4.10 EVERY 250 OPERATING HOURS OR MONTHLY...3176
4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION...3177
4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE...3179
4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE...3179
4.10.4 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...3179
4.10.5 RADIATOR FAN BEARING HOUSING - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...3179
4.10.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER...3181
4.10.7 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT...3185
4.10.8 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL...3187
4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL...3189
4.11 EVERY 500 OPERATING HOURS OR MONTHLY...3190
4.11.1 BATTERIES - CHECK FLUID LEVEL...3191
4.11.2 FLEXIBLE DRIVE COUPLING - CHECK OIL LEVEL...3193
4.11.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS - CHECK OIL LEVEL...3195
4.11.4 FUEL TANK - DRAIN CONDENSATION...3197
4.11.5 CRAWLER TRACK - INSPECTION...3199
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH...3204
4.12.1 HIGH STRENGTH BOLT CONNECTIONS...3205
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE...3247
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING MACHINERY AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...3259
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE...3261
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK ACCUMULATORS...3263
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE...3265
4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES...3267
4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES...3269
4.13 EVERY 2000 OPERATING HOURS OR YEARLY...3270
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER...3271
4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION...3283
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR...3284
4.14.1 SWING MACHINERY AND MOTOR ADAPTER HOUSING - CHANGE OIL...3285
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL...3293
4.14.3 FINAL DRIVE HOUSINGS - CHANGE OIL...3297
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL...3299
4.15 FIRE PREVENTION...3300
4.16 WELD REPAIRS...3302
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE...3305
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT...3307
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...3309
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE...3310
OMPC40008172 - Hydraulic Mining Shovel PC4000-6 Operation & Maintenance Manual...3317
COVER...3317
1. INTRODUCTION...3319
1.1 CONTENTS OF THE BINDER...3320
1.2 DIVISION OF THE BINDER...3321
1.3 DESIGNATED USE OF THE SHOVEL...3322
1.4 DELIVERY OF THE SHOVEL...3323
1.5 EXPLANATION OF ABBREVIATIONS...3324
1.6 TABLE OF CONTENTS...3325
2. SAFETY...3331
2.1 SAFETY INSTRUCTIONS...3332
2.1.1 WARNINGS AND SYMBOLS...3332
2.1.2 BASIC OPERATION AND DESIGNATED USE OF THE HYDRAULIC MINING SHOVEL...3332
2.1.3 ORGANIZATIONAL MEASURES...3333
2.1.4 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...3335
2.1.5 SAFETY INSTRUCTIONS GOVERNING SPECIFIC OPERATIONAL PHASES...3336
2.1.6 WARNING OF SPECIAL DANGERS...3339
2.1.7 TRANSPORTING AND TOWING -RECOMMISSIONING...3341
2.1.8 SPECIAL SAFETY EQUIPMENT...3341
2.1.9 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...3345
3. OPERATION...3353
3.1 FOREWORD...3354
3.2 CONSTRUCTION OF THE SHOVEL...3355
3.2.1 OVERALL VIEW...3355
3.2.2 SUPERSTRUCTURE...3356
3.2.3 HYDRAULICALLY OPERATED ACCESS LADDER...3366
3.2.4 EMERGENCY ESCAPE LADDER...3370
3.2.5 EMERGENCY ENGINE SHUTDOWN FROM GROUND MAN OR OPERATOR WARNING SYSTEM...3372
3.2.6 OPERATOR’S CAB WITH INTEGRATED FALLING OBJECT PROTECTIVE STRUCTURE (FOPS)...3374
3.2.7 UNDERCARRIAGE...3385
3.2.8 WORKING ATTACHMENT...3386
3.2.9 DIESEL ENGINE TYPE SDA 16V160...3388
3.2.10 ENGINE OIL MANAGEMENT SYSTEM...3390
3.3 OPERATOR’S CAB - CONTROLS...3394
3.3.1 CONTROLS WITH BACKHOE ATTACHMENT...3394
3.3.2 SAFETY CIRCUIT FOR CONTROLS...3395
3.3.3 CONTROLS WITH BOTTOM DUMP BUCKET ATTACHMENT...3398
3.3.4 SAFETY CIRCUIT FOR CONTROLS...3399
3.3.5 AUTOMATIC FLOAT POSITION FOR BOOM AND STICK...3401
3.3.6 OPERATOR’S CONSOLE...3403
3.3.7 INTERFACE PANEL FOR DIAGNOSTICS AND CONTROLS FOR HEATING AND AIR CONDITIONING...3409
3.4 VEHICLE HEALTH MONITORING SYSTEM VHMS – HEALTH MONITOR...3412
3.4.1 INITIALIZATION SCREEN NO. 0.0...3412
3.4.2 OPERATOR INFORMATION SCREEN NO. 1.1...3412
3.4.3 STANDARD MONITOR 1 (NO. 1.2)...3413
3.4.4 TABLE OF ALL TOP MESSAGES PROVIDED BY THE SYSTEM...3427
3.4.5 TABLE OF AVAILABLE INSTRUCTION MESSAGES...3436
3.5 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING...3438
3.5.1 A - HEATING...3439
3.5.2 B - COOLING...3439
3.5.3 COMBINED OPERATION OF AIR CONDITIONING AND HEATING...3439
3.5.4 AUXILIARY HEATER FOR OPERATOR’S CAB...3441
3.6 POWER HOUSE...3442
3.6.1 EMERGENCY ENGINE SHUTDOWN SWITCHES...3443
3.6.2 MAINTENANCE SAFETY SWITCH AND BATTERY MAIN SWITCHES...3445
3.6.3 CENTRAL CONTROL AND FILTER PANEL...3447
3.7 ELECTRICAL EQUIPMENT IN CAB BASE...3450
3.7.1 STANDARD COMPONENTS IN CAB BASE...3451
3.7.2 SWITCH BOARD (X2) IN CAB BASE...3453
3.7.3 COMPONENTS OF ELECTRICAL PRE-HEATING SYSTEM LOCATED IN THE CAB BASE...3463
3.8 CHECKS BEFORE STARTING THE ENGINE...3470
3.9 STARTING THE ENGINE...3476
3.9.1 STARTING PROCEDURE...3479
3.9.2 ENGINE WARM-UP...3483
3.9.3 HYDRAULIC OIL WARM-UP...3483
3.10 MOVING THE SHOVEL...3485
3.10.1 TRAVEL CONTROL WITH FOOT PEDALS...3485
3.10.2 TRAVELLING INSTRUCTIONS...3488
3.11 SLEWING AND BRAKING THE SUPERSTRUCTURE...3489
3.11.1 SLEWING THE SUPERSTRUCTURE...3489
3.11.2 BRAKING THE SUPERSTRUCTURE...3491
3.11.3 SLEW PARKING BRAKE...3492
3.12 WORKING WITH THE ATTACHMENT...3494
3.12.1 MACHINES EQUIPPED WITH ”EURO” CONTROL SYSTEM...3494
3.12.2 MACHINES EQUIPPED WITH ”KMG” CONTROL SYSTEM...3495
3.12.3 BOTTOM DUMP BUCKET...3496
3.12.4 DROP BALL OPERATION...3497
3.12.5 COMBINED OPERATION CYCLES...3500
3.13 WORKING INSTRUCTIONS...3502
3.13.1 STABILITY OF THE SHOVEL...3502
3.13.2 SHOVEL OPERATION...3502
3.14 PARKING THE SHOVEL...3505
3.15 STOPPING THE ENGINE...3506
3.15.1 RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM...3509
3.16 OPERATION OF THE LUBRICATION SYSTEM...3510
3.16.1 CENTRAL LUBRICATION SYSTEM ”CLS”...3510
3.16.2 SWING CIRCLE PINION LUBRICATION SYSTEM ”SLS”...3512
3.17 FIRE DETECTION AND SUPPRESSION SYSTEM...3514
3.17.1 HIGH LEVEL ALARM ”FIRE”...3517
3.17.2 ENGINE SHUT-DOWN THROUGH FUEL SHUT-OFF SOLENOID VALVE...3517
3.17.3 ACTUATION MODES OF THE FIRE SUPPRESSION SYSTEM...3517
3.17.4 INDICATION OF OPERATIONAL MODES AT CONTROL MODULE, AFTER AUTOMATIC ACTUATION OF THE FIRE S...3519
3.17.5 LOCATION OF THE EXTINGUISHING AGENT TANK ASSEMBLIES AND EXPELLANT GAS CARTRIDGES ON POWER...3521
3.18 TRANSFER PUMP FOR HYDRAULIC OIL...3522
3.18.1 OPERATING THE TRANSFER PUMP...3523
3.18.2 FUNCTIONS OF THE TRANSFER PUMP...3525
3.19 CENTRAL REFILLING SYSTEM...3528
3.19.1 SYSTEMS CONNECTED TO THE REFILLING SYSTEM...3529
3.19.2 OPERATING THE HYDRAULIC SERVICE ARM...3531
3.19.3 RECEIVER PANEL WITH MONITOR BOX...3533
3.19.4 REFILLABLE GREASE CONTAINERS OF THE CENTRAL LUBRICATION SYSTEM AND SWING CIRCLE PINION LUB...3539
3.20 WORK ON THE LOADER ATTACHMENT...3542
3.21 TRANSPORTATION AND LIFTING OF THE SHOVEL...3543
3.21.1 DISASSEMBLING OF THE SHOVEL...3543
3.21.2 TRANSPORTATION AND LIFTING...3543
3.22 RETRIEVAL PROCEDURE...3544
3.23 SHOVEL STORAGE...3545
3.23.1 PREPARING FOR STORAGE...3545
3.23.2 ONE MONTH REPETITIVE SERVICE PERIOD...3546
3.23.3 SIX MONTH REPETITIVE SERVICE PERIOD...3546
3.23.4 PREPARING FOR OPERATION...3547
3.24 TROUBLE SHOOTING...3548
3.24.1 ENGINE...3548
3.24.2 HYDRAULIC SYSTEM...3549
3.24.3 FINAL DRIVES AND SWING MACHINERY...3550
3.24.4 CRAWLER TRACKS...3550
4. MAINTENANCE...3551
4.1 FOREWORD...3552
4.2 PRECAUTIONS FOR MAINTENANCE...3553
4.3 FUEL AND LUBRICANTS...3555
4.4 FILLING CAPACITIES...3557
4.5 STANDARD TORQUE LIST...3558
4.6 LUBRICATION AND MAINTENANCE SCHEDULE...3559
4.6.1 INITIAL SERVICING...3559
4.6.2 PERIODIC SERVICING INTERVALS...3559
4.6.3 PERIODIC SERVICING SCHEDULE...3560
4.6.4 EXTENDED SERVICE INTERVALS FOR ENGINES EQUIPPED WITH ENGINE OIL MANAGEMENT SYSTEM...3567
4.6.5 MAINTENANCE OF THE ENGINE...3569
4.7 WHEN NECESSARY...3570
4.7.1 ENGINE AIR CLEANER SERVICE...3571
4.7.2 SWING CIRCLE TOOTHING LUBRICATION...3575
4.7.3 AUTOMATIC LUBRICATION SYSTEMS FILL GREASE BARRELS...3577
4.7.4 TRACK ROLLERS AND GUIDE WHEELS - REPLACE FLOATING SEALS...3581
4.8 EVERY 10 OPERATING HOURS OR DAILY...3582
4.8.1 WALK-AROUND INSPECTION...3583
4.8.2 AIR CLEANER - CLEAN PRE-CLEANER...3593
4.8.3 RADIATOR - CHECK COOLANT LEVEL...3595
4.8.4 TRACK GROUPS - CLEAN...3595
4.8.5 FUEL SYSTEM WATER SEPARATOR - DRAIN WATER...3597
4.9 EVERY 50 OPERATING HOURS OR WEEKLY...3598
4.9.1 SWING MACHINERY AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...3599
4.9.2 TRAVEL GEARS, BRAKE HOUSINGS AND MOTOR ADAPTER HOUSINGS - CHECK OIL LEVELS...3603
4.9.3 FINAL DRIVE HOUSINGS - CHECK OIL LEVEL...3605
4.9.4 PTO (PUMP DISTRIBUTOR GEAR) AND OIL RESERVOIR - CHECK OIL LEVEL...3607
4.9.5 HYDRAULIC ACCESS LADDER - CHECK SAFETY SENSOR...3609
4.9.6 HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY...3611
4.10 EVERY 250 OPERATING HOURS OR MONTHLY...3612
4.10.1 AIR CONDITIONING COMPRESSOR - CHECK DRIVE BELT TENSION...3613
4.10.2 UNDERCARRIAGE PIN CONNECTIONS - LUBRICATE...3615
4.10.3 SIGNAL HORN COMPRESSOR - LUBRICATE...3615
4.10.4 HYDRAULIC OIL COOLER FAN BEARING HOUSINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...3615
4.10.5 RADIATOR FAN BEARING HOUSING - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER...3615
4.10.6 AUTOMATIC LUBRICATION SYSTEMS - CLEAN IN-LINE GREASE FILTER...3617
4.10.7 CAB AIR CLEANER - CLEAN OR REPLACE FILTER ELEMENT...3621
4.10.8 WINDSHIELD WASHER SYSTEM - CHECK FLUID LEVEL...3623
4.10.9 AIR CONDITIONING FOR OPERATOR’S CAB - CHECK REFRIGERANT LEVEL...3625
4.11 EVERY 500 OPERATING HOURS OR MONTHLY...3626
4.11.1 BATTERIES - CHECK FLUID LEVEL...3627
4.11.2 FLEXIBLE DRIVE COUPLING - CHECK OIL LEVEL...3629
4.11.3 PTO (PUMP DISTRIBUTOR GEAR) MAIN PUMP DRIVE SHAFT HOUSINGS - CHECK OIL LEVEL...3631
4.11.4 FUEL TANK - DRAIN CONDENSATION...3633
4.11.5 CRAWLER TRACK - INSPECTION...3635
4.12 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTH...3640
4.12.1 HIGH STRENGTH BOLT CONNECTIONS...3641
4.12.2 HYDRAULIC SYSTEM - FILTER SERVICE...3683
4.12.3 PTO (PUMP DISTRIBUTOR GEAR), SWING MACHINERY AND TRAVEL GEARS - OIL SAMPLE ANALYSIS...3695
4.12.4 SIGNAL HORN COMPRESSOR - CLEAN AND LUBRICATE...3697
4.12.5 HYDRAULIC TRACK TENSIONING SYSTEM - CHECK ACCUMULATORS...3699
4.12.6 WATER FILTER - REPLACE FILTER CARTRIDGE...3701
4.12.7 HYDRAULIC OIL COOLER - INSPECT AND LUBRICATE DOOR HINGES...3703
4.12.8 MACHINERY HOUSE DOORS - INSPECT AND LUBRICATE DOOR HINGES...3705
4.13 EVERY 2000 OPERATING HOURS OR YEARLY...3706
4.13.1 HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER...3707
4.13.2 EMERGENCY ESCAPE LADDER - INSPECTION...3719
4.14 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR...3720
4.14.1 SWING MACHINERY AND MOTOR ADAPTER HOUSING - CHANGE OIL...3721
4.14.2 TRAVEL GEARS, BRAKE AND MOTOR ADAPTER HOUSINGS - CHANGE OIL...3729
4.14.3 FINAL DRIVE HOUSINGS - CHANGE OIL...3733
4.14.4 PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL...3735
4.15 FIRE PREVENTION...3736
4.16 WELD REPAIRS...3738
4.16.1 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE UNDERCARRIAGE...3741
4.16.2 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE LOADER ATTACHMENT...3743
4.16.3 PROTECTIVE MEASURES BEFORE STARTING WELD REPAIRS ON THE SUPERSTRUCTURE...3745
4.16.4 AFTER FINISHING THE WELD REPAIRS ON THE SUPERSTRUCTURE...3746
RRPC4000-6 - Hydraulic Mining Shovel PC4000-6 Remove & Replace Procedures...3753
1 Introduction...3765
1.1 Contents of the binder...3766
1.2 Foreword...3767
1.2.1 Service...3768
2 Safety...3769
2.1 Safety Instructions...3770
2.1.1 Method of using this manual...3770
2.1.2 General precautions...3772
2.1.3 Preparations for work...3773
2.1.4 Precautions during work...3774
2.1.5 WARNING OF SPECIAL DANGERS...3776
2.1.5.1 ELECTRICal ENERGY...3776
2.1.5.2 GAS, DUST, STEAM AND SMOKE...3777
2.1.5.3 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT...3778
2.1.5.4 NOISE...3778
2.1.5.5 Heat...3779
2.1.5.6 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES...3779
2.1.5.7 Height...3779
2.1.6 SPECIAL SAFETY EQUIPMENT...3781
2.1.6.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...3781
2.1.6.2 INSTRUCTIONS FOR USE...3783
2.1.6.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS...3785
2.1.6.4 INSTRUCTIONS FOR USE...3787
2.2 Lifting Gears...3788
2.2.1 Wire ropes...3788
2.2.2 Sling accessory...3790
2.2.3 Weight tables...3791
2.2.3.1 Superstructure...3791
2.2.3.2 Undercarriage...3793
2.2.3.3 Backhoe AttachmenT (BHA)...3794
2.2.3.4 Faceshovel Attachment (FSA)...3795
2.3 Torque charts according to DIN...3797
2.3.1 Metric standard thread...3797
2.3.2 Metric fine thread...3798
2.3.3 Cummins motor torques - metric...3799
2.3.4 Cummins motor torques - U.S. Customary...3799
2.3.5 Flange connections...3800
2.4 Conversation table...3801
2.4.1 Method of using the conversation table...3801
2.4.2 Millimeter - Inch & Kilogram - Pound...3802
2.4.3 Liter - U.S. Gallon & Liter - U.K. Gallon...3803
2.4.4 KGm - ft.lb...3804
2.4.5 bar - PSI / PSI - bar...3805
2.4.6 Basic Values in Ohm according to DIN 43 76...3806
2.4.7 Temperature...3807
2.5 Explanation of abbreviations...3808
3 Superstructure...3809
3.1 Diesel Engine...3810
3.1.1 Removal of the Diesel engine...3810
3.1.2 Replacement of the Diesel engine...3817
3.1.3 Engine torque support and engine/PTO mounts...3820
3.1.3.1 Flexible mounts...3821
3.1.3.2 Torque support...3823
3.1.4 Alternator...3824
3.1.4.1 Removal of the alternator...3824
3.1.4.2 Replacement of the alternator...3825
3.1.5 Batteries...3826
3.1.5.1 Removal of the batteries...3826
3.1.5.2 Replacement of the batteries...3828
3.1.6 Radiator fan...3830
3.1.6.1 Removal of the radiator fan assembly...3831
3.1.6.2 Replacement of the radiator fan assembly...3835
3.1.6.3 Removal of the radiator fan...3837
3.1.6.4 Replacement of the radiator fan...3837
3.1.6.5 Removal of the radiator fan drive pump...3838
3.1.6.6 Replacement of the radiator fan drive pump...3840
3.1.7 Radiators...3841
3.1.7.1 Removal of the Radiator assembly...3841
3.1.7.2 Replacement of the radiator assembly...3845
3.1.8 Fuel cooler...3846
3.1.8.1 Removal of the fuel cooler...3846
3.1.8.2 Replacement of the fuel cooler...3848
3.1.9 Starter system...3849
3.1.9.1 Removal of the starter motor...3849
3.1.9.2 Replacement of the starter motor...3849
3.1.10 Geislinger coupling...3850
3.1.10.1 Removal of the Geislinger coupling...3851
3.1.10.2 Replacement of the Geislinger coupling...3853
3.2 PTO...3854
3.2.1 Main pumps...3854
3.2.1.1 Preparatory works for main pump removal...3855
3.2.1.2 Removal of Main Pump 1...3858
3.2.1.3 Replacement of main pump 1...3859
3.2.1.4 Removal of Main Pump 2...3861
3.2.1.5 Replacement of main pump 2...3863
3.2.1.6 Removal of Main Pump 3...3865
3.2.1.7 Replacement of main pump 3...3867
3.2.1.8 Removal of Main Pump 4...3868
3.2.1.9 Replacement of main pump 4...3870
3.2.2 PTO oil circulation pump (auxiliary pump)...3871
3.2.2.1 Removal of the oil circulation pump (auxiliary pump)...3871
3.2.2.2 Replacement of the oil circulation pump (auxiliary pump)...3873
3.2.3 Pump distributor gearbox (PTO)...3874
3.2.3.1 Removal of the Pump distributor gearbox (PTO)...3876
3.2.3.2 Replacement of the Pump distributor gearbox (PTO)...3879
3.3 Hydraulics...3880
3.3.1 Hydraulic cooler fan Drive Pump...3880
3.3.1.1 Removal of the hydraulic cooler fan drive pump...3880
3.3.1.2 Replacement of the hydraulic cooler fan drive pump...3883
3.3.2 Hydraulic Cooler Fan Assembly...3884
3.3.2.1 Removal of hydraulic cooler fan assembly...3884
3.3.2.2 Replacement of hydraulic cooler fan assembly...3887
3.3.2.3 Removal of hydraulic cooler Fan and motor...3888
3.3.2.4 Replacement of hydraulic cooler Fan and motor...3890
3.3.3 Hydraulic Oil Coolers...3892
3.3.3.1 Removal of the hydraulic oil coolers...3894
3.3.3.2 Replacement of the hydraulic oil coolers...3898
3.3.3.3 Removal of the hydraulic oil cooler frame...3900
3.3.3.4 Replacement of the hydraulic oil cooler frame...3905
3.3.4 Main Relief Valves (MRV)...3906
3.3.4.1 Removal of the MRV...3906
3.3.4.2 Replacement of the MRV...3907
3.3.5 pilot oil pump (Gear pump)...3908
3.3.5.1 Removal of the pilot oil pump)...3908
3.3.5.2 Replacement of the pilot oil pump...3910
3.3.6 Main Gate Valve...3910
3.3.6.1 Removal of the main gate valve...3911
3.3.6.2 Replacement of the main gate valve...3912
3.3.7 Hydraulic Oil Reservoir...3914
3.3.7.1 Removal of the hydraulic oil reservoir...3916
3.3.7.2 Replacement of the hydraulic oil reservoir...3923
3.3.8 Main Control Valve Blocks...3925
3.3.8.1 Removal of the main control valve blocks...3934
3.3.8.2 Replacement of the main control valve blocks...3938
3.3.9 Service line Relief Valves (SRV)...3939
3.3.9.1 Removal of SRV on main Control valve block...3939
3.3.9.2 Replacement of SRV on main control valve blocks...3942
3.3.10 Anti-cavitation Valves (ACV)...3944
3.3.10.1 Removal of ACV on Manifold...3945
3.3.10.2 Replacement of ACV on Manifold...3950
3.3.10.3 Removal of ACV on main control valve blocks...3951
3.3.10.4 Replacement of ACV on main control valve blocks...3953
3.3.11 Throttle check valves...3954
3.3.11.1 Removal of throttle check valves...3956
3.3.11.2 Replacement of throttle check valves...3959
3.3.12 manifold...3960
3.3.12.1 Removal of the manifold...3960
3.3.12.2 Replacement of the manifold...3962
3.3.12.3 Removal of the Diffuser on the Manifold (FSA only)...3963
3.3.12.4 Replacement of Diffuser on Manifold (FSA only)...3965
3.4 Slew Drive...3967
3.4.1 Slew Gear...3968
3.4.1.1 Removal of the slew gear...3969
3.4.1.2 Replacement of the slew gear...3971
3.4.2 Swing Motor...3974
3.4.2.1 Removal of the swing motor...3975
3.4.2.2 Replacement of the swing motor...3978
3.4.3 Slew parking brake...3981
3.4.3.1 Removal/Disassembly of the slew parking brake...3983
3.4.3.2 Replacement/assembly of the slew parking brake...3986
3.4.4 Dynamic Slew Brake...3988
3.4.4.1 Removal of the slew brake valve...3991
3.4.4.2 Replacement of the slew brake valve...3993
3.4.5 Swing circle lubrication pinion (dummy wheel)...3994
3.4.5.1 Removal of the lubrication pinion assembly...3996
3.4.5.2 Replacement of the lubrication pinion assembly...3998
3.5 Lubrication pumps...3999
3.5.1 Removal of the Lubrication pump...3999
3.5.2 Replacement of the lubricating pump...4001
3.6 Pump controller MC7...4002
3.6.1 Removal of the pump controller MC7...4002
3.6.2 Replacement of the pump controller MC7...4003
3.7 Operator’s Cab...4004
3.7.1 Removal of the operator’s cab...4007
3.7.2 Replacement of the operator’s cab...4012
3.7.3 Cab-mounts...4013
3.7.3.1 Removal of the cab-mounts...4013
3.7.3.2 replacement of the cab-mounts...4015
3.7.4 FRONT WINDOW...4016
3.7.4.1 Removal of the Front window...4016
3.7.4.2 Replacement of the front window...4017
3.7.5 Operator’s seat...4018
3.7.5.1 Removal of the operator’s seat...4018
3.7.5.2 Replacement of the operator’s seat...4019
3.7.6 VHMS...4020
3.7.6.1 Removal of the VHMS-Controller...4020
3.7.6.2 Replacement of the VHMS-Controller...4021
3.7.7 Access Ladder...4022
3.7.7.1 Removal of the access Ladder...4025
3.7.7.2 Replacement of the access ladder...4027
3.7.7.3 Removal of the access ladder cylinder...4029
3.7.7.4 Replacement of the access ladder cylinder...4031
3.7.8 Removal of the cab base...4032
3.7.9 Replacement of the cab base...4034
3.8 Counterweight...4036
3.8.1 Removal of the counterweight...4037
3.8.2 Replacement of the counterweight...4039
3.9 Superstructure Lifting...4040
3.9.1 Remove the Superstructure from the Undercarriage...4040
3.9.2 Install the Superstructure onto the undercarriage...4043
3.10 Fuel Tank...4046
3.10.1 Removal of the Fuel tank...4047
3.10.2 Replacement of the Fuel tank...4050
4 Undercarriage...4053
4.1 Travel System...4054
4.1.1 Track group...4054
4.1.1.1 Changing of the track group...4054
4.1.2 Sprocket...4058
4.1.2.1 Removal of the sprocket...4058
4.1.2.2 Replacement of the sprocket...4062
4.1.3 Guide wheels...4064
4.1.3.1 Removal of the guide wheel assembly...4064
4.1.3.2 Replacement of the guide wheel assembly...4065
4.1.4 Track tensioning accumulators...4066
4.1.4.1 Removal of the low pressure accumulators...4066
4.1.4.2 Replacement of the low pressure accumulators...4068
4.1.4.3 Removal of the high pressure accumulators...4069
4.1.4.4 Replacement of the high pressure accumulators...4070
4.1.5 Track tension valve block...4071
4.1.5.1 Removal of the track tensioning valve block...4071
4.1.5.2 Replacement of the track tensioning valve block...4072
4.1.6 Hydraulic hoses of the track tensioning system...4073
4.1.6.1 Substitute the hydraulic hoses...4073
4.1.7 Travel brake valve block (overspeed valve)...4076
4.1.7.1 Removal of the travel brake valve block...4077
4.1.7.2 Replacement of the travel brake valve block...4079
4.1.8 Track tensioning cylinders...4080
4.1.8.1 Removal of the track tensioning cylinders...4080
4.1.8.2 Replacement of the track tensioning cylinders...4081
4.1.9 Travel motor...4082
4.1.9.1 Removal of the travel motors...4082
4.1.9.2 Replacement of the travel motors...4084
4.1.10 travel parking brake...4086
4.1.10.1 Removal/disassembly of the travel parking brake...4089
4.1.10.2 Replacement/assembly of the travel parking brake...4092
4.1.11 Travel gearbox...4094
4.1.11.1 Removal of the travel gearbox...4095
4.1.11.2 Replacement of the travel gearbox...4097
4.1.12 Carrier roller...4098
4.1.12.1 Removal of the carrier roller assembly...4098
4.1.12.2 Replacement of the carrier roller assembly...4100
4.1.13 Track roller...4101
4.1.13.1 Removal of the Track roller assembly...4101
4.1.13.2 Replacement of the Track roller assembly...4103
4.2 Car body...4104
4.2.1 Removal of the car bodY (previous type with mounting pins)...4104
4.2.2 Replacement of the car bodY (previous type with mounting pins)...4108
4.2.3 Removal OF the car Body (NEW type with bolted connection)...4112
4.2.4 Replacement of the car body (NEW type with bolted connection)...4117
4.2.4.1 Tightening torque for the crawler carrier mounting bolts...4122
4.2.5 Rotary joint...4126
4.2.5.1 Removal of the rotary joint...4128
4.2.5.2 Replacement of the rotary joint...4131
4.2.6 swing circle...4132
4.2.6.1 Removal of the swing circle...4134
4.2.6.2 Replacement of the swing circle...4136
5 Attachment...4141
5.1 Backhoe...4142
5.1.1 Boom...4144
5.1.1.1 Removal of the Boom...4144
5.1.1.2 Replacement of the boom...4148
5.1.1.3 Removal of boom cylinders...4150
5.1.1.4 Replacement of boom cylinders...4155
5.1.2 Stick...4158
5.1.2.1 Removal of the Stick...4158
5.1.2.2 Replacement of Stick...4162
5.1.2.3 Removal of Stick Cylinders...4164
5.1.2.4 Replacement of Stick cylinders...4169
5.1.3 Bucket...4172
5.1.3.1 Removal of the bucket...4172
5.1.3.2 Replacement of the bucket...4175
5.1.3.3 Removal of Bucket Cylinders...4176
5.1.3.4 Replacement of Bucket Cylinders...4181
5.1.4 Bucket link rod and steering rods...4183
5.1.4.1 Removal of the bucket link rod...4183
5.1.4.2 Replacement of the bucket link rod...4185
5.1.4.3 Removal of the steering rods...4186
5.1.4.4 Replacement of the steering rods...4189
5.1.5 Ground engaging tools (GET)...4190
5.1.5.1 Removal and replacement of the GET...4190
5.1.6 Hydraulic hoses at the backhoe attachment...4192
5.1.6.1 Substitute the boom arc hoses...4192
5.1.6.2 Substitute the boom cylinder hoses...4196
5.1.6.3 Substitute the stick cylinder hoses...4200
5.1.6.4 Substitute the bucket cylinder hoses...4204
5.2 Faceshovel...4209
5.2.1 Boom...4210
5.2.1.1 Removal of the boom...4210
5.2.1.2 Replacement of the boom...4215
5.2.1.3 Removal of the boom cylinders...4220
5.2.1.4 Replacement of the boom cylinders...4225
5.2.2 Stick...4228
5.2.2.1 Removal of the stick...4228
5.2.2.2 Replacement of the stick...4232
5.2.2.3 Removal of the stick cylinders...4234
5.2.2.4 Replacement of the stick cylinders...4239
5.2.3 Bullclam bucket...4242
5.2.3.1 Removal of the bull clam bucket...4242
5.2.3.2 Replacement of the bull clam bucket...4248
5.2.3.3 Removal of the bucket cylinders...4250
5.2.3.4 Replacement of the bucket cylinders...4254
5.2.3.5 Removal of the clam cylinders...4258
5.2.3.6 Replacement of the clam cylinders...4262
5.2.4 Ground engaging tools (GET)...4264
5.2.4.1 Removal and replacement of the GET...4264
5.2.5 Hydraulic hoses at the Faceshovel attachment...4266
5.2.5.1 Substitute the boom arc hoses...4266
5.2.5.2 Substitute the boom cylinder hoses...4270
5.2.5.3 Substitute the stick arc hoses...4274
5.2.5.4 Substitute the stick cylinder hoses...4278
5.2.5.5 Substitute the bucket cylinder hoses...4282
5.2.5.6 Substitute the clam cylinder hoses...4286
5.3 Metering valves (grease injectors) at the attachment...4294
5.3.1 Removal of the metering valves (grease injectors)...4294
5.3.2 Replacement of the metering valves (grease injectors)...4295
5.4 Cylinder bypass test...4296
6 Appendix...4299
6.1 Fuel and Lubricants...4300
6.2 Filling Capacities...4302
6.3 Tools List...4304
6.3.1 Used special tools (Overview)...4304
6.3.2 KOMATSU tools catalogue...4307
6.4 Work instructions...4354
6.4.1 Remove / install the crawler carrier...4354
6.4.2 Use of the hydraulic torque wrench (supplier’s documentation)...4355
6.5 Service Bulletins...4383
6.5.1 AH00511d...4385
6.5.2 AH00514...4407
6.5.3 AH00519...4421
6.5.4 AH01512...4427
6.5.5 AH01521a...4437
6.5.6 AH01531A...4449
6.5.7 AH02513b...4461
6.5.8 AH02521...4467
6.5.9 AH03506B...4475
6.5.10 AH03509a...4483
6.5.11 AH03510...4511
6.5.12 AH03526a...4531
6.5.13 AH03538...4535
6.5.14 AH04518...4563
6.5.15 AH05510...4567
6.5.16 AH05511...4571
6.5.17 AH05546...4577
6.5.18 AH06524...4581
6.5.19 AH06530...4585
SMPC4000-8199 - Hydraulic Mining Shovel PC4000-6 Shop Manual...4589
1 Foreword...4591
1.1 Purpose of this THIS MANUAL...4592
1.2 Contents of thE Shop Manual...4593
1.2.1 Contacting the Service...4593
1.2.2 Guarantee...4593
1.3 DIVISION OF THE Shop Manual...4594
00_SAFETY.pdf...0
2 SAFETY...4597
2.1 SAFETY INFORMATION...4598
2.2 OVERVIEW...4599
2.2.1 NORMAL OPERATIONS...4599
2.2.2 REGULAR MAINTENANCE...4599
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR...4599
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR...4599
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB...4600
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR...4601
2.4.1 UNDERSTANDING THE MACHINE...4601
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR...4601
2.4.2.1 ENSURING SAFE OPERATION...4601
2.4.3 PREPARATIONS FOR SAFE OPERATION...4601
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT...4601
2.4.3.2 INSPECTING THE MACHINE...4601
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT...4602
2.4.3.4 KEEP MACHINE CLEAN...4602
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT...4602
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT...4603
2.4.3.7 IF A PROBLEM IS FOUND...4603
2.4.4 FIRE PREVENTION...4603
2.4.4.1 PRECAUTIONS TO PREVENT FIRE...4603
2.4.4.2 ACTION IF FIRE OCCURS...4604
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB...4605
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE...4605
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE...4605
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE...4605
2.4.5.3 NO PEOPLE ON THE ATTACHMENT...4605
2.4.5.4 WORKING IN HIGH PLACES...4605
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK...4606
2.4.5.6 LEAVING THE MACHINE...4606
2.4.6 BURN PREVENTION...4607
2.4.6.1 Hot coolant...4607
2.4.6.2 Hot oil...4607
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS...4607
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...4608
2.4.8.1 UNAUTHORIZED MODIFICATION...4608
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...4608
2.4.9 ELECTROMAGNETIC COMPATIBILITY (EMC)...4609
2.4.10 PRECAUTIONS AT JOBSITE...4610
2.4.10.1 VISIBILITY FROM OPERATOR’S SEAT...4611
2.4.10.2 CAMERA SYSTEM WITH MONITORS...4611
2.4.10.3 ENSURE GOOD VISIBILITY...4611
2.4.10.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS...4611
2.4.10.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS...4612
2.4.10.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES...4612
2.4.10.7 WORKING ON LOOSE GROUND...4613
2.4.10.8 GAS, DUST, STEAM AND SMOKE...4613
2.4.10.9 VENTILATION OF ENCLOSED AREAS...4614
2.4.11 STARTING ENGINE...4615
2.4.11.1 WARNING TAG...4615
2.4.11.2 CHECKS BEFORE STARTING ENGINE...4615
2.4.11.3 PRECAUTION WHEN STARTING ENGINE...4615
2.4.11.4 PRECAUTION IN COLD AREAS...4616
2.4.12 OPERATION...4616
2.4.12.1 CHECKS BEFORE OPERATION...4616
2.4.12.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE...4617
2.4.12.3 PRECAUTIONS WHEN travelling...4618
2.4.12.4 TRAVELLING ON SLOPES...4619
2.4.12.5 OPERATIONS ON SLOPES...4620
2.4.12.6 PROHIBITED OPERATIONS...4620
2.4.12.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES...4621
2.4.12.8 PARKING THE MACHINE...4621
2.4.12.9 TRANSPORTATION...4621
2.5 PRECAUTION FOR MAINTENANCE...4622
2.5.1 GENERAL PRECAUTIONS...4622
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...4623
2.5.1.2 STOP ENGINE FOR MAINTENANCE...4624
2.5.1.3 WARNING TAG...4625
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY...4626
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS...4626
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING...4627
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS...4627
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT...4628
2.5.1.9 NOISE...4628
2.5.1.10 WHEN USING A HAMMER...4628
2.5.1.11 PROPER TOOLS...4629
2.5.1.12 ACCUMULATOR...4629
2.5.1.13 PERSONNEL...4629
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE...4630
2.5.2.1 PRECAUTION WHEN WELDING...4630
2.5.2.2 BATTERY HANDLING...4630
2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID...4631
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE...4631
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES...4632
2.5.3.3 REPLACEMENT OF HOSE LINES...4632
2.5.3.4 INSPECTION OF HOSE LINES...4632
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...4633
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE...4633
2.5.3.7 AIR CONDITIONING MAINTENANCE...4633
2.5.3.8 COMPRESSED AIR...4634
2.5.3.9 WASTE MATERIALS...4634
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS...4635
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM...4635
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS...4635
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...4635
2.7 SPECIAL SAFETY EQUIPMENT...4636
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB...4637
2.7.2 OBJECT HANDLING...4637
2.7.3 LIGHTING...4637
2.7.4 WARNING BEACON...4637
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...4637
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...4637
2.7.5.2 INSTRUCTIONS FOR USE...4639
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL...4641
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD- BACK HOOKS OF THE SAFETY HARNESS (1),...4641
2.7.5.5 INSTRUCTIONS FOR USE...4643
START PAGE Safety 00.pdf...0
00 Safety...4595
01_SPECIFICATIONS.pdf...0
START PAGE Specifications 01.pdf...0
01 SPECIFICATION...4645
10_STRUCTURE, FUNCTION.pdf...0
I. INTRODUCTION...4667
I.I Contents of the Binder...4668
I.II Foreword...4669
SERVICE...4669
I.III RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE OF HYDRAULIC MINING SHOVELS...4670
Operation...4670
Maintenance and repair...4670
I.IV Explanation of Abbrevations...4671
I.V Diagrams and Illustrations in this manual...4672
Wiring Diagrams & Hydraulic Diagrams...4672
Illustrations & technical drawings...4672
II. ...4675
CONTENTS...4676
Overview...4677
NORMAL OPERATIONS...4677
REGULAR MAINTENANCE...4677
TROUBLESHOOTING, ADJUSTMENTS AND REPAIR...4677
ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR...4677
GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR...4678
PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR...4678
ENSURING SAFE OPERATION...4678
UNDERSTANDING THE MACHINE...4678
PREPARATIONS FOR SAFE OPERATION...4678
PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT...4678
INSPECTING THE MACHINE...4678
WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT...4679
KEEP MACHINE CLEAN...4679
PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT...4679
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT...4680
IF A PROBLEM IS FOUND...4680
FIRE PREVENTION...4680
ACTION IF FIRE OCCURS...4680
PRECAUTIONS TO PREVENT FIRE...4681
PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE...4682
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE...4682
NO JUMPING ON OR OFF THE MACHINE...4682
NO PEOPLE ON THE ATTACHMENT...4682
LEAVING OPERATOR’S SEAT WITH LOCK...4682
LEAVING THE MACHINE...4683
BURN PREVENTION...4683
PRECAUTIONS WHEN CLEANING CAB GLASS...4683
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...4684
UNAUTHORIZED MODIFICATION...4684
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...4684
PRECAUTIONS AT JOBSITE...4685
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS...4685
WORKING ON LOOSE GROUND...4685
DO NOT GO CLOSE TO HIGH VOLTAGE CABLES...4686
Camera System with Monitors...4689
CHECKING SIGNS AND SIGNALMAN’S SIGNALS...4689
GAS, DUST, STEAM AND SMOKE...4690
VENTILATION OF ENCLOSED AREAS...4690
EMERGENCY EXIT FROM OPERATOR’S CAB...4690
STARTING ENGINE...4691
WARNING TAG...4691
PRECAUTION WHEN STARTING ENGINE...4692
PRECAUTION IN COLD AREAS...4692
OPERATION...4692
CHECKS BEFORE OPERATION...4692
PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE...4693
PRECAUTIONS WHEN travelling...4694
TRAVELLING ON SLOPES...4694
OPERATIONS ON SLOPES...4695
PROHIBITED OPERATIONS...4696
TRAVELLING ON FROZEN OR SNOW COVERED SURFACES...4696
PARKING THE MACHINE...4697
TRANSPORTATION...4697
PRECAUTION FOR MAINTENANCE...4698
STOP ENGINE FOR MAINTENANCE...4699
WARNING TAG...4700
KEEP WORKPLACE CLEAN AND TIDY...4701
APPOINT LEADER WHEN WORKING WITH OTHERS...4701
TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING...4701
INSTALLING, REMOVING OR STORING ATTACHMENTS...4701
PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT...4702
NOISE...4702
WHEN USING A HAMMER...4702
PROPER TOOLS...4703
ACCUMULATOR...4703
PERSONNEL...4703
PRECAUTIONS FOR INSPECTION AND MAINTENANCE...4704
PRECAUTION WHEN WELDING...4704
BATTERY HANDLING...4704
PRECAUTIONS WITH HIGH PRESSURE OIL...4705
PRECAUTIONS WITH HIGH FUEL PRESSURE...4705
HANDLING HIGH PRESSURES HOSES OR PIPES...4705
REPLACEMENT OF HOSE LINES...4705
INSPECTION OF HOSE LINES...4706
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...4706
PRECAUTIONS FOR HIGH VOLTAGE...4708
SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...4708
WASTE MATERIALS...4708
AIR CONDITIONING MAINTENANCE...4709
COMPRESSED AIR...4709
ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS...4710
INSPECTION OF THE HYDRAULIC SYSTEM...4710
TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS...4710
AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...4711
SPECIAL SAFETY EQUIPMENT...4712
FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB...4713
OBJECT HANDLING...4713
LIGHTING...4713
WARNING BEACON...4713
SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...4713
SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...4714
INSTRUCTIONS FOR USE...4717
PRIOR TO USING THE HARNESS (1), THE WEARER SHALL...4719
RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1),...4719
INSTRUCTIONS FOR USE...4721
III. SPECIFICATIONS...4723
III.I Lifting Gears...4724
III.II Safety hints for sling accessory...4726
III.III Standard Tightening Torque Chart...4727
III.IV Conversion Table...4728
III.V Blind plugs...4735
III.VI Classification of threads to the nominal width...4737
III.VII Plugs and fittings according to ISO 8434-1 / DIN 2353...4738
1. MAIN ASSEMBLY GROUPS...4741
1.1 General Layout...4742
1.2 Superstructure...4744
1.3 Machine House...4746
1.4 Hydraulic Oil tank...4748
1.5 Hydraulic Oil Cooler...4750
1.6 Fuel Tank...4752
1.7 Counterweight...4754
1.8 Cab Support...4756
1.9 Operator’s Cab...4758
1.10 Control Blocks...4760
1.11 Swing machinery...4762
1.11.1 Swing Machinery L&S...4762
1.11.2 Swing Machinery SIEBENHAAR...4764
1.12 Undercarriage...4766
1.13 Backhoe Attachment (BHA)...4768
1.14 Front Shovel Attachment (FSA)...4770
2. DRIVE...4773
2.1 Prime Drive Assembly...4774
2.2 Engine and PTO Mounts...4776
2.2.1 engine Mounts...4777
2.2.2 Torque Support...4778
2.3 Geislinger Coupling...4780
2.4 Fan Drive and Radiator Assembly...4782
2.4.1 Radiator Fan Drive Speed Adjustment...4786
2.5 Pump Distributor Gearbox (PTO)...4790
2.5.1 Pump Drive Shaft Housing...4792
2.5.2 PTO Lubrication and Cooling...4794
2.5.3 Hydraulic Pumps – Location, Drive Speed and Flow Rates...4798
2.6 Air Filter...4800
3. HYDRAULIC OIL TANK...4803
3.1 General Layout...4804
3.2 Hydraulic Oil Tank, Location of the Electric Equipment...4806
3.3 Suction Oil Tank with Strainers...4808
3.4 Return Oil Collector Pipe with Strainer...4810
3.5 Back Pressure Valve...4812
3.6 Transfer Pump for hydraulic oil...4814
3.7 Return and Leak Oil Filter...4816
3.8 Breather Filter...4818
4. HYDRAULIC OIL COOLING...4821
4.1 Overall view of the hydraulic oil cooling...4822
4.2 Function of the Hydraulic Oil Cooling Circuit...4824
4.3 Adjustment of the Back Pressure Valve...4826
4.4 Fan Drive (Two Stage Cooler Fan RPM Control)...4828
4.4.1 Fixed Displacement Pump, with Variable Setting...4830
4.4.2 Pressure Relief Valve...4832
4.4.3 Solenoid Valve...4834
4.5 Adjustment of the Cooler Fan Drive Speed...4836
4.5.1 Maximum speed...4836
4.5.2 Medium speed...4839
4.5.3 Function Check of Fan Speed Control...4840
5. CONTROLLING...4843
5.1 General layout...4844
5.2 Valve cartridge block...4846
5.3 Pilot pressure supply and adjustments...4852
5.3.1 Pilot pressure control (PPC) circuit...4853
5.3.2 Checks and adjustment of pilot pressure...4856
5.3.3 Remote control valves arrangement...4858
5.4 Function of the electro hydraulic control system...4860
5.5 Hand lever (joystick) control...4864
5.6 Foot pedal control...4866
5.7 Proportional amplifier module, type A...4868
5.8 Proportional amplifier module, type B...4870
5.9 Ramp time module...4872
5.10 Adjustments of amplifier modules...4874
5.10.1 General...4875
5.10.2 Adjusting the amplifiers type A...4876
5.10.3 Adjusting the amplifiers type B...4878
5.11 Adjusting the ramp time modul...4880
6. COMPONENTS...4885
6.1 Main control blocks and high pressure filter (FSA)...4886
6.2 Main control blocks and high pressure filter (BHA)...4888
6.3 Distributor manifold - location of restrictor blocks and anti cavitation valves (FSA)...4890
6.4 Distributor manifold - location of restrictor blocks and anti cavitation valves (BHA)...4892
6.5 Single control blocks (floating) for stick and boom (FSA)...4894
6.6 Restrictor block with pressure relief valve...4896
6.7 Anti cavitation valve block...4898
6.8 Remote control valves...4900
6.9 4/3 Directional solenoid valves...4902
6.10 Proportional solenoid valves...4904
6.11 High pressure filter...4906
6.12 Control blocks and valves...4908
6.13 Travel brake valve...4920
6.14 Pressure reducing valve...4922
6.15 4/2 Directional solenoid valves...4924
6.16 Pressure double stage valve...4926
6.17 Hydraulic cylinder...4928
6.18 Slew ring...4932
7. MAIN HYDRAULIC PUMPS AND PUMP REGULATION...4935
7.1 General...4936
7.2 Main pumps...4944
7.2.1 Location of pumps...4945
7.2.2 Pump bearing flushing / lubrication...4946
7.2.3 Operating principle...4948
7.2.4 Checks / adjustments...4964
7.3 Electronic Pump Regulation System...4972
7.3.1 Electronic Load Limiting Control - General...4973
7.3.2 Microcontroller RC4-4...4975
7.3.3 Checks and adjustments...4977
7.4 Hydraulic Constant Regulation System...4984
7.4.1 General...4985
7.4.2 X1 Pressure adjustment (constant pressure)...4986
7.5 Determination of the peak point (engine performance)...4988
7.6 Engine speed sensor (pick-up)...4990
7.6.1 General...4991
7.6.2 Engine speed sensor (pick-up) adjustment...4991
7.7 Energy Efficiency...4992
7.7.1 General...4993
7.7.2 Checks and adjustments...4994
8. OPERATING HYDRAULICS...4999
8.1 General...5000
8.1.1 Floating system...5002
8.2 Hydraulics for the attachment cylinder FSA and BHA...5004
8.2.1 Electric / hydraulic flowchart "boom raise" FSA...5004
8.2.2 Electric / hydraulic flowchart "boom raise" BHA...5006
8.2.3 Electric / hydraulic flowchart "boom lowering" FSA...5008
8.2.4 Electric / hydraulic flowchart "boom lowering" BHA...5010
8.2.5 Electric / hydraulic flowchart "stick extend" FSA...5012
8.2.6 Electric / hydraulic flowchart "stick extend" BHA...5014
8.2.7 Electric / hydraulic flowchart "stick retract" FSA...5016
8.2.8 Electric / hydraulic flowchart "stick retract" BHA...5018
8.2.9 Electric / hydraulic flowchart "bucket curl" FSA...5020
8.2.10 Electric / hydraulic flowchart "bucket curl" BHA...5022
8.2.11 Electric / hydraulic flowchart "bucket dump" FSA...5024
8.2.12 Electric / hydraulic flowchart "bucket dump" BHA...5026
8.2.13 Electric / hydraulic flowchart "clam Open" FSA...5028
8.2.14 Electric / hydraulic flowchart "clam close" FSA...5030
8.2.15 Checks and adjustments of the main relief valves (FSA)...5032
8.2.16 Checks and adjustments of the main relief valves (BHA)...5034
8.2.17 Checks and adjustments of the secondary relief valves (SRV)...5036
8.2.17.1 Boom cylinder "Piston Side" FSA + BHA...5037
8.2.17.2 Boom Cylinder "Piston Rod Side" FSA +BHA...5041
8.2.17.3 Stick Cylinder "Piston Side" FSA...5045
8.2.17.4 Stick Cylinder "Piston Side" BHA...5049
8.2.18 Stick cylinder "piston rod side" FSA...5053
8.2.18.1 Stick Cylinder "Piston Rod Side" BHA...5057
8.2.18.2 Bucket Cylinder "Piston Side" FSA...5061
8.2.18.3 Bucket Cylinder "Piston Side" BHA...5065
8.2.18.4 Bucket Cylinder "Piston Rod Side" FSA...5069
8.2.18.5 Bucket Cylinder "Piston Rod Side" BHA...5073
8.2.18.6 Clam Cylinder "Piston Rod Side" FSA...5077
8.2.18.7 Clam Cylinder "Piston Side" FSA...5079
8.2.18.8 Checks and Adjustments of the Lowering Speed...5081
8.3 Hydraulics for the swing circuit...5100
8.3.1 Swing circuit...5100
8.3.2 Swing motor...5104
8.3.3 Swing gearbox (L & S)...5106
8.3.4 Swing gearbox (Siebenhaar)...5108
8.3.5 Slew parking brake (L & S)...5110
8.3.6 Slew parking brake (Siebenhaar)...5112
8.3.7 Swing brake valve...5114
8.3.8 Electric / hydraulic flowchart "swing left"...5116
8.3.9 Electric / hydraulic flowchart "swing right"...5118
8.3.10 Checks and adjustments for the swing circuit...5120
8.3.11 Function check for the hydraulic swing brake...5126
8.3.12 Function check for the slew parking brake...5128
8.4 Hydraulics for the travel circuit...5130
8.4.1 Travel circuit...5130
8.4.2 Travel motor...5134
8.4.3 Rotary joint...5136
8.4.4 Travel gearbox (L & S)...5138
8.4.5 Travel gearbox (Zollern)...5140
8.4.6 Travel parking brake (gear house brake)...5142
8.4.7 Travel brake valve...5144
8.4.8 Electric / hydraulic flowchart “travel forward”...5146
8.4.9 Electric / hydraulic flowchart “travel backwards”...5148
8.4.10 Checks and adjustments for the travel circuit...5150
8.4.11 Function check for the travel parking brake...5152
9. HYDRAULIC TRACK TENSIONING SYSTEM...5155
9.1 General...5156
9.2 Functional description...5158
9.3 Pressure double stage valve...5160
9.4 Tensioning cylinder...5162
9.5 Adjustments / checks...5164
10. ACCESS LADDER, HYDRAULICALLY OPERATED...5167
10.1 General...5168
10.2 Function of Hydraulically Operated Access Ladder...5170
10.3 Adjustments / Checks...5174
11. CENTRAL REFILLING SYSTEM (SERVICE ARM)...5177
11.1 General...5178
11.2 Function...5180
12. HINTS FOR READING THE HYDRAULIC DIAGRAM...5183
12.1 General...5184
12.2 Hydraulic symbols...5186
12.2.1 Lines, unions...5187
12.2.2 Components, valves...5189
12.2.3 Sensors...5189
12.2.4 Valves, valve components...5190
12.2.5 Pump, motor, cylinder...5194
13. HINTS FOR READING THE ELECTRIC WIRING DIAGRAM...5199
13.1 General...5200
13.2 Reference designation of the electrical components...5201
13.2.1 Area code...5201
13.2.2 Component identifying letter...5203
13.3 Graphical symbols...5204
13.4 Drawing concept...5208
13.5 Cable marking...5218
13.6 Table of new and old component designations...5219
14. VEHICLE HEALTH MONITORING SYSTEM (VHMS) & MTC CONTROL SYSTEM...5255
14.1 General...5256
14.2 Specifications for Operators...5258
14.2.1 Sequence of Displays...5259
14.2.2 Opening Screen...5259
14.2.3 Main Gauge Screens 1 to 3...5260
14.2.4 Fuel Consumption Screen...5265
14.2.5 Failure message Screen for the Operator...5267
14.2.6 Main Gauge Screens - Changing of Time / SMR / Date...5269
14.2.7 Maintenance Monitor...5270
14.2.8 Settings for Operators...5272
14.2.9 Automatic Messages...5280
14.2.10 Tables of all Messages provided by the System...5283
14.2.10.1 Table of G-Codes...5284
14.2.10.2 Table of C-Codes - Diesel engines with emission standard TIER 2...5293
14.2.10.3 Table of C-Codes - Diesel engines with emission standard TIER 1...5300
14.2.10.4 Table of available Instruction Messages...5306
14.3 Flow Charts (1-4) VHMS Main Screens...5309
14.4 VHMS Service Level...5313
14.4.1 Explanation of the Button Symbols (Service Level)...5314
14.4.2 Service Menu Select Screen...5315
14.4.3 Real Time Menu Select Screen...5316
14.4.3.1 Real Time Menu, option: 01 Engine 1...5316
14.4.3.2 Real Time Menu, option: 02 PTO 1...5317
14.4.3.3 Real Time Menu, option: 03 Hydraulic...5318
14.4.3.4 Real Time Menu, option: 04 Slew...5319
14.4.3.5 Real Time Menu, option: 05 Electrical Equipment...5319
14.4.3.6 Real Time Menu, option: 06 Emergency Stop...5319
14.4.3.7 Real Time Menu, option: 07 Manual Switch...5320
14.4.3.8 Real Time Menu, option: 08 Central lUBE System 1...5321
14.4.3.9 Real Time Menu, option: 09 Slew Ring Gear Lube System...5321
14.4.3.10 Real Time Menu, option: 10 Windscreen Wiper...5322
14.4.3.11 Real Time Menu, option: 11 lADDER...5322
14.4.3.12 Real Time Menu, option: 12 Service Arm...5323
14.4.3.13 Real Time Menu, option: 13 Pilot Control...5324
14.4.3.14 Real Time Menu, option: 14 oTHER ITEMS...5325
14.4.3.15 Real Time Menu, option: 15 Output Signals...5326
14.4.3.16 Output Signals with deactivated MTC- Evaluation...5331
14.4.4 PM-Clinic...5332
14.4.4.1 General...5332
14.4.4.2 Power Check...5333
14.4.5 Serial/GCC No. Setting...5334
14.4.6 Memory Clear...5335
14.4.6.1 Input Memory Clear ID...5335
14.4.6.2 Memory Clear Screen...5336
14.4.7 Failure History...5337
14.4.8 Maintenance Monitor...5338
14.4.9 Snapshot...5339
14.4.10 Settings...5340
14.4.10.1 Central Lubrication System (CLS 1), screen 1/8...5340
14.4.10.2 Swing Lubrication System (SLS), screen 2/8...5341
14.4.10.3 Qmin - Qmax - Setting, screen 3/8...5342
14.4.10.4 Other Settings 1/2, screen 4/8...5342
14.4.10.5 Other Settings 2/2, screen 5/8...5344
14.4.10.6 Shutdown Bypass ON/OFF...5346
14.5 Interface-Connection VHMS-Controller...5348
14.5.1 VHMS-Controller...5349
14.6 Wiring of the VHMS-Controller...5350
14.7 Global Layout of the MTC Control System...5354
14.7.1 MTC (Master Turbo Controller)...5356
14.7.1.1 MTC-Flowchart...5356
14.7.1.2 MTC Features...5356
14.7.1.3 MTC-Firmware and Software...5357
14.7.1.4 View onto the MTC unit and its Connectors...5358
14.8 Global Layout of the Internal CAN bus...5360
14.8.1 General Information about a CAN bus System...5360
14.8.1.1 General CAN bus description...5361
14.8.1.2 CAN bus troubleshooting...5361
14.8.1.3 Can bus wiring...5362
14.8.1.4 CAN bus End Resistor...5364
14.9 The Nodes in the CAN bus System...5366
14.9.1 Global Layout...5366
14.9.2 Introduction...5367
14.9.2.1 ICN-V Features...5368
14.9.2.2 ICN-D Features...5369
14.9.3 Node DIP-Switches...5370
14.9.4 Node Box...5371
14.9.5 Node Locations on the Machine...5372
14.9.5.1 Node & Location Chart...5373
14.9.5.2 Exemplary View onto Location 11 (Cab base)...5374
15. AUTOMATIC LUBRICATION SYSTEMS...5377
15.1 General Overview CLS & SLS...5378
15.1.1 General Description...5379
15.2 Basic Function of the Lubrication Systems...5380
15.3 Central Lubrication System (CLS)...5382
15.3.1 General Information on CLS...5384
15.4 Lubrication Pump Station (SLS)...5386
15.4.1 General Information on SLS...5388
15.5 Lubrication Cycle...5389
15.5.1 Operation and Control...5389
15.5.2 Lubrication Cycle - Components...5390
15.5.3 Lubrication Cycle - Processing...5392
15.5.4 Time Segments & Switch Points of a Lubrication Cycle...5393
15.5.5 Lubrication Modes...5394
15.5.5.1 Automatic Lubrication Mode...5394
15.5.5.2 Manual Lubrication Mode...5394
15.5.5.3 VHMS Service Mode...5394
15.6 Hydraulically Driven Lube Pump...5396
15.6.1 Adjustment of Lube Pump Speed & Working Pressure...5398
15.6.1.1 Stroke Speed Adjustment...5399
15.6.1.2 Working Pressure Adjustment...5399
15.7 Lubricant Injectors...5400
15.7.1 Tightening torque for fittings at the grease incetors...5401
15.7.2 Description...5401
15.7.3 Adjustment of the Lubricant Output...5401
15.7.4 Operation Principle of Lubricant Injectors...5402
15.7.4.1 Function Description...5404
15.7.5 Connection of one or more Injectors...5405
15.8 Vent Valve...5406
15.8.1 Description...5407
15.9 End-Line Switch...5408
15.9.1 Description...5409
15.9.2 CLS End-Line Switch Adjustment...5410
15.9.3 SLS End-Line Switch Adjustment...5412
15.10 In-Line Filter...5414
15.10.1 Description...5415
15.10.2 Maintenance procedure...5415
15.11 Lubricant Level Sensor...5416
15.11.1 Description...5417
15.11.1.1 LEDs at the sonar sensor...5417
15.12 Lubrication Pinion (SLS)...5420
15.12.1 Description...5421
15.13 Commissioning...5422
15.13.1 COMMISSIONING OF THE CLS Lubrication SYSTEM...5422
15.13.2 Fine Adjustment...5423
15.13.3 COMMISSIONING OF THE SLS Lubrication SYSTEM...5424
START PAGE Structure_Function 10.pdf...0
10 STRUCTURE, FUNCTION...4655
40_TROUBLESHOOTING.pdf...0
1 SAFETY...5443
1.1 SAFETY INFORMATION...5444
1.2 OVERVIEW...5445
1.2.1 NORMAL OPERATIONS...5445
1.2.2 REGULAR MAINTENANCE...5445
1.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR...5445
1.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR...5445
1.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB...5446
1.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR...5447
1.4.1 UNDERSTANDING THE MACHINE...5447
1.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR...5447
1.4.2.1 ENSURING SAFE OPERATION...5447
1.4.3 PREPARATIONS FOR SAFE OPERATION...5447
1.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT...5447
1.4.3.2 INSPECTING THE MACHINE...5447
1.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT...5448
1.4.3.4 KEEP MACHINE CLEAN...5448
1.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT...5448
1.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT...5449
1.4.3.7 IF A PROBLEM IS FOUND...5449
1.4.4 FIRE PREVENTION...5449
1.4.4.1 PRECAUTIONS TO PREVENT FIRE...5449
1.4.4.2 ACTION IF FIRE OCCURS...5450
1.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB...5451
1.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE...5451
1.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE...5451
1.4.5.2 NO JUMPING ON OR OFF THE MACHINE...5451
1.4.5.3 NO PEOPLE ON THE ATTACHMENT...5451
1.4.5.4 WORKING IN HIGH PLACES...5451
1.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK...5452
1.4.5.6 LEAVING THE MACHINE...5452
1.4.6 BURN PREVENTION...5453
1.4.6.1 Hot coolant...5453
1.4.6.2 Hot oil...5453
1.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS...5453
1.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...5454
1.4.8.1 UNAUTHORIZED MODIFICATION...5454
1.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...5454
1.4.9 PRECAUTIONS AT JOBSITE...5455
1.4.9.1 VISIBILITY FROM OPERATOR’S SEAT...5456
1.4.9.2 CAMERA SYSTEM WITH MONITORS...5456
1.4.9.3 ENSURE GOOD VISIBILITY...5456
1.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS...5456
1.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS...5457
1.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES...5457
1.4.9.7 WORKING ON LOOSE GROUND...5458
1.4.9.8 GAS, DUST, STEAM AND SMOKE...5458
1.4.9.9 VENTILATION OF ENCLOSED AREAS...5459
1.4.10 STARTING ENGINE...5460
1.4.10.1 WARNING TAG...5460
1.4.10.2 CHECKS BEFORE STARTING ENGINE...5460
1.4.10.3 PRECAUTION WHEN STARTING ENGINE...5460
1.4.10.4 PRECAUTION IN COLD AREAS...5461
1.4.11 OPERATION...5461
1.4.11.1 CHECKS BEFORE OPERATION...5461
1.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE...5462
1.4.11.3 PRECAUTIONS WHEN travelling...5463
1.4.11.4 TRAVELLING ON SLOPES...5464
1.4.11.5 OPERATIONS ON SLOPES...5465
1.4.11.6 PROHIBITED OPERATIONS...5465
1.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES...5466
1.4.11.8 PARKING THE MACHINE...5466
1.4.11.9 TRANSPORTATION...5466
1.5 PRECAUTION FOR MAINTENANCE...5467
1.5.1 GENERAL PRECAUTIONS...5467
1.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...5468
1.5.1.2 STOP ENGINE FOR MAINTENANCE...5469
1.5.1.3 WARNING TAG...5470
1.5.1.4 KEEP WORKPLACE CLEAN AND TIDY...5471
1.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS...5471
1.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING...5472
1.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS...5472
1.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT...5473
1.5.1.9 NOISE...5473
1.5.1.10 WHEN USING A HAMMER...5473
1.5.1.11 PROPER TOOLS...5474
1.5.1.12 ACCUMULATOR...5474
1.5.1.13 PERSONNEL...5474
1.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE...5475
1.5.2.1 PRECAUTION WHEN WELDING...5475
1.5.2.2 BATTERY HANDLING...5475
1.5.3 PRECAUTIONS WITH HIGH PRESSURE Fluid...5476
1.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE...5476
1.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES...5477
1.5.3.3 REPLACEMENT OF HOSE LINES...5477
1.5.3.4 INSPECTION OF HOSE LINES...5477
1.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...5478
1.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE...5478
1.5.3.7 AIR CONDITIONING MAINTENANCE...5478
1.5.3.8 COMPRESSED AIR...5479
1.5.3.9 WASTE MATERIALS...5479
1.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS...5480
1.6.1 INSPECTION OF THE HYDRAULIC SYSTEM...5480
1.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS...5480
1.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...5480
1.7 SPECIAL SAFETY EQUIPMENT...5481
1.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB...5482
1.7.2 OBJECT HANDLING...5482
1.7.3 LIGHTING...5482
1.7.4 WARNING BEACON...5482
1.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...5482
1.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...5482
1.7.5.2 INSTRUCTIONS FOR USE...5484
1.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL...5486
1.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1)...5486
1.7.5.5 INSTRUCTIONS FOR USE...5488
2 Introduction & General Information for Troubleshooting...5489
2.1 Overview...5490
2.1.1 General advice when using troubleshooting charts...5490
2.2 General Precautions...5491
2.3 Preparations For Work...5492
2.4 Precautions During Work...5492
2.5 Precautions When Carrying Out Any Operation...5493
2.5.1 Precautions when carrying out removal work...5493
2.5.2 Precautions when carrying out installation work...5493
2.5.3 Precautions when completing the operation...5494
2.6 Fundamental Requirements for Troubleshooting...5495
2.6.1 Technical documentation...5495
2.6.2 Tools...5495
2.6.2.1 Reference Guide for Deutsch Removal Tools...5498
2.6.3 Personnel...5499
2.7 Points To Remember When Troubleshooting...5499
2.8 Sequence Of Events In Troubleshooting...5501
2.9 Checks Before Troubleshooting...5502
2.10 Handling Of Electric Equipment And Hydraulic Components...5503
2.10.1 Points to remember when handling electric equipment...5503
2.10.2 Points To Remember When Handling Hydraulic Equipment...5505
2.11 General working procedures...5508
2.11.1 Air Bleeding of Various Hydraulic Parts...5508
2.11.2 Air bleeding from the hydraulic pumps...5508
2.11.3 Air bleeding from hydraulic cylinders...5508
2.12 Cylinder bypass test...5509
2.13 Information about MTC & Nodes...5510
2.13.1 Outline of the MTC and its connector locations...5510
2.13.1.1 View onto the MTC connectors* LH & RH...5510
2.13.1.2 General description of the MTC...5510
2.13.1.3 Information about the LED indications at the MTC...5511
2.13.2 Information about the ICN-D node...5511
2.13.2.1 View onto an ICN-D node without wiring...5512
2.13.2.2 View onto the Status LEDs at the ICN-D node...5513
2.13.2.3 General information on the LED control...5513
2.13.3 Information about the ICN-V node...5515
2.13.3.1 View onto an ICN-V node...5515
2.13.3.2 View onto an open ICN-V node and its DIP-switches...5516
2.13.4 DIP switches at the ICN-D and ICN-V nodes...5517
2.14 Basics about "How to crimp"...5518
2.14.1 Stripping a wire for use with the HDT 48 crimp tool...5518
2.14.2 View onto the Deutsch crimp tool HDT 48...5518
2.14.3 Adjustment of the wire size at the Deutsch crimp tool HDT 48...5519
2.14.3.1 Wire cross section units in mm2 and AWG...5519
2.14.4 Crimping instructions (for Deutsch crimp tool HDT 48)...5520
2.15 Cable Shielding...5521
3 Mounting Locations and Connector Types...5523
3.1 Component location...5524
3.1.1 View onto the Superstructure...5524
3.1.2 Location of Engine Electrical Parts (1)...5526
3.1.3 Location of Engine Electrical Parts (2)...5528
3.1.4 Location of Hydraulic Components (1)...5529
3.1.5 Location of Hydraulic Components (2)...5531
3.1.6 Location of the Remote Control Valves...5532
3.1.7 Location of the High Pressure Sensors...5534
3.1.8 View onto the SLS and CLS Grease Barrel and the Lubrication Cycle Components...5535
3.1.9 View onto the Electrical Components in the Cab Base...5537
3.1.10 Hydraulic Oil Tank - Location of Electrical Components...5539
3.1.11 Hydraulically Operated Access Ladder...5541
3.2 Connector Types Overview...5543
4 Standard Value Table for Electrical Components...5549
5 References for Troubleshooting (CAN Bus & Node Outputs)...5561
5.1 CAN-Bus trouble or Node Output Trouble...5562
5.1.1 Trouble CAN-BUS or CAN-Hardware (G00308)...5563
5.1.2 Trouble output short-circuit (G00043)...5564
5.2 Sequence of the CAN nodes at the CAN bus...5566
5.3 Troubleshooting for Relay Monitored Node Outputs...5567
5.3.1 Relay Check...5567
G00107 - Trouble slew parking brake control 56K250a...5568
G00109 - Trouble slew parking brake control 56K250b...5568
View onto the CoDeSys HMI Visualization screen for trouble code G00107...5570
Wiring Diagram (56K250a & 56K250b) for trouble code G00107...5571
5.3.2 Output Check...5572
G00108 - Trouble slew parking brake control Output to 56K250a...5573
G00110 - Trouble slew parking brake control Output to 56K250b...5573
View onto the CoDeSys HMI Visualization screen for trouble code G00108...5575
Wiring Diagram (56K250a & 56K250b) for trouble code G00108...5576
6 Tables for Testing and Troubleshooting...5579
6.1 Index of Tables in this section...5580
6.2 Test Value Table for Temperature Sensors (PT100) g Centigrade - Volt...5581
6.3 Test Value Table for Temperature Sensors (PT100) g Centigrade - Ohm...5582
6.4 Table of Trouble Codes (G-Codes)...5583
6.5 Table of Instruction Messages...5589
6.6 Table of Binary Codes...5592
6.6.1 Table of Add-On Binary Codes for G00308...5594
6.7 Binary Output Signals on the VHMS Monitor...5595
6.8 Power Supply...5597
6.9 Cable colour identification...5598
7 Troubleshooting by Trouble Code...5599
G00001 - Trouble Shut-Off (gate) valve...5600
View onto the gap of proximity switch 40B031...5602
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR...5603
View onto the setting for SHUTDOWN BYPASS on the VHMS monitor...5603
Wiring Diagram (40B031) for trouble code G00001 (Main gate valve open)...5604
G00002 - Test speed 1800 1/min engine 1...5605
Wiring Diagram (11S041-1) for trouble code G00002...5606
G00003 - Trouble pump controller...5607
G00005 - Low hydraulic oil level...5611
Wiring Diagram, oil level label, and defined position of the attachment (G00005)...5613
G00007 - Trouble hydraulic oil level...5614
Wiring Diagram (40B004) and the defined position of the attachment (G00007)...5615
G00012 - Central lubrication system grease level too low...5616
G00013 - Slew ring gear lubr. system grease level too low...5616
Wiring Diagram (62B108 & 62B109) for trouble codes G00012 & G00013...5620
Wiring Diagram (junction box) for trouble codes G00012 & G00013...5621
G00020 - Trouble Shut-Off (gate) valve (Start blocked)...5622
View onto the gap of proximity switch 40B031 (G00020)...5624
Wiring Diagram (40B031) for trouble code G00020 (Main gate valve closed)...5625
Input signal (analog) of the proximity switch 40B031 on the REAL TIME MONITOR...5626
View onto the setting for SHUTDOWN BYPASS on the VHMS monitor...5626
G00031 - Set engine to low idle...5627
Wiring Diagram (20S030) for trouble code G00031...5628
Input signal of the engine speed switch 20S030 on the REAL TIME MONITOR...5628
G00032 - Trouble starter...5629
Wiring Diagram (Cold Start Signal) for trouble code G00032...5630
Wiring Diagram ("Engine running" signal) for trouble code G00032...5631
G00033 - Trouble VHMS-Controller...5632
G00034 - Trouble VHMS-Display...5633
G00035 - Trouble totally loss gear oil (PTO 1)...5634
View onto the location of sensor 57B175-1 at the PTO (G00035)...5636
Input signal (analog) of the PTO 1 gear oil sensor 57B175-1 on the REAL TIME MONITOR...5637
View onto the setting for SHUTDOWN BYPASS on the VHMS monitor...5637
Wiring Diagram (57B175-1) for trouble code G00035...5638
G00039 - Actuate engine speed selector switch...5639
G00043 - Trouble output short-circuit...5640
G00048 - Trouble emergency safety circuit...5641
Wiring Diagram (11K044a) for trouble code G00048...5641
G00053 - Reset emergency safety circuit...5642
G00054 - Monitoring idle position cut off...5643
Wiring Diagram (11K032) for trouble code G00054...5644
Input signal (analog) of relay 11K032 on the REAL TIME MONITOR (G00054)...5645
Exemplary view onto the VHMS Failure History (G00054)...5645
G00060 - Fire in the power house...5646
Wiring Diagram (fire alarm) for trouble code G00060...5648
Wiring Diagram (10B351 in the safety circuit) for G00060...5649
G00061 - Trouble monitoring, engine 1 speed too low...5650
Input signal (analog) of 51K003b-1 on the REAL TIME MONITOR (G00061)...5651
Wrong signal of the engine speed converter on the REAL TIME MONITOR (G00061)...5652
Wiring Diagram (engine speed) for trouble code G00061...5652
G00062 - Trouble monitoring, engine 1 speed too high...5653
Wiring Diagram (engine speed) for trouble code G00062...5654
G00063 - Trouble monitoring hydraulic oil temp...5655
Wiring Diagram (59B015) for trouble code G00063...5656
G00064 - Trouble monitoring hydraulic oil level...5657
Wiring Diagram (40B004) for trouble code G00064...5659
G00065 - Very low hydraulic oil level...5660
View onto the hydraulic oil level label...5660
G00066 - Trouble hydraulic oil temperature...5661
Wiring Diagram (57K506a-1 / 57K506b-1) and location for G00066...5663
Hydraulic oil temperature table...5663
G00067 - Trouble battery voltage too high...5664
Wiring Diagram (11T080) and component location for G00067...5665
G00067 - Input signal of 11T080 on the REAL TIME MONITOR...5665
G00069 - Trouble monitoring oil temperature gear (PTO 1)...5666
Input of 57B049-1 on the REAL TIME MONITOR (G00069)...5667
Gear oil temperature (PTO 1) on the Main Gauge Screen (G00069)...5667
Wiring Diagram (57B049-1) and component location for G00069...5668
G00070 - Trouble oil temperature gear (PTO 1)...5669
Location of the PTO 1 gear oil level dipstick and temperature sensor 57B049-1...5671
G00071 - Trouble gear lubrication (PTO 1)...5672
Wiring Diagram (57B017-1) for trouble code G00071...5673
G00081 - Trouble lubrication system...5674
Operation cycles of the lubrication systems...5676
Wiring Diagram (11K050) for trouble code G00081...5677
Wiring Diagram (pilot control slew & stick) for trouble code G00081...5678
G00086 - SHUTDOWN...5679
G00087 - Stop all movements for low idle...5680
G00090 - Trouble power supply...5681
G00099 - Trouble power supply...5681
Wiring Diagram (stabilized power supply) for G00090 & G00099...5682
G00091 - Pilot control cut out...5683
View onto the lock lever and the cover of 20S105 (G00091)...5684
G00092 - Emergency shut-down at access ladder...5685
G00093 - Emergency shut-down at valve block...5685
G00094 - Emergency shut-down at hydraulic control panel...5685
G00095 - Emergency shut-down in cabin...5685
Wiring Diagram (emergency switches) for G00092~G00095...5686
G00096 - Pilot control cut out...5687
Wiring Diagram (20S094) for trouble code G00096...5688
G00100 - Maintenance Safety Switch...5689
Wiring Diagram (50S058) for trouble code G00100...5690
G00102 - Switch off wiper [S/N 08199 only]...5691
G00103 - Faulty switch 20M004 [S/N 08199 only]...5692
Wiring Diagram 1 (wiper) for trouble code G00103 [S/N 08199 only]...5694
Wiring Diagram 2 (wiper) for trouble code G00103 [S/N 08199 only]...5695
G00104 - Trouble battery current...5696
Wiring Diagram (battery current) for trouble code G00104...5698
G00105 - Trouble battery charging current too low...5699
Wiring Diagram (11T080) for trouble code G00105...5700
G00107 - Trouble slew parking brake control 56K250a...5701
G00109 - Trouble slew parking brake control 56K250b...5701
View onto the CoDeSys HMI Visualization screen for trouble code G00107...5703
Wiring Diagram (56K250a & 56K250b) for trouble code G00107...5704
G00108 - Trouble slew parking brake control Output to 56K250a...5705
G00110 - Trouble slew parking brake control Output to 56K250b...5705
View onto the CoDeSys HMI Visualization screen for trouble code G00108...5707
Wiring Diagram (56K250a & 56K250b) for trouble code G00108...5708
G00111 - Trouble travel parking brake control 56K251a...5709
G00113 - Trouble travel parking brake control 56K251b...5709
G00112 - Trouble travel parking brake control Output to 56K251a...5710
G00114 - Trouble travel parking brake control Output to 56K251b...5710
G00115 - Trouble slew hydraulic brake control 56K252a...5711
G00117 - Trouble slew hydraulic brake control 56K252b...5711
G00116 - Trouble slew hydraulic brake control Output to 56K252a...5712
G00118 - Trouble slew hydraulic brake control Output to 56K252b...5712
G00140 - Trouble monitoring X1-1 pressure...5713
Wiring Diagram (57B085-1) for trouble code G00140...5715
G00141 - Trouble monitoring X2 pressure...5716
Wiring Diagram (57B086) for trouble code G00141...5718
G00147 - Trouble monitoring gear lubrication (PTO 1)...5719
Wiring Diagram (57B017-1) for trouble code G00147...5721
G00148 - Trouble monitoring fuel level...5722
Wiring Diagram (31B063) and component location for G00148...5724
G00151 - Trouble monitoring gear (PTO) oil filter 1...5725
Wiring Diagram (57B027-1) and component location for trouble code G00151...5727
G00154 - Trouble monitoring return oil filter...5728
Wiring Diagram (40B163) for trouble code G00154...5730
G00155 - Trouble monitoring leak oil filter...5731
Wiring Diagram (40B164) for trouble code G00155...5733
G00159 - Trouble monitoring breather filter...5734
Wiring Diagram (40B024) for trouble code G00159...5736
G00160 - Trouble monitoring engine air cleaner 1...5737
Wiring diagram (52B018-1 & 52B019-1) for trouble code G00160...5739
G00161 - Trouble monitoring battery voltage...5740
Wiring Diagram (11T080) for trouble code G00161...5742
G00162 - Trouble monitoring charging-/discharging current...5743
Wiring Diagram (battery charging current) for trouble code G00162...5745
G00164 - Trouble air cleaner 1...5746
View onto the engine air cleaner (G00164)...5747
G00165 - Trouble breather filter hydraulic oil tank...5748
Label showing temperature information and defined positions (G00165)...5749
G00166 - Trouble oil filter gear (PTO 1)...5750
View onto the PTO 1 gear oil filter with pressure sensor 57B027-1 (G00166)...5751
G00169 - Trouble return oil filter hydraulic oil tank...5752
G00170 - Trouble leak oil filter hydraulic oil tank...5753
G00176 - Trouble battery voltage too low...5754
Wiring Diagram (batteries) for trouble code G00176...5756
G00177 - Trouble battery charging circuit...5757
Wiring Diagram (measuring points 1-4) for trouble code G00177...5758
G00178 - Trouble battery charging current too high...5759
Wiring Diagram (51T017) for trouble code G00178...5760
G00179 - Trouble control pressure X1-1...5761
View onto the valve cartridge block (G00179)...5762
G00180 - Trouble pilot pressure X2 too low...5763
Valve cartridge block with X2 pressure sensor 57B086 & M1.2...5764
G00181 - Trouble pilot pressure X2 too high...5765
Valve cartridge block with X2 pressure sensor 57B086 & M1.2...5766
G00184 - Central lubrication system empty...5767
G00187 - Slew ring gear lubrication system empty...5767
Grease level (CLS & SLS) on the REAL TIME MONITOR...5768
G00185 - Trouble central lubrication system...5769
G00188 - Trouble slew ring gear lubrication system...5769
Allocation of vent valves and end-of-line switches...5770
Action chart for lube cycles...5771
View onto the vent valve (62Q507a/62Q509a)...5772
Wiring Diagram (80B043 & 62B046) for trouble codes G00185/G00188...5773
G00186 - Trouble central lubrication system...5774
G00189 - Trouble slew ring gear lubrication system...5774
Allocation of vent valves...5774
Action chart for lube cycles...5775
View onto the vent valve (62Q507a/62Q509a)...5776
G00207 - Engine remote oil tank 1 empty...5777
G00216 - Trouble software not compatible...5778
G00218 - Switch off all motors for running transfer pump...5780
G00220 - Trouble transfer pump motor overheated...5781
Wiring Diagram (transfer pump) for trouble code G00220...5782
G00223 - Trouble starter control 51K001a-1...5783
G00225 - Trouble starter control 51K001b-1...5783
G00224 - Trouble starter control Output to 51K001a-1...5784
G00226 - Trouble starter control Output to 51K001b-1...5784
G00231 - Trouble pilot control lever 20S019...5785
Wiring Diagram (20S019) for trouble code G00231...5786
Wiring Diagram (20S020) for trouble code G00232...5787
G00233 - Trouble pilot control 11Q045...5788
Wiring Diagram (11Q045) for trouble code G00233...5789
G00234 - Trouble pilot control 11K111a...5790
G00236 - Trouble pilot control 11K111b...5790
G00235 - Trouble pilot control Output to 11K111a...5791
G00237 - Trouble pilot control Output to 11K111b...5791
G00238 - Trouble supply by key switch 11Q044...5792
Input signal of 11Q044 on the REAL TIME MONITOR (G00238)...5792
Wiring Diagram (11Q044) for trouble code G00238...5793
G00240 - Trouble hydraulic oil temperature...5794
G00242 - Engine 1 already running...5795
G00243 - Fill up fuel tank...5795
G00245 - Engine shutdown from ground...5796
Input signal of 54S007 & 54S008 on the REAL TIME MONITOR (G00245)...5797
G00246 - Hydraulic oil temperature...5798
G00252 - Emergency shut-down at access ladder...5799
G00253 - Emergency shut-down at valve block...5799
G00254 - Emergency shut-down at hydraulic control panel...5799
G00255 - Emergency shut-down in cabin...5799
Wiring Diagram (emergency switches) for trouble codes G00252~G00255...5800
G00257 - Hydraulic oil temperature...5801
G00261 - Maintenance Safety Switch...5802
Wiring Diagram (50S058) for trouble code G00261...5803
G00262 - Trouble screen at hydr. cooler entry clogged...5804
40B166 and 40B165 on the REAL TIME MONITOR 03 Hydraulic (G00262)...5804
Location of 40B166 and 40B165 at the hydraulic oil tank (G00262)...5805
Wiring Diagram (40B166 & 40B165) for trouble code G00262...5806
G00308 - Trouble CAN-Bus or CAN-Hardware...5807
G00309 - Trouble ladder up 56K253a...5810
G00311 - Trouble ladder up redundant 56K253b...5810
G00310 - Trouble ladder up Output to 56K253a...5811
G00312 - Trouble ladder up redundant Output to 56K253b...5811
G00313 - Trouble ladder down 56K254a...5812
G00315 - Trouble ladder down redundant 56K254b...5812
G00314 - Trouble ladder down Output to 56K254a...5813
G00316 - Trouble ladder down redundant Output to 56K254b...5813
G00317 - Trouble service arm up 56K255a...5814
G00319 - Trouble service arm up redundant 56K255b...5814
G00318 - Trouble service arm up Output to 56K255a...5815
G00320 - Trouble service arm up redundant Output to 56K255b...5815
G00321 - Trouble service arm down 56K256a...5816
G00323 - Trouble service arm down redundant 56K256b...5816
G00322 - Trouble service arm down Output to 56K256a...5817
G00324 - Trouble service arm down redundant Output to 56K256b...5817
G00325 - Trouble service arm Input...5818
G00326 - Trouble ladder Input...5818
G00327 - Trouble parking brake Input...5818
G00328 - Trouble start Input...5818
G00330 - Trouble pilot control 11Q111...5821
Wiring Diagram (11Q111/11K126) for trouble code G00330...5823
G00331 - Automatic after_running engine 1...5824
G00333 - Trouble battery charger relay...5825
Wiring Diagram (11Q122) for trouble code G00333...5826
G00351 - Engine 1 running...5827
G00352 - Engine 1 standstill...5827
G00417 - Communication failure PLC [MTC] <=> VHMS-controller...5828
G00420 - Connector sel error...5829
G00421 - Farm sys error...5830
G00422 - Can-net sys (J1939)...5831
G00423 - Application sys error...5832
G00425 - Settings impossible to take over into the PLC...5833
Wiring Diagram overview for G00425: VHMS monitor → VHMS controller → MTC...5834
G00491 - Communication failure MH800 <=> VHMS-Controller...5835
Wiring Diagram overview for G00491: VHMS monitor (MH801) → VHMS controller...5836
8 Troubleshooting by Symptoms...5839
8.1 Symptoms of the Engine and Related Electrical System...5840
SEL001 - Engine does not start (engine does not rotate)...5840
Wiring Diagram 1 (engine start) for trouble code SEL001...5842
Wiring Diagram 2 (engine start) for trouble code SEL001...5844
SEL002 - Engine stops while in operation...5845
View onto the fuel system water separator (SEL002)...5847
SEL003 - Engine speed is hunting during boom-up movement...5848
SEL004 - Engine does not stop...5849
SEL005 - Engine lacks output (no power)...5850
Judgment Table for SEL005...5851
SEL006 - Exhaust smoke is black...5852
Judgment Table for SEL006...5853
SEL007 - Oil consumption is excessive...5854
Judgment Table for SEL007...5855
SEL008 - Oil becomes contaminated quickly...5856
Judgment Table for SEL008...5857
SEL009 - Fuel consumption is excessive...5858
Judgment Table for SEL009...5859
SEL010 - Oil is in engine coolant...5860
Judgment Table for SEL010...5861
SEL011 - Oil level rises...5862
Judgment Table for SEL011...5863
SEL012 - Coolant temperature becomes too high (overheating)...5864
Judgment Table for SEL012...5865
8.2 Symptoms of the Hydraulic System...5866
SHY001 - All the work equipment shows lack of power or slow movement (especially the "boom up" function)...5866
SHY002 - Engine speed sharply drops or engine stalls too much...5868
SHY003 - No work equipment, travel or swing movement...5870
SHY004 - Work equipment has too much hydraulic drift...5871
SHY005 - Work equipment has big time lag...5873
SHY006 - Machine deviates during travel movement...5874
SHY007 - Hydraulic system has lack of power (Energy Efficiency)...5875
SHY008 - Machine does not swing...5877
SHY009 - Swing acceleration is poor...5878
SHY010 - Excessive overrun when stopping swing...5880
SHY011 - Floating system without function...5882
SHY012 - Abnormal noise coming from SRV or MRV...5883
SHY013 - Track tensioning system without function...5884
SHY014 - Ladder does not move, or slow movement...5885
SHY015 - Refilling arm does not move, or slow movement...5887
SHY016 - The hydraulic driven grease pump does not move...5889
SHY017 - Trouble pump bearing lubrication...5891
SHY018 - Abnormal track chain movement during digging...5892
SHY019 - Swing parking brake without function...5893
SHY020 - Travel parking brake without function...5894
8.3 Symptoms of the Mechanical System...5895
SME001 - Abnormal noise is made...5895
Judgment Table for SME001...5896
SME002 - Abnormal noise around the PTO / hydraulic pumps...5897
SME003 - Vibration is excessive (engine mountings)...5899
Judgment Table for SME003...5900
SME004 - Vibration is excessive (engine torsion)...5901
SME005 - There is a big shock when stopping swing...5902
SME006 - There is a big abnormal noise when moving/stopping swing...5903
SME007 - Fan hub bearing noise is abnormal...5905
SME008 - Abnormal noise coming from a travel gearbox...5906
SME009 - Abnormal noise coming from the work equipment (lack of grease)...5908
SME010 - Abnormal idler movement...5910
SME011 - Leak at the PTO shaft seal...5911
8.4 Symptoms of Additional Systems...5913
SAD001 - Air conditioner does not work...5913
View onto the A/C unit (SAD001)...5914
SAD002 - Air conditioner compressor clutch is burnt...5915
View onto the A/C compressor and its mounting (SAD002)...5916
SAD003 - Air conditioning system defective (pipes and hoses full of moisture)...5917
SAD004 - Travel alarm does not sound...5918
Wiring Diagram (60P140) for trouble code SAD004...5919
START PAGE Troubleshooting 40.pdf...0
40 TROUBLESHOOTING...5427
50_DISASSEMBLY AND ASSEMBLY.pdf...0
Table of Contents...5923
1 Introduction...5933
1.1 Contents of this binder...5934
1.2 Preface...5935
1.2.1 Contacting the Service...5935
1.2.2 Guarantee...5935
2 SAFETY...5937
2.1 SAFETY INFORMATION...5939
2.2 OVERVIEW...5940
2.2.1 NORMAL OPERATIONS...5940
2.2.2 REGULAR MAINTENANCE...5940
2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR...5940
2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR...5940
2.3 SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB...5941
2.4 GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR...5942
2.4.1 UNDERSTANDING THE MACHINE...5942
2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR...5942
2.4.2.1 ENSURING SAFE OPERATION...5942
2.4.3 PREPARATIONS FOR SAFE OPERATION...5942
2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT...5942
2.4.3.2 INSPECTING THE MACHINE...5942
2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT...5943
2.4.3.4 KEEP MACHINE CLEAN...5943
2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT...5943
2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT...5944
2.4.3.7 IF A PROBLEM IS FOUND...5944
2.4.4 FIRE PREVENTION...5944
2.4.4.1 PRECAUTIONS TO PREVENT FIRE...5944
2.4.4.2 ACTION IF FIRE OCCURS...5945
2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB...5946
2.4.5 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE...5946
2.4.5.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE...5946
2.4.5.2 NO JUMPING ON OR OFF THE MACHINE...5946
2.4.5.3 NO PEOPLE ON THE ATTACHMENT...5946
2.4.5.4 WORKING IN HIGH PLACES...5946
2.4.5.5 LEAVING OPERATOR’S SEAT WITH LOCK...5947
2.4.5.6 LEAVING THE MACHINE...5947
2.4.6 BURN PREVENTION...5948
2.4.6.1 Hot coolant...5948
2.4.6.2 Hot oil...5948
2.4.7 PRECAUTIONS WHEN CLEANING CAB GLASS...5948
2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...5949
2.4.8.1 UNAUTHORIZED MODIFICATION...5949
2.4.8.2 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...5949
2.4.9 PRECAUTIONS AT JOBSITE...5950
2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT...5951
2.4.9.2 CAMERA SYSTEM WITH MONITORS...5951
2.4.9.3 ENSURE GOOD VISIBILITY...5951
2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS...5951
2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS...5952
2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES...5952
2.4.9.7 WORKING ON LOOSE GROUND...5953
2.4.9.8 GAS, DUST, STEAM AND SMOKE...5953
2.4.9.9 VENTILATION OF ENCLOSED AREAS...5954
2.4.10 STARTING ENGINE...5955
2.4.10.1 WARNING TAG...5955
2.4.10.2 CHECKS BEFORE STARTING ENGINE...5955
2.4.10.3 PRECAUTION WHEN STARTING ENGINE...5955
2.4.10.4 PRECAUTION IN COLD AREAS...5956
2.4.11 OPERATION...5956
2.4.11.1 CHECKS BEFORE OPERATION...5956
2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE...5957
2.4.11.3 PRECAUTIONS WHEN travelling...5958
2.4.11.4 TRAVELLING ON SLOPES...5959
2.4.11.5 OPERATIONS ON SLOPES...5960
2.4.11.6 PROHIBITED OPERATIONS...5960
2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES...5961
2.4.11.8 PARKING THE MACHINE...5961
2.4.11.9 TRANSPORTATION...5961
2.5 PRECAUTION FOR MAINTENANCE...5962
2.5.1 GENERAL PRECAUTIONS...5962
2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES...5963
2.5.1.2 STOP ENGINE FOR MAINTENANCE...5964
2.5.1.3 WARNING TAG...5965
2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY...5966
2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS...5966
2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING...5967
2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS...5967
2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT...5968
2.5.1.9 NOISE...5968
2.5.1.10 WHEN USING A HAMMER...5968
2.5.1.11 PROPER TOOLS...5969
2.5.1.12 ACCUMULATOR...5969
2.5.1.13 PERSONNEL...5969
2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE...5970
2.5.2.1 PRECAUTION WHEN WELDING...5970
2.5.2.2 BATTERY HANDLING...5970
2.5.3 PRECAUTIONS WITH HIGH PRESSURE Fluid...5971
2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE...5971
2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES...5972
2.5.3.3 REPLACEMENT OF HOSE LINES...5972
2.5.3.4 INSPECTION OF HOSE LINES...5972
2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...5973
2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE...5973
2.5.3.7 AIR CONDITIONING MAINTENANCE...5973
2.5.3.8 COMPRESSED AIR...5974
2.5.3.9 WASTE MATERIALS...5974
2.6 ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS...5975
2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM...5975
2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS...5975
2.6.3 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...5975
2.7 SPECIAL SAFETY EQUIPMENT...5976
2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB...5977
2.7.2 OBJECT HANDLING...5977
2.7.3 LIGHTING...5977
2.7.4 WARNING BEACON...5977
2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...5977
2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)...5977
2.7.5.2 INSTRUCTIONS FOR USE...5979
2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL...5981
2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1),...5981
2.7.5.5 INSTRUCTIONS FOR USE...5983
3 Superstructure...5985
3.1 Superstructure overview...5986
3.2 Diesel engine...5988
3.2.1 Removal of the Diesel engine...5988
3.2.2 Replacement of the Diesel engine...5996
3.2.3 Engine torque support and engine/PTO mounts...5998
3.2.3.1 Flexible mounts...5999
3.2.3.2 Torque support...6001
3.2.4 Alternator...6002
3.2.4.1 Removal of the alternator...6002
3.2.4.2 Replacement of the alternator...6003
3.2.5 Starter system...6004
3.2.5.1 Removal of the starter motor...6004
3.2.5.2 Replacement of the starter motor...6005
3.2.6 Batteries...6005
3.2.6.1 Removal of the batteries...6005
3.2.6.2 Replacement of the batteries...6007
3.3 Engine radiator assembly...6008
3.3.1 Radiator fan assembly...6008
3.3.1.1 Removal of the radiator fan bearing block and motor...6009
3.3.1.2 Replacement of the radiator fan bearing block and motor...6013
3.3.1.3 Removal of the radiator fan...6015
3.3.1.4 Replacement of the radiator fan...6017
3.3.2 Radiator assembly...6018
3.3.2.1 Removal of the Radiator assembly...6018
3.3.2.2 Replacement of the radiator assembly...6023
3.3.3 Fuel cooler...6024
3.3.3.1 Removal of the fuel cooler...6024
3.3.3.2 Replacement of the fuel cooler...6026
3.4 Coupling assembly...6028
3.4.1 Geislinger coupling...6028
3.4.1.1 Removal of the Geislinger coupling...6029
3.4.1.2 Replacement of the Geislinger coupling...6033
3.5 PTO...6034
3.5.1 Overview of the PTO and the mounting of the pumps...6034
3.5.2 Main pumps...6036
3.5.2.1 Preparatory works for main pump removal...6036
3.5.2.2 Removal of main pump 1...6039
3.5.2.3 Replacement of main pump 1...6041
3.5.2.4 Removal of main pump 2...6042
3.5.2.5 Replacement of main pump 2...6044
3.5.2.6 Removal of main pump 3...6045
3.5.2.7 Replacement of main pump 3...6045
3.5.2.8 Removal of main pump 4...6045
3.5.2.9 Replacement of main pump 4...6045
3.5.3 PTO oil circulation pump (auxiliary pump)...6046
3.5.3.1 Removal of the oil circulation pump (auxiliary pump)...6046
3.5.3.2 Replacement of the oil circulation pump (auxiliary pump)...6048
3.5.4 Pilot oil pump...6049
3.5.4.1 Removal of the pilot oil pump...6049
3.5.4.2 Replacement of the pilot oil pump...6049
3.5.5 Radiator drive pump...6051
3.5.5.1 Removal of the radiator fan drive pump...6051
3.5.5.2 Replacement of the radiator fan drive pump...6053
3.5.6 Hydraulic oil cooler fan drive pump...6054
3.5.6.1 Removal of the hydraulic oil cooler fan drive pump...6054
3.5.6.2 Replacement of the hydraulic oil cooler fan drive pump...6054
3.5.7 Pump distributor gearbox (PTO)...6056
3.5.7.1 Removal of the pump distributor gearbox (PTO)...6058
3.5.7.2 Replacement of the pump distributor gearbox (PTO)...6061
3.6 Hydraulics...6062
3.6.1 Hydraulic oil cooler assembly...6062
3.6.1.1 Removal of hydraulic cooler fan...6063
3.6.1.2 Replacement of hydraulic cooler fan...6064
3.6.1.3 Removal of hydraulic cooler fan bearings and motors...6065
3.6.1.4 Replacement of hydraulic cooler fan bearings and motors...6067
3.6.1.5 Removal of the hydraulic oil coolers...6068
3.6.1.6 Replacement of the hydraulic oil coolers...6071
3.6.1.7 Removal of the hydraulic oil cooler assembly...6072
3.6.1.8 Replacement of the hydraulic oil cooler assembly...6077
3.6.2 Main gate valve...6078
3.6.2.1 Removal of the main gate valve...6078
3.6.2.2 Replacement of the main gate valve...6079
3.6.3 Hydraulic oil reservoir...6080
3.6.3.1 Removal of the hydraulic oil reservoir...6081
3.6.3.2 Replacement of the hydraulic oil reservoir...6087
3.6.4 Main control valve blocks...6090
3.6.4.1 General information...6090
3.6.4.2 Removal of the main control valve blocks...6098
3.6.4.3 Replacement of the main control valve blocks...6102
3.6.5 Main relief valves (MRV)...6103
3.6.5.1 Removal of the MRV at the main control valve blocks...6103
3.6.5.2 Replacement of the MRV at the main control valve blocks...6104
3.6.6 Service line relief valves (SRV)...6107
3.6.6.1 Removal of SRV on main control valve block...6107
3.6.6.2 Replacement of SRV on main control valve blocks...6108
3.6.7 Anti-cavitation valves (ACV)...6109
3.6.7.1 Removal of single ACV at the manifold...6111
3.6.7.2 Replacement of single ACV at the manifold...6114
3.6.7.3 Removal of ACV with attached check valve at the manifold...6115
3.6.7.4 Replacement of ACV with attached check valve at the manifold...6117
3.6.7.5 Removal of ACV on main control valve blocks...6119
3.6.7.6 Replacement of ACV on main control valve blocks...6120
3.6.8 Throttle check valves...6122
3.6.8.1 Removal of throttle check valves...6125
3.6.8.2 Replacement of throttle check valves...6127
3.6.9 Diffuser block (FSA only)...6128
3.6.9.1 Removal of the Diffuser block at the manifold...6128
3.6.9.2 Replacement of the Diffuser block at the manifold...6129
3.6.10 Manifold...6130
3.6.10.1 Removal of the manifold...6130
3.6.10.2 Replacement of the manifold...6132
3.7 Slew system...6133
3.7.1 Slew gear...6133
3.7.1.1 Removal of the slew gear...6135
3.7.1.2 Replacement of the slew gear...6138
3.7.2 Swing motor...6140
3.7.2.1 Removal of the swing motor...6141
3.7.2.2 Replacement of the swing motor...6143
3.7.3 Slew parking brake...6144
3.7.3.1 Removal/disassembly of the slew parking brake (L&S)...6145
3.7.3.2 Replacement/assembly of the slew parking brake (L&S)...6148
3.7.3.3 Removal of the slew parking brake (siebenhaar)...6151
3.7.3.4 Replacement of the slew parking brake (Siebenhaar)...6154
3.7.4 Dynamic slew brake...6158
3.7.4.1 Removal of the slew brake valve...6161
3.7.4.2 Replacement of the slew brake valve...6163
3.7.5 Swing circle...6164
3.7.5.1 Removal of the swing circle...6165
3.7.5.2 Replacement of the swing circle...6168
3.7.6 Swing circle lubrication pinion (dummy wheel)...6172
3.7.6.1 Removal of the lubrication pinion assembly...6173
3.7.6.2 Replacement of the lubrication pinion assembly...6175
3.8 Lubrication pumps...6176
3.8.1 Removal of the lubrication pump...6176
3.8.2 Replacement of the lubricating pump...6178
3.9 Operator’s cab...6180
3.9.1 Removal of the operator’s cab...6182
3.9.2 Replacement of the operator’s cab...6188
3.9.3 Cab-mounts...6190
3.9.3.1 Removal of the cab-mounts...6190
3.9.3.2 replacement of the cab-mounts...6192
3.9.4 Front window...6194
3.9.4.1 Removal of the front window...6194
3.9.4.2 Replacement of the front window...6195
3.9.5 Operator’s seat...6196
3.9.5.1 Removal of the operator’s seat...6196
3.9.5.2 Replacement of the operator’s seat...6197
3.10 Cab base...6198
3.10.1 Removal of the cab base...6198
3.10.2 Replacement of the cab base...6201
3.10.3 Pump controller...6203
3.10.3.1 Removal of the pump controller...6203
3.10.3.2 Replacement of the pump controller...6203
3.10.4 VHMS...6204
3.10.4.1 Removal of the VHMS-controller...6204
3.10.4.2 Replacement of the VHMS-controller...6205
3.11 Access ladder...6206
3.11.1 Removal of the access ladder...6207
3.11.2 Replacement of the access ladder...6209
3.11.3 Removal of the access ladder cylinder...6211
3.11.4 Replacement of the access ladder cylinder...6213
3.12 Counterweight...6214
3.12.1 Removal of the counterweight...6215
3.12.2 Replacement of the counterweight...6217
3.13 Superstructure Lifting...6218
3.13.1 Remove the superstructure from the undercarriage...6218
3.13.2 Install the superstructure onto the undercarriage...6223
3.14 Fuel tank...6226
3.14.1 General information...6227
3.14.2 Removal of the fuel tank...6228
3.14.3 Replacement of the fuel tank...6234
4 Undercarriage...6237
4.1 Undercarriage overview...6238
4.2 Travel system...6240
4.2.1 Track group...6240
4.2.1.1 Changing of the track group...6240
4.2.2 Sprocket...6245
4.2.2.1 Removal of the sprocket...6245
4.2.2.2 Replacement of the sprocket...6250
4.2.3 Guide wheels...6252
4.2.3.1 Removal of the guide wheel assembly...6252
4.2.3.2 Replacement of the guide wheel assembly...6254
4.2.4 Track tensioning accumulators...6256
4.2.4.1 Removal of the low pressure accumulators...6256
4.2.4.2 Replacement of the low pressure accumulators...6258
4.2.4.3 Removal of the high pressure accumulators...6259
4.2.4.4 Replacement of the high pressure accumulators...6260
4.2.5 Track tension valve block...6261
4.2.5.1 Removal of the track tensioning valve block...6261
4.2.5.2 Replacement of the track tensioning valve block...6263
4.2.6 Track tensioning cylinders...6264
4.2.6.1 Removal of the track tensioning cylinders...6264
4.2.6.2 Replacement of the track tensioning cylinders...6266
4.2.7 Hydraulic hoses of the track tensioning system...6267
4.2.7.1 Precursory work...6267
4.2.7.2 Substitute the hydraulic hoses inside the car body...6269
4.2.7.3 Substitute the hydraulic hoses between car body and crawler frame...6269
4.2.7.4 Substitute the hydraulic hoses inside the crawler frame...6271
4.2.7.5 Subsequent work...6271
4.2.8 Travel brake valve block (overspeed valve)...6273
4.2.8.1 Removal of the travel brake valve block...6276
4.2.8.2 Replacement of the travel brake valve block...6277
4.2.9 Travel motors...6278
4.2.9.1 Removal of the travel motors...6278
4.2.9.2 Replacement of the travel motors...6280
4.2.10 Travel parking brake...6282
4.2.10.1 Travel parking brake overview...6282
4.2.10.2 Removal/disassembly of the travel parking brake (L&S)...6287
4.2.10.3 Replacement/assembly of the travel parking brake (L&S)...6290
4.2.10.4 Removal/disassembly of the travel parking brake (Zollern)...6293
4.2.10.5 Replacement/assembly of the travel parking brake (Zollern)...6296
4.2.11 Travel gear box...6298
4.2.11.1 Removal of the travel gear box...6299
4.2.11.2 Replacement of the travel gear box...6301
4.2.12 Carrier roller...6303
4.2.12.1 Removal of the carrier roller assembly...6303
4.2.12.2 Replacement of the carrier roller assembly...6306
4.2.13 Track roller...6307
4.2.13.1 Removal of the track roller assembly...6307
4.2.13.2 Replacement of the track roller assembly...6309
4.3 Car body...6310
4.3.1 Removal of the car body and the crawler carriers (type with mounting pins)...6310
4.3.2 Replacement of the car body and the crawler carriers (type with mounting pins)...6314
4.3.3 Removal of the car Body and the crawler carriers (type with bolted connection)...6318
4.3.4 Replacement of the car body and the crawler carriers (type with bolted connection)...6324
4.3.5 Rotary joint...6333
4.3.5.1 Removal of the rotary joint...6335
4.3.5.2 Replacement of the rotary joint...6338
5 Attachment...6341
5.1 Backhoe...6342
5.1.1 Boom...6343
5.1.1.1 Removal of the Boom...6343
5.1.1.2 Replacement of the boom...6346
5.1.1.3 Removal of the boom cylinders...6348
5.1.1.4 Replacement of the boom cylinders...6353
5.1.2 Stick...6358
5.1.2.1 Removal of the Stick...6358
5.1.2.2 Replacement of the Stick...6362
5.1.2.3 Removal of the Stick Cylinders...6364
5.1.2.4 Replacement of the Stick cylinders...6369
5.1.3 Bucket...6374
5.1.3.1 Removal of the bucket...6374
5.1.3.2 Replacement of the bucket...6377
5.1.3.3 Removal of the Bucket Cylinders...6378
5.1.3.4 Replacement of the Bucket Cylinders...6384
5.1.4 Bucket link rod and steering rods...6387
5.1.4.1 Removal of the bucket link rod...6387
5.1.4.2 Replacement of the bucket link rod...6389
5.1.4.3 Removal of the steering rods...6390
5.1.4.4 Replacement of the steering rods...6393
5.1.5 Ground engaging tools (GET)...6394
5.1.5.1 Removal and replacement of the GET...6394
5.1.6 Hydraulic hoses at the backhoe attachment...6396
5.1.6.1 Substitute the boom arc hoses...6396
5.1.6.2 Substitute the boom cylinder hoses...6402
5.1.6.3 Substitute the stick cylinder hoses...6406
5.1.6.4 Substitute the bucket cylinder hoses...6410
5.2 Faceshovel...6414
5.2.1 Using the installation tools for hydraulic cylinders...6415
5.2.2 Boom...6416
5.2.2.1 Removal of the boom...6416
5.2.2.2 Replacement of the boom...6423
5.2.2.3 Removal of the boom cylinders...6428
5.2.2.4 Replacement of the boom cylinders...6432
5.2.3 Stick...6436
5.2.3.1 Removal of the stick...6436
5.2.3.2 Replacement of the stick...6440
5.2.3.3 Removal of the stick cylinders...6444
5.2.3.4 Replacement of the stick cylinders...6448
5.2.4 Bull Clam bucket...6452
5.2.4.1 Removal of the bull clam bucket...6452
5.2.4.2 Replacement of the bull clam bucket...6458
5.2.4.3 Removal of the bucket cylinders...6460
5.2.4.4 Replacement of the bucket cylinders...6464
5.2.4.5 Removal of the clam cylinders...6468
5.2.4.6 Replacement of the clam cylinders...6472
5.2.5 Ground engaging tools (GET)...6475
5.2.5.1 Removal and replacement of the GET...6475
5.2.6 Hydraulic hoses at the Faceshovel attachment...6476
5.2.6.1 Substitute the boom arc hoses...6476
5.2.6.2 Substitute the boom cylinder hoses...6482
5.2.6.3 Substitute the stick arc hoses...6486
5.2.6.4 Substitute the stick cylinder hoses...6490
5.2.6.5 Substitute the bucket cylinder hoses...6494
5.2.6.6 Substitute the clam cylinder hoses...6498
5.3 Metering valves (grease injectors) at the attachment...6506
5.3.1 Operation test of the metering valves (grease injectors)...6507
5.3.2 Removal of the metering valves (grease injectors)...6508
5.3.3 Replacement of the metering valves (grease injectors)...6510
5.4 Cylinder bypass test...6511
6 Service Information...6513
6.1 Fluids and lubricants...6514
6.2 Filling capacities...6515
6.3 Work instructions...6516
6.3.1 Remove / install the crawler carrier...6516
6.4 Weight tables...6517
6.4.1 Superstructure...6517
6.4.2 Undercarriage...6519
6.4.3 Backhoe attachment (BHA)...6520
6.4.4 Face shovel attachment (FSA)...6521
6.5 Torque charts according to KOMATSU company standard...6522
6.5.1 Metric standard thread...6522
6.5.2 Metric fine thread...6523
6.5.3 Cummins motor torques - metric...6524
6.5.4 Cummins motor torques - U.S. customary...6524
6.5.5 Flange connections...6525
6.6 Blind plugs...6526
6.6.1 Dummy plates for SAE–flanges...6526
6.6.2 Classification of threads to the nominal width...6528
6.6.3 Plugs and fittings according to DIN 2353...6529
6.7 Conversion table...6530
6.7.1 Method of using the conversion table...6530
6.7.2 Millimeter - inch & kilogram - pound...6531
6.7.3 Liter - U.S. gallon & liter - U.K. gallon...6532
6.7.4 Nm- ft.lb...6533
6.7.5 Bar - PSI - kPa - MPa...6534
6.7.6 Basic values in Ohm according to ISO 43 76...6535
6.7.7 Temperature...6536
6.8 Tools...6537
6.8.1 Standard tool case...6537
6.8.2 Used special tools (Overview)...6539
7 Tools catalogue...6541
8 Parts & Service News...6597
8.1 List of the PARTS AND SERVICE NEWS...6598
AH00511h...6601
AH00514...6623
AH00515c...6635
AH01512...6645
AH01531...6653
AH02513...6663
AH02521...6667
AH03506...6677
AH03509...6683
AH03510...6709
AH03538...6729
AH04518...6755
AH05510...6757
AH05518...6763
AH05535...6765
AH05537...6789
AH05546...6805
AH06524...6807
AH06530...6809
AH06544...6811
AH06545...6823
AH08502...6827
AH08504...6835
AH08508...6837
AH08512...6841
AH09522...6861
AH10530...6863
9 Supplier’s documentation...7007
START PAGE Disassembly and Assembly 50.pdf...0
50 DISASSEMBLY AND ASSEMBLY...5921
SMPC40008152 - Hydraulic Mining Shovel PC4000-6 Shop Manual...7034
Cover...7034
Contents...7035
TABLE OF CONTENTS...7035
SAFETY - FOREWORD...7036
SAFETY NOTICE...7036
GENERAL PRECAUTIONS...7036
PREPARATIONS FOR WORK...7037
PRECAUTIONS DURING WORK...7037
FOREWORD...7039
HOISTING INSTRUCTIONS...7040
HOISTING...7040
WIRE ROPES...7040
STANDARD TIGHTENING TORQUE...7042
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...7042
CONVERSION TABLE...7043
METHOD OF USING THE CONVERSION TABLE...7043
TEMPERATURE...7049
Section 1.0 - Main Assembly Groups...7050
Table of contents Section 1.0 - Main assembly groups...7050
1.0 - Main Assembly Groups - General lay out...7052
1.1 Superstructure...7054
1.1.1 Machine house...7056
1.1.2 Hydraulic Oil Reservoir...7058
1.1.3 Hydraulic Oil Cooler...7060
1.1.4 Fuel tank (Fuel reservoir)...7062
1.1.5 Counter weight...7064
1.1.6 Cab support...7066
1.1.7 Operators cab...7068
1.1.8 Control blocks...7070
1.1.9 Swing gears...7072
1.2 Under carriage...7074
1.3 Attachment...7076
1.3.1 Backhoe attachment (BHA)...7076
1.3.2 Front Shovel Attachment (FSA)...7078
Section 2.0 - Drive...7079
Table of contents Section 2.0 - Drive...7079
2.0 Prime Drive Assembly - General Lay Out...7081
2.1 Engine and PTO mounts...7083
2.2 Coupling...7087
2.3 Air Filter...7089
2.4 Fan drive and radiator assembly...7091
2.5 Radiator fan drive speed adjustment...7095
2.6 Pump distributor gearbox (PTO)...7099
2.7 Pump-spline lubrication...7101
2.8 PTO Lubrication and cooling...7103
2.9 Hydraulic pumps – location, drive speed and flow rates...7107
Section 3.0 - Hydraulic Oil Reservoir...7108
Table of contents Section 3.0 - Hydraulic Oil Reservoir...7108
3.0 Hydraulic Oil Reservoir - General Lay Out...7110
3.1 Main oil tank, location of switches, sensors etc...7112
3.2 Suction oil tank with strainers...7114
3.3 Return oil collector tube with strainer...7116
3.4 Back pressure valve...7118
3.5 Transfer pump (Optional Equipment)...7120
3.6 Return and Leak Oil Filter...7122
3.7 Breather filter...7124
Section 4.0 - Hydraulic Oil Cooling...7125
Table of contents section 4.0 - Hydraulic Oil Cooling...7125
4.1 General...7127
4.2 Function of the hydraulic oil cooling circuit...7129
4.3 Adjustment of the Back Pressure Valve...7131
4.4 Fan drive (Two stage cooler fan RPM control)...7133
4.5 Pressure relief valves and solenoid valve...7135
4.5 Fixed Displacement Pump, with variable setting...7139
Section 5.0 - Controlling...7140
Table of contents Section 5.0 - Controlling...7140
5.0 General Lay Out...7142
5.1 Control and filter panel location of components...7144
5.2 Pilot Pressure Supply and Adjustments...7148
5.3 Remote control valves arrangement...7154
5.4 Function principle of the Electro-Hydraulic- Proportional Control...7156
5.5 Potentiometer Control (Lever, Joy Stick)...7160
5.6 Potentiometer Control (Pedal)...7162
5.7 Proportional Amplifier Module, Type A...7164
5.8 Proportional Amplifier Module, Type B...7166
5.9 Ramp Time Module...7168
5.10 Adjustments of Amplifier Modules (General)...7170
5.11 Adjusting the Amplifiers Type B, illustration (Z 21642)...7172
5.12 Adjusting the Amplifiers Type B, illustration (Z 21643)...7176
5.13 Adjusting the Ramp Time Module...7180
Section 6.0 - Components...7185
Table of contents Section 6.0 - Components...7185
6.0 Components...7185
6.1 Hydraulic...7185
6.1.1 Main Control Blocks and High Pressure Filter FSA...7187
6.1.2 Main Control Blocks and High Pressure Filter BHA...7189
6.1.3 Distributor Manifold - Location of restrictor blocks and anti cavitation valves FSA...7191
6.1.4 Distributor Manifold - Location of restrictor blocks and anti cavitation valves BHA...7193
6.1.5 Single Control Blocks (Floating) for Stick and Boom FSA...7195
6.1.6 Restrictor Block with Pressure Relief Valve...7197
6.1.7 Anti Cavitation Valve Block...7199
6.1.8 Remote control valves...7201
6.1.9 Directional Solenoid Valves (Three positions / 4-ways)...7203
6.1.10 Proportional Solenoid Valve...7205
6.1.11 High Pressure Filter...7207
6.1.12 Control Blocks and Valves...7209
6.1.13 Travel Brake Valve...7221
6.1.14 Pressure Reducing Valve...7223
6.1.15 Directional Solenoid Valves (Two positions / 4-ways)...7225
6.1.16 Pressure Increasing Valve...7227
Section 7.0 - Main Hydraulic Pumps and Pump Regulation System...7228
Table of contents Section 7.0 - Main Hyraulic Pumps and Pump Regulation System...7228
7.0 Main hydraulic pumps and pump regulation system...7230
7.1 Main Pumps...7238
7.1.1. Location of Pumps...7238
7.1.2. Pump bearing flushing / lubrication...7240
7.1.3 Operating Principles...7242
7.1.4 Checks / Adjustments...7258
7.2 Electronic Pump Regulation System...7268
7.2.1 Electronic load limiting control - general, illustration (Z 21713)...7268
7.2.2 Microcontroller MC7, illustration (Z 21716)...7270
7.2.3 Checks and adjustments...7272
Method A...7274
X1-pressure with 24V supply to separating terminals at the X2-switch board...7274
Method B...7276
With the electronic service tool (EST) BB-3 connected to the serial interface X13-1 (located in the operators cab)...7276
Language selection...7276
Excavator Type selection...7280
X1-Pressure (maximum current) Adjustment...7284
Method C...7288
With a laptop computer and BODEM software connected to the serial interface X13-1 (located in the operators cab)...7288
Language selection...7292
Excavator Type selection...7294
X1-Pressure (maximum current) Adjustment...7296
7.3 Hydraulic Constant Regulation System...7298
7.3.1. General...7298
7.3.2. X1-pressure adjustment (constant-pressure) , illustration (Z 22360)...7300
7.4 Determination of the Peak point (Engine performance) ,illustration (Z 22360)...7302
Section 8.0 - Operating Hydraulic...7303
Table of contents Section 8.0 - Operating Hydraulic...7303
8.0 General...7305
8.1 Table of Contents - Hydraulic for the Attachment Cylinders...7308
8.1.1 Electric / Hydraulic flowchart “ Boom raising ” FSA...7310
8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA...7314
8.1.3 Electric / Hydraulic flowchart “ Stick extending ” FSA...7318
8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA...7322
8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” FSA...7326
8.1.6 Electric / Hydraulic flowchart “ Bucket emptying ” FSA...7330
8.1.7 Electric / Hydraulic flowchart “ Clam opening ” FSA...7334
8.1.8 Electric / Hydraulic flowchart “ Clam closing ” FSA...7336
8.1.9 Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 21972)...7338
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z21973)...7342
Boom cylinder “Piston side” FSA + BHA...7342
Boom cylinder “Piston rod side” FSA +BHA...7346
Stick cylinder “Piston side” FSA...7350
Stick cylinder “Piston side” BHA...7354
Stick cylinder “Piston rod side” FSA...7358
Stick cylinder “Piston rod side” BHA...7362
Bucket cylinder “Piston side” FSA...7366
Bucket cylinder “Piston side” BHA...7370
Bucket cylinder “Piston rod side” FSA...7374
Bucket cylinder “Piston rod side” BHA...7378
Clam cylinder “Piston rod side” FSA...7382
Clam cylinder “Piston side” FSA...7384
8.1.11 Checks and adjustments of the lowering speed, illustration (Z 22033)...7386
General...7386
Boom cylinder FSA...7388
Boom cylinder BHA...7392
Stick cylinder FSA...7394
Stick cylinder BHA...7398
Bucket cylinder FSA...7400
Bucket cylinder BHA...7402
Clam cylinder BHA...7404
8.2 Table of Contents - Hydraulic for the Swing Circuit...7405
8.2.1 Swing Circuit...7407
8.2.2 Swing Motor...7411
8.2.3 Swing Gear Box...7415
8.2.4 Swing Parking Brake (Gear house Brake)...7417
8.2.5 Swing Brake Valve...7419
8.2.6 Electric / Hydraulic flowchart “Swing Left”...7423
8.2.7 Electric / Hydraulic flowchart “Swing Right”...7425
8.2.8 Swing Monitoring System, illustration (Z 21947)...7427
8.2.9 Checks and adjustments for the swing circuit...7431
8.2.10 Function check for the swing parking brake...7437
8.3 Table of Contents - Hydraulic for the Travel Circuit...7438
8.3.1 Travel Circuit...7440
8.3.2 Travel Motor...7444
8.3.3 Rotary Distributor...7446
8.3.4 Travel gear...7448
8.3.5 Travel parking brake (Gear house brake)...7450
8.3.6 Travel Brake Valve...7452
8.3.7 Electric / Hydraulic flowchart “Traveling forward”...7454
8.3.8 Electric / Hydraulic flowchart “Traveling backward”...7456
8.3.9 Checks and adjustments for the travel circuit...7458
8.3.10 Function check for the travel parking brake...7460
Section 9.0 - Hydraulic Track Tensioning System...7461
Table of contents Section 9.0 - Hydraulic Track Tensioning System...7461
9.0 General - Hydraulic Track Tensioning System...7463
9.1 Functional description...7465
9.2 Pressure Increasing Valve...7469
9.3 Tensioning cylinder...7471
9.4 Adjustments / Checks...7473
9.5 Functional Test...7477
Section 10.0 - Access Ladder Hydraulically Operated...7478
Table of contents Section 10.0 - Access Ladder Hydraulic Operated...7478
10.0 General...7480
10.1 Function of hydraulic operated access ladder illustration (Z 22495)...7482
Section 11.0 - Hydraulic Operated Refilling Arm...7485
Table of contents Section 11.0 - Hydraulic Operated Refilling Arm...7485
11.0 Hydraulic operated refilling arm - General...7487
11.1 Function of hydraulic operated refilling arm...7489
Section 12.0 - Hints For Reading The Hydraulic Circuit Diagram...7490
Table of contents Section 12 - Hints For Reading The Hydraulic Circuit Diagram...7490
12.0 General - Hints For Reading The Hydraulic Circuit Diagram...7491
Section 14.0 - VHMS / ECS-T / ETM...7642
Table of contents Section 14.0 - Vehicle Health Monitoring System...7642
14.0 General - VHMS...7644
14.1 Colored Graphic Console (CGC) for PC4000 - Specifications for Operators...7645
Table of contents section 14.1 - Colored Graphic Console (CGC) for PC4000...7645
14.1.1 Graphic Flow Chart...7647
14.1.2 Initialization Screen (No. 0.0)...7649
14.1.3 Operator Information Screen (No. 1.1)...7649
14.1.4 Monitoring Screens...7651
Standard Monitor 1 (No. 1.2)...7651
Expansion monitor 2 (No. 1.3)...7651
Expansion monitor 3 (No. 1.4)...7651
14.1.5 Brightness and Contrast Setting Screen (No. 1.2.1)...7653
14.1.6 Fuel Consumption Screen (No. 1.2.2)...7655
14.1.7 Settings for Operator, Screen (No. 1.2.3)...7657
Entry of the Operator identification number...7657
Resetting the Truck Counter...7657
14.1.8 Maintenance Monitor (No. 1.2.4)...7659
14.1.9 Failure Message (No. 1.2.5)...7663
Failure history for Operator...7663
14.1.10 Automatic Messages...7665
14.2 Colored Graphic Console (CGC) for PC4000 - Specifications for Servicemen...7666
Table of contents Section 14.2 - Colored Graphic Console (CGC) for PC4000...7666
14.2.1 Graphic Flow Chart...7668
14.2.2 Service ID Setup Screen (No. 2.0)...7670
14.2.3 Service Menu Select Screen (No. 3.1)...7672
14.2.4 Real Time Menu Select Screen (No. 4.1.1)...7674
Engine (No. 5.1.1 - No. 5.1.4)...7674
Engine (No. 5.2.1)...7676
Hydraulic (No. 5.3.1 - No. 5.3.7)...7678
Electrical Equipment (No. 5.4.1 - 5.4.2)...7680
Emergency Stop (No. 5.5.1 - No. 5.5.2)...7682
Manual Switch (No. 5.6.1 - No. 5.6.3)...7684
Central Lubrication System (No. 5.7.1 - No. 5.7.2)...7686
Swing Lubrication System (No. 5.8.1 - No. 5.8.2)...7688
Other Items (No. 5.9.1 - No. 5.9.3)...7690
Output Signals (No. 5.10.1 - No. 5.10.6)...7692
14.2.5 PM-Clinic (No. 4.2.1 + 4.2.2) General...7694
(No. 4.2.1 + 4.2.2) General...7694
(No. 4.2.3 – 4.2.5) Power Check...7696
14.2.6 Serial No. Setting (No. 4.3.1) Machine...7698
(No. 4.3.1) Machine...7698
(No. 4.3.2) Engine...7700
14.2.7 Memory Clear (No. 4.3.2) Input Memory Clear ID...7702
Entry of the identification number...7702
Memory Clear (No. 4.4.1) Memory Clear Screen...7704
14.2.8 Maintenance Monitor (No. 4.5 – 4.5.1) Maintenance Acknowledgement...7706
14.2.9 Failure History for Service (No. 4.6)...7708
14.2.10 Snapshot Trigger (No. 4.7)...7710
14.2.11 Settings (No. 4.8.1 – No. 4.8.10)...7712
Central Lubrication System CLS No. 4.8.1)...7712
Swing Lubrication System SLS No. 4.8.2)...7714
Other Settings 1/2 (No. 4.8.3)...7716
Language selector button...7716
Operating Hours...7716
Date Settings...7716
Time Settings...7718
GMT Ref...7718
Other Settings 2/2 (No. 4.8.4)...7720
Oil Viscosity Hydraulic...7720
Oil Viscosity Gear...7720
Messages ON/OFF...7722
PLC-autom. ON/OFF...7722
Shut Down ON / OFF (No. 4.8.5 - No. 4.8.10)...7724
14.4 Wiring of the Main Components...7725
Table of contents section 14.4 - Wiring of the Main Components...7725
14.4 Wiring of the main components...7727
14.4.1 Wiring of the engine...7729
14.4.2 Wiring of the VHMS Controller...7731
14.4.3 Wiring of the CGC Monitor...7735
14.4.4 Wiring of the PLC...7737
Section 15.0 - Lubrication Systems...7738
Introduction...7738
General Contents...7740
Table of Contents Chapter 1 - Hydraulically Driven Lube Pump...7741
Function - Hydraulically Driven Lube Pump Power Master III...7743
Oscillation Cylinder and Control Block, illustration Z 21174...7747
Adjustments (illustration Z21175)...7749
Table of Contents Chapter 2 - One Line System With Hydraulically Driven "Power Master III" Pump...7750
Function Central Lubrication System...7752
Electrical Function...7756
Sonar Sensor For Grease Level...7760
Adjustments...7762
End Line Pressure Switch...7762
Injectors...7764
Table of Contents Chapter 3 - Pinion Type System With Hydr. Driven "Power Master III" Pump...7765
Function Pinion type (dummy wheel) system...7767
Electrical Function (dummy wheel) system...7771
Lubricant Level Monitoring...7775
Adjustments...7777
End-Of-Line Switch Setting...7777
Injectors...7779
Table of Contents Chapter 4 - Components...7780
Hydraulically Drive Lube Pump...7782
Lubricant Injectors...7786
End-Of-Line Switch...7792
Filter...7794
Vent valve (Solenoid valve)...7796
Magnetventile Solenoid Valves - Owner's Manual...7797
Table of Content...7798
Safety Instructions...7798
Application...7799
Examples of Application...7799
Erection and Installation...7799
Operating Instructions...7799
Type Identification...7800
Troubleshooting...7801
Technical Data...7801
Electrical Data...7801
Dimensions...7802
Troubleshooting Flowcharts 898 688 40 (50 Pages)...7805
Flowcharts 898 688 40 (Page 1 of 50)...7805
Flowcharts 898 688 40 (Page 2 of 50)...7806
Flowcharts 898 688 40 (Page 3 of 50)...7807
Flowcharts 898 688 40 (Page 4 of 50)...7808
Flowcharts 898 688 40 (Page 5 of 50)...7809
Flowcharts 898 688 40 (Page 6 of 50)...7810
Flowcharts 898 688 40 (Page 7 of 50)...7811
Flowcharts 898 688 40 (Page 8 of 50)...7812
Flowcharts 898 688 40 (Page 9 of 50)...7813
Flowcharts 898 688 40 (Page 10 of 50)...7814
Flowcharts 898 688 40 (Page 11 of 50)...7815
Flowcharts 898 688 40 (Page 12 of 50)...7816
Flowcharts 898 688 40 (Page 13 of 50)...7817
Flowcharts 898 688 40 (Page 14 of 50)...7818
Flowcharts 898 688 40 (Page 15 of 50)...7819
Flowcharts 898 688 40 (Page 16 of 50)...7820
Flowcharts 898 688 40 (Page 17 of 50)...7821
Flowcharts 898 688 40 (Page 18 of 50)...7822
Flowcharts 898 688 40 (Page 19 of 50)...7823
Flowcharts 898 688 40 (Page 20 of 50)...7824
Flowcharts 898 688 40 (Page 21 of 50)...7825
Flowcharts 898 688 40 (Page 22 of 50)...7826
Flowcharts 898 688 40 (Page 23 of 50)...7827
Flowcharts 898 688 40 (Page 24 of 50)...7828
Flowcharts 898 688 40 (Page 25 of 50)...7829
Flowcharts 898 688 40 (Page 26 of 50)...7830
Flowcharts 898 688 40 (Page 27 of 50)...7831
Flowcharts 898 688 40 (Page 28 of 50)...7832
Flowcharts 898 688 40 (Page 29 of 50)...7833
Flowcharts 898 688 40 (Page 30 of 50)...7834
Flowcharts 898 688 40 (Page 31 of 50)...7835
Flowcharts 898 688 40 (Page 32 of 50)...7836
Flowcharts 898 688 40 (Page 33 of 50)...7837
Flowcharts 898 688 40 (Page 34 of 50)...7838
Flowcharts 898 688 40 (Page 35 of 50)...7839
Flowcharts 898 688 40 (Page 36 of 50)...7840
Flowcharts 898 688 40 (Page 37 of 50)...7841
Flowcharts 898 688 40 (Page 38 of 50)...7842
Flowcharts 898 688 40 (Page 39 of 50)...7843
Flowcharts 898 688 40 (Page 40 of 50)...7844
Flowcharts 898 688 40 (Page 41 of 50)...7845
Flowcharts 898 688 40 (Page 42 of 50)...7846
Flowcharts 898 688 40 (Page 43 of 50)...7847
Flowcharts 898 688 40 (Page 44 of 50)...7848
Flowcharts 898 688 40 (Page 45 of 50)...7849
Flowcharts 898 688 40 (Page 46 of 50)...7850
Flowcharts 898 688 40 (Page 47 of 50)...7851
Flowcharts 898 688 40 (Page 48 of 50)...7852
Flowcharts 898 688 40 (Page 49 of 50)...7853
Flowcharts 898 688 40 (Page 50 of 50)...7854
SMPC40008155 - Hydraulic Mining Shovel PC4000-6 Shop Manual...7855
Cover...7855
Contents...7856
TABLE OF CONTENTS...7856
SAFETY - FOREWORD...7857
SAFETY NOTICE...7857
GENERAL PRECAUTIONS...7857
PREPARATIONS FOR WORK...7858
PRECAUTIONS DURING WORK...7858
FOREWORD...7860
HOISTING INSTRUCTIONS...7861
HOISTING...7861
WIRE ROPES...7861
STANDARD TIGHTENING TORQUE...7863
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...7863
CONVERSION TABLE...7864
METHOD OF USING THE CONVERSION TABLE...7864
TEMPERATURE...7870
Section 1.0 - Main Assembly Groups...7871
Table of contents Section 1.0 - Main assembly groups...7871
1.0 - Main Assembly Groups - General lay out...7873
1.1 Superstructure...7875
1.1.1 Machine house...7877
1.1.2 Hydraulic Oil Reservoir...7879
1.1.3 Hydraulic Oil Cooler...7881
1.1.4 Fuel tank (Fuel reservoir)...7883
1.1.5 Counter weight...7885
1.1.6 Cab support...7887
1.1.7 Operators cab...7889
1.1.8 Control blocks...7891
1.1.9 Swing gears...7893
1.2 Under carriage...7895
1.3 Attachment...7897
1.3.1 Backhoe attachment (BHA)...7897
1.3.2 Front Shovel Attachment (FSA)...7899
Section 2.0 - Drive...7900
Table of contents Section 2.0 - Drive...7900
2.0 Prime Drive Assembly - General Lay Out...7902
2.1 Engine and PTO mounts...7904
2.2 Coupling...7908
2.3 Air Filter...7910
2.4 Fan drive and radiator assembly...7912
2.5 Radiator fan drive speed adjustment...7916
2.6 Pump distributor gearbox (PTO)...7920
2.7 Pump-spline lubrication...7922
2.8 PTO Lubrication and cooling...7924
2.9 Hydraulic pumps – location, drive speed and flow rates...7928
Section 3.0 - Hydraulic Oil Reservoir...7929
Table of contents Section 3.0 - Hydraulic Oil Reservoir...7929
3.0 Hydraulic Oil Reservoir - General Lay Out...7931
3.1 Main oil tank, location of switches, sensors etc...7933
3.2 Suction oil tank with strainers...7935
3.3 Return oil collector tube with strainer...7937
3.4 Back pressure valve...7939
3.5 Transfer pump (Optional Equipment)...7941
3.6 Return and Leak Oil Filter...7943
3.7 Breather filter...7945
Section 4.0 - Hydraulic Oil Cooling...7946
Table of contents section 4.0 - Hydraulic Oil Cooling...7946
4.1 General...7948
4.2 Function of the hydraulic oil cooling circuit...7950
4.3 Adjustment of the Back Pressure Valve...7952
4.4 Fan drive (Two stage cooler fan RPM control)...7954
4.5 Pressure relief valves and solenoid valve...7956
4.5 Fixed Displacement Pump, with variable setting...7960
Section 5.0 - Controlling...7961
Table of contents Section 5.0 - Controlling...7961
5.0 General Lay Out...7963
5.1 Control and filter panel location of components...7965
5.2 Pilot Pressure Supply and Adjustments...7969
5.3 Remote control valves arrangement...7975
5.4 Function principle of the Electro-Hydraulic- Proportional Control...7977
5.5 Potentiometer Control (Lever, Joy Stick)...7981
5.6 Potentiometer Control (Pedal)...7983
5.7 Proportional Amplifier Module, Type A...7985
5.8 Proportional Amplifier Module, Type B...7987
5.9 Ramp Time Module...7989
5.10 Adjustments of Amplifier Modules (General)...7991
5.11 Adjusting the Amplifiers Type B, illustration (Z 21642)...7993
5.12 Adjusting the Amplifiers Type B, illustration (Z 21643)...7997
5.13 Adjusting the Ramp Time Module...8001
Section 6.0 - Components...8006
Table of contents Section 6.0 - Components...8006
6.0 Components...8006
6.1 Hydraulic...8006
6.1.1 Main Control Blocks and High Pressure Filter FSA...8008
6.1.2 Main Control Blocks and High Pressure Filter BHA...8010
6.1.3 Distributor Manifold - Location of restrictor blocks and anti cavitation valves FSA...8012
6.1.4 Distributor Manifold - Location of restrictor blocks and anti cavitation valves BHA...8014
6.1.5 Single Control Blocks (Floating) for Stick and Boom FSA...8016
6.1.6 Restrictor Block with Pressure Relief Valve...8018
6.1.7 Anti Cavitation Valve Block...8020
6.1.8 Remote control valves...8022
6.1.9 Directional Solenoid Valves (Three positions / 4-ways)...8024
6.1.10 Proportional Solenoid Valve...8026
6.1.11 High Pressure Filter...8028
6.1.12 Control Blocks and Valves...8030
6.1.13 Travel Brake Valve...8042
6.1.14 Pressure Reducing Valve...8044
6.1.15 Directional Solenoid Valves (Two positions / 4-ways)...8046
6.1.16 Pressure Increasing Valve...8048
Section 7.0 - Main Hydraulic Pumps and Pump Regulation System...8049
Table of contents Section 7.0 - Main Hyraulic Pumps and Pump Regulation System...8049
7.0 Main hydraulic pumps and pump regulation system...8051
7.1 Main Pumps...8059
7.1.1. Location of Pumps...8059
7.1.2. Pump bearing flushing / lubrication...8061
7.1.3 Operating Principles...8063
7.1.4 Checks / Adjustments...8079
7.2 Electronic Pump Regulation System...8089
7.2.1 Electronic load limiting control - general, illustration (Z 21713)...8089
7.2.2 Microcontroller MC7, illustration (Z 21716)...8091
7.2.3 Checks and adjustments...8093
Method A...8095
X1-pressure with 24V supply to separating terminals at the X2-switch board...8095
Method B...8097
With the electronic service tool (EST) BB-3 connected to the serial interface X13-1 (located in the operators cab)...8097
Language selection...8097
Excavator Type selection...8101
X1-Pressure (maximum current) Adjustment...8105
Method C...8109
With a laptop computer and BODEM software connected to the serial interface X13-1 (located in the operators cab)...8109
Language selection...8113
Excavator Type selection...8115
X1-Pressure (maximum current) Adjustment...8117
7.3 Hydraulic Constant Regulation System...8119
7.3.1. General...8119
7.3.2. X1-pressure adjustment (constant-pressure) , illustration (Z 22360)...8121
7.4 Determination of the Peak point (Engine performance) ,illustration (Z 22360)...8123
Section 8.0 - Operating Hydraulic...8124
Table of contents Section 8.0 - Operating Hydraulic...8124
8.0 General...8126
8.1 Table of Contents - Hydraulic for the Attachment Cylinders...8129
8.1.1 Electric / Hydraulic flowchart “ Boom raising ” FSA...8131
8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA...8135
8.1.3 Electric / Hydraulic flowchart “ Stick extending ” FSA...8139
8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA...8143
8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” FSA...8147
8.1.6 Electric / Hydraulic flowchart “ Bucket emptying ” FSA...8151
8.1.7 Electric / Hydraulic flowchart “ Clam opening ” FSA...8155
8.1.8 Electric / Hydraulic flowchart “ Clam closing ” FSA...8157
8.1.9 Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 21972)...8159
8.1.10 Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z21973)...8163
Boom cylinder “Piston side” FSA + BHA...8163
Boom cylinder “Piston rod side” FSA +BHA...8167
Stick cylinder “Piston side” FSA...8171
Stick cylinder “Piston side” BHA...8175
Stick cylinder “Piston rod side” FSA...8179
Stick cylinder “Piston rod side” BHA...8183
Bucket cylinder “Piston side” FSA...8187
Bucket cylinder “Piston side” BHA...8191
Bucket cylinder “Piston rod side” FSA...8195
Bucket cylinder “Piston rod side” BHA...8199
Clam cylinder “Piston rod side” FSA...8203
Clam cylinder “Piston side” FSA...8205
8.1.11 Checks and adjustments of the lowering speed, illustration (Z 22033)...8207
General...8207
Boom cylinder FSA...8209
Boom cylinder BHA...8213
Stick cylinder FSA...8215
Stick cylinder BHA...8219
Bucket cylinder FSA...8221
Bucket cylinder BHA...8223
Clam cylinder BHA...8225
8.2 Table of Contents - Hydraulic for the Swing Circuit...8226
8.2.1 Swing Circuit...8228
8.2.2 Swing Motor...8232
8.2.3 Swing Gear Box...8236
8.2.4 Swing Parking Brake (Gear house Brake)...8238
8.2.5 Swing Brake Valve...8240
8.2.6 Electric / Hydraulic flowchart “Swing Left”...8244
8.2.7 Electric / Hydraulic flowchart “Swing Right”...8246
8.2.8 Swing Monitoring System, illustration (Z 21947)...8248
8.2.9 Checks and adjustments for the swing circuit...8252
8.2.10 Function check for the swing parking brake...8258
8.3 Table of Contents - Hydraulic for the Travel Circuit...8259
8.3.1 Travel Circuit...8261
8.3.2 Travel Motor...8265
8.3.3 Rotary Distributor...8267
8.3.4 Travel gear...8269
8.3.5 Travel parking brake (Gear house brake)...8271
8.3.6 Travel Brake Valve...8273
8.3.7 Electric / Hydraulic flowchart “Traveling forward”...8275
8.3.8 Electric / Hydraulic flowchart “Traveling backward”...8277
8.3.9 Checks and adjustments for the travel circuit...8279
8.3.10 Function check for the travel parking brake...8281
Section 9.0 - Hydraulic Track Tensioning System...8282
Table of contents Section 9.0 - Hydraulic Track Tensioning System...8282
9.0 General - Hydraulic Track Tensioning System...8284
9.1 Functional description...8286
9.2 Pressure Increasing Valve...8290
9.3 Tensioning cylinder...8292
9.4 Adjustments / Checks...8294
9.5 Functional Test...8298
Section 10.0 - Access Ladder Hydraulically Operated...8299
Table of contents Section 10.0 - Access Ladder Hydraulic Operated...8299
10.0 General...8301
10.1 Function of hydraulic operated access ladder illustration (Z 22495)...8303
Section 11.0 - Hydraulic Operated Refilling Arm...8306
Table of contents Section 11.0 - Hydraulic Operated Refilling Arm...8306
11.0 Hydraulic operated refilling arm - General...8308
11.1 Function of hydraulic operated refilling arm...8310
Section 12.0 - Hints For Reading The Hydraulic Circuit Diagram...8311
Table of contents Section 12 - Hints For Reading The Hydraulic Circuit Diagram...8311
12.0 General - Hints For Reading The Hydraulic Circuit Diagram...8312
12.1 Legend for the circuit diagram...8313
12.2 How to read the circuit diagram...8321
Hydraulic Plans 897 969 40 - (9 Pages)...8322
Hydraulic Plan 897 969 40 (Page 1 of 9)...8322
Hydraulic Plan 897 969 40 (Page 2 of 9)...8323
Hydraulic Plan 897 969 40 (Page 3 of 9)...8324
Hydraulic Plan 897 969 40 (Page 4 of 9)...8325
Hydraulic Plan 897 969 40 (Page 5 of 9)...8326
Hydraulic Plan 897 969 40 (Page 6 of 9)...8327
Hydraulic Plan 897 969 40 (Page 7 of 9)...8328
Hydraulic Plan 897 969 40 (Page 8 of 9)...8329
Hydraulic Plan 897 969 40 (Page 9 of 9)...8330
Section 13.0 - Hints For Reading The Electric Circuit Diagram...8331
Table of contents Section 13.0 - Hints For Reading The Electric Circuit Diagram...8331
13.0 Hints For Reading The Electric Circuit Diagram...8331
13.1 Designation of electrical devices...8332
13.2 Symbols...8334
13.3 General information...8338
13.4 Reading a Circuit Diagram...8342
13.5 Component list...8346
Electrical Plans 897 844 40 (64 Pages)...8399
Electrical Plans 897 844 40 (1 of 64 Pages)...8399
Electrical Plans 897 844 40 (2 of 64 Pages)...8400
Electrical Plans 897 844 40 (3 of 64 Pages)...8401
Electrical Plans 897 844 40 (4 of 64 Pages)...8402
Electrical Plans 897 844 40 (5 of 64 Pages)...8403
Electrical Plans 897 844 40 (6 of 64 Pages)...8404
Electrical Plans 897 844 40 (7 of 64 Pages)...8405
Electrical Plans 897 844 40 (8 of 64 Pages)...8406
Electrical Plans 897 844 40 (9 of 64 Pages)...8407
Electrical Plans 897 844 40 (10 of 64 Pages)...8408
Electrical Plans 897 844 40 (11 of 64 Pages)...8409
Electrical Plans 897 844 40 (12 of 64 Pages)...8410
Electrical Plans 897 844 40 (13 of 64 Pages)...8411
Electrical Plans 897 844 40 (14 of 64 Pages)...8412
Electrical Plans 897 844 40 (15 of 64 Pages)...8413
Electrical Plans 897 844 40 (16 of 64 Pages)...8414
Electrical Plans 897 844 40 (17 of 64 Pages)...8415
Electrical Plans 897 844 40 (18 of 64 Pages)...8416
Electrical Plans 897 844 40 (19 of 64 Pages)...8417
Electrical Plans 897 844 40 (20 of 64 Pages)...8418
Electrical Plans 897 844 40 (21 of 64 Pages)...8419
Electrical Plans 897 844 40 (22 of 64 Pages)...8420
Electrical Plans 897 844 40 (23 of 64 Pages)...8421
Electrical Plans 897 844 40 (24 of 64 Pages)...8422
Electrical Plans 897 844 40 (25 of 64 Pages)...8423
Electrical Plans 897 844 40 (26 of 64 Pages)...8424
Electrical Plans 897 844 40 (27 of 64 Pages)...8425
Electrical Plans 897 844 40 (28 of 64 Pages)...8426
Electrical Plans 897 844 40 (29 of 64 Pages)...8427
Electrical Plans 897 844 40 (30 of 64 Pages)...8428
Electrical Plans 897 844 40 (31 of 64 Pages)...8429
Electrical Plans 897 844 40 (32 of 64 Pages)...8430
Electrical Plans 897 844 40 (33 of 64 Pages)...8431
Electrical Plans 897 844 40 (34 of 64 Pages)...8432
Electrical Plans 897 844 40 (35 of 64 Pages)...8433
Electrical Plans 897 844 40 (36 of 64 Pages)...8434
Electrical Plans 897 844 40 (37 of 64 Pages)...8435
Electrical Plans 897 844 40 (38 of 64 Pages)...8436
Electrical Plans 897 844 40 (39 of 64 Pages)...8437
Electrical Plans 897 844 40 (40 of 64 Pages)...8438
Electrical Plans 897 844 40 (41 of 64 Pages)...8439
Electrical Plans 897 844 40 (42 of 64 Pages)...8440
Electrical Plans 897 844 40 (43 of 64 Pages)...8441
Electrical Plans 897 844 40 (44 of 64 Pages)...8442
Electrical Plans 897 844 40 (45 of 64 Pages)...8443
Electrical Plans 897 844 40 (46 of 64 Pages)...8444
Electrical Plans 897 844 40 (47 of 64 Pages)...8445
Electrical Plans 897 844 40 (48 of 64 Pages)...8446
Electrical Plans 897 844 40 (49 of 64 Pages)...8447
Electrical Plans 897 844 40 (50 of 64 Pages)...8448
Electrical Plans 897 844 40 (51 of 64 Pages)...8449
Electrical Plans 897 844 40 (52 of 64 Pages)...8450
Electrical Plans 897 844 40 (53 of 64 Pages)...8451
Electrical Plans 897 844 40 (54 of 64 Pages)...8452
Electrical Plans 897 844 40 (55 of 64 Pages)...8453
Electrical Plans 897 844 40 (56 of 64 Pages)...8454
Electrical Plans 897 844 40 (57 of 64 Pages)...8455
Electrical Plans 897 844 40 (58 of 64 Pages)...8456
Electrical Plans 897 844 40 (59 of 64 Pages)...8457
Electrical Plans 897 844 40 (60 of 64 Pages)...8458
Electrical Plans 897 844 40 (61 of 64 Pages)...8459
Electrical Plans 897 844 40 (62 of 64 Pages)...8460
Electrical Plans 897 844 40 (63 of 64 Pages)...8461
Electrical Plans 897 844 40 (64 of 64 Pages)...8462
Section 14.0 - VHMS / ECS-T / ETM...8463
Table of contents Section 14.0 - Vehicle Health Monitoring System...8463
14.0 General - VHMS...8465
14.1 Colored Graphic Console (CGC) for PC4000 - Specifications for Operators...8466
Table of contents section 14.1 - Colored Graphic Console (CGC) for PC4000...8466
14.1.1 Graphic Flow Chart...8468
14.1.2 Initialization Screen (No. 0.0)...8470
14.1.3 Operator Information Screen (No. 1.1)...8470
14.1.4 Monitoring Screens...8472
Standard Monitor 1 (No. 1.2)...8472
Expansion monitor 2 (No. 1.3)...8472
Expansion monitor 3 (No. 1.4)...8472
14.1.5 Brightness and Contrast Setting Screen (No. 1.2.1)...8474
14.1.6 Fuel Consumption Screen (No. 1.2.2)...8476
14.1.7 Settings for Operator, Screen (No. 1.2.3)...8478
Entry of the Operator identification number...8478
Resetting the Truck Counter...8478
14.1.8 Maintenance Monitor (No. 1.2.4)...8480
14.1.9 Failure Message (No. 1.2.5)...8484
Failure history for Operator...8484
14.1.10 Automatic Messages...8486
14.2 Colored Graphic Console (CGC) for PC4000 - Specifications for Servicemen...8487
Table of contents Section 14.2 - Colored Graphic Console (CGC) for PC4000...8487
14.2.1 Graphic Flow Chart...8489
14.2.2 Service ID Setup Screen (No. 2.0)...8491
14.2.3 Service Menu Select Screen (No. 3.1)...8493
14.2.4 Real Time Menu Select Screen (No. 4.1.1)...8495
Engine (No. 5.1.1 - No. 5.1.4)...8495
Engine (No. 5.2.1)...8497
Hydraulic (No. 5.3.1 - No. 5.3.7)...8499
Electrical Equipment (No. 5.4.1 - 5.4.2)...8501
Emergency Stop (No. 5.5.1 - No. 5.5.2)...8503
Manual Switch (No. 5.6.1 - No. 5.6.3)...8505
Central Lubrication System (No. 5.7.1 - No. 5.7.2)...8507
Swing Lubrication System (No. 5.8.1 - No. 5.8.2)...8509
Other Items (No. 5.9.1 - No. 5.9.3)...8511
Output Signals (No. 5.10.1 - No. 5.10.6)...8513
14.2.5 PM-Clinic (No. 4.2.1 + 4.2.2) General...8515
(No. 4.2.1 + 4.2.2) General...8515
(No. 4.2.3 – 4.2.5) Power Check...8517
14.2.6 Serial No. Setting (No. 4.3.1) Machine...8519
(No. 4.3.1) Machine...8519
(No. 4.3.2) Engine...8521
14.2.7 Memory Clear (No. 4.3.2) Input Memory Clear ID...8523
Entry of the identification number...8523
Memory Clear (No. 4.4.1) Memory Clear Screen...8525
14.2.8 Maintenance Monitor (No. 4.5 – 4.5.1) Maintenance Acknowledgement...8527
14.2.9 Failure History for Service (No. 4.6)...8529
14.2.10 Snapshot Trigger (No. 4.7)...8531
14.2.11 Settings (No. 4.8.1 – No. 4.8.10)...8533
Central Lubrication System CLS No. 4.8.1)...8533
Swing Lubrication System SLS No. 4.8.2)...8535
Other Settings 1/2 (No. 4.8.3)...8537
Language selector button...8537
Operating Hours...8537
Date Settings...8537
Time Settings...8539
GMT Ref...8539
Other Settings 2/2 (No. 4.8.4)...8541
Oil Viscosity Hydraulic...8541
Oil Viscosity Gear...8541
Messages ON/OFF...8543
PLC-autom. ON/OFF...8543
Shut Down ON / OFF (No. 4.8.5 - No. 4.8.10)...8545
14.4 Wiring of the Main Components...8546
Table of contents section 14.4 - Wiring of the Main Components...8546
14.4 Wiring of the main components...8548
14.4.1 Wiring of the engine...8550
14.4.2 Wiring of the VHMS Controller...8552
14.4.3 Wiring of the CGC Monitor...8556
14.4.4 Wiring of the PLC...8558
Section 15.0 - Lubrication Systems...8559
Introduction...8559
General Contents...8561
Table of Contents Chapter 1 - Hydraulically Driven Lube Pump...8562
Function - Hydraulically Driven Lube Pump Power Master III...8564
Oscillation Cylinder and Control Block, illustration Z 21174...8568
Adjustments (illustration Z21175)...8570
Table of Contents Chapter 2 - One Line System With Hydraulically Driven "Power Master III" Pump...8571
Function Central Lubrication System...8573
Electrical Function...8577
Sonar Sensor For Grease Level...8581
Adjustments...8583
End Line Pressure Switch...8583
Injectors...8585
Table of Contents Chapter 3 - Pinion Type System With Hydr. Driven "Power Master III" Pump...8586
Function Pinion type (dummy wheel) system...8588
Electrical Function (dummy wheel) system...8592
Lubricant Level Monitoring...8596
Adjustments...8598
End-Of-Line Switch Setting...8598
Injectors...8600
Table of Contents Chapter 4 - Components...8601
Hydraulically Drive Lube Pump...8603
Lubricant Injectors...8607
End-Of-Line Switch...8613
Filter...8615
Vent valve (Solenoid valve)...8617
Magnetventile Solenoid Valves - Owner's Manual...8618
Table of Content...8619
Safety Instructions...8619
Application...8620
Examples of Application...8620
Erection and Installation...8620
Operating Instructions...8620
Type Identification...8621
Troubleshooting...8622
Technical Data...8622
Electrical Data...8622
Dimensions...8623
Troubleshooting Elektro Plan 897 888 40 (68 Pages)...8626
Elektroplan 897 888 40 (Page 1 of 68)...8626
Elektroplan 897 888 40 (Page 2 of 68)...8627
Elektroplan 897 888 40 (Page 3 of 68)...8628
Elektroplan 897 888 40 (Page 4 of 68)...8629
Elektroplan 897 888 40 (Page 5 of 68)...8630
Elektroplan 897 888 40 (Page 6 of 68)...8631
Elektroplan 897 888 40 (Page 7 of 68)...8632
Elektroplan 897 888 40 (Page 8 of 68)...8633
Elektroplan 897 888 40 (Page 9 of 68)...8634
Elektroplan 897 888 40 (Page 10 of 68)...8635
Elektroplan 897 888 40 (Page 11 of 68)...8636
Elektroplan 897 888 40 (Page 12 of 68)...8637
Elektroplan 897 888 40 (Page 13 of 68)...8638
Elektroplan 897 888 40 (Page 14 of 68)...8639
Elektroplan 897 888 40 (Page 15 of 68)...8640
Elektroplan 897 888 40 (Page 16 of 68)...8641
Elektroplan 897 888 40 (Page 17 of 68)...8642
Elektroplan 897 888 40 (Page 18 of 68)...8643
Elektroplan 897 888 40 (Page 19 of 68)...8644
Elektroplan 897 888 40 (Page 20 of 68)...8645
Elektroplan 897 888 40 (Page 21 of 68)...8646
Elektroplan 897 888 40 (Page 22 of 68)...8647
Elektroplan 897 888 40 (Page 23 of 68)...8648
Elektroplan 897 888 40 (Page 24 of 68)...8649
Elektroplan 897 888 40 (Page 25 of 68)...8650
Elektroplan 897 888 40 (Page 26 of 68)...8651
Elektroplan 897 888 40 (Page 27 of 68)...8652
Elektroplan 897 888 40 (Page 28 of 68)...8653
Elektroplan 897 888 40 (Page 29 of 68)...8654
Elektroplan 897 888 40 (Page 30 of 68)...8655
Elektroplan 897 888 40 (Page 31 of 68)...8656
Elektroplan 897 888 40 (Page 32 of 68)...8657
Elektroplan 897 888 40 (Page 33 of 68)...8658
Elektroplan 897 888 40 (Page 34 of 68)...8659
Elektroplan 897 888 40 (Page 35 of 68)...8660
Elektroplan 897 888 40 (Page 36 of 68)...8661
Elektroplan 897 888 40 (Page 37 of 68)...8662
Elektroplan 897 888 40 (Page 38 of 68)...8663
Elektroplan 897 888 40 (Page 39 of 68)...8664
Elektroplan 897 888 40 (Page 40 of 68)...8665
Elektroplan 897 888 40 (Page 41 of 68)...8666
Elektroplan 897 888 40 (Page 42 of 68)...8667
Elektroplan 897 888 40 (Page 43 of 68)...8668
Elektroplan 897 888 40 (Page 44 of 68)...8669
Elektroplan 897 888 40 (Page 45 of 68)...8670
Elektroplan 897 888 40 (Page 46 of 68)...8671
Elektroplan 897 888 40 (Page 47 of 68)...8672
Elektroplan 897 888 40 (Page 48 of 68)...8673
Elektroplan 897 888 40 (Page 49 of 68)...8674
Elektroplan 897 888 40 (Page 50 of 68)...8675
Elektroplan 897 888 40 (Page 51 of 68)...8676
Elektroplan 897 888 40 (Page 52 of 68)...8677
Elektroplan 897 888 40 (Page 53 of 68)...8678
Elektroplan 897 888 40 (Page 54 of 68)...8679
Elektroplan 897 888 40 (Page 55 of 68)...8680
Elektroplan 897 888 40 (Page 56 of 68)...8681
Elektroplan 897 888 40 (Page 57 of 68)...8682
Elektroplan 897 888 40 (Page 58 of 68)...8683
Elektroplan 897 888 40 (Page 59 of 68)...8684
Elektroplan 897 888 40 (Page 60 of 68)...8685
Elektroplan 897 888 40 (Page 61 of 68)...8686
Elektroplan 897 888 40 (Page 62 of 68)...8687
Elektroplan 897 888 40 (Page 63 of 68)...8688
Elektroplan 897 888 40 (Page 64 of 68)...8689
Elektroplan 897 888 40 (Page 65 of 68)...8690
Elektroplan 897 888 40 (Page 66 of 68)...8691
Elektroplan 897 888 40 (Page 67 of 68)...8692
Elektroplan 897 888 40 (Page 68 of 68)...8693
Troubleshooting Hydraulic Plan 897 893 40 (9 Pages)...8694
Hydraulikplan 897 893 40 (Page 1 of 9)...8694
Hydraulikplan 897 893 40 (Page 2 of 9)...8695
Hydraulikplan 897 893 40 (Page 3 of 9)...8696
Hydraulikplan 897 893 40 (Page 4 of 9)...8697
Hydraulikplan 897 893 40 (Page 5 of 9)...8698
Hydraulikplan 897 893 40 (Page 6 of 9)...8699
Hydraulikplan 897 893 40 (Page 7 of 9)...8700
Hydraulikplan 897 893 40 (Page 8 of 9)...8701
Hydraulikplan 897 893 40 (Page 9 of 9)...8702
Troubleshooting Flowchart 897 894 40 (51 Pages)...8703
Ablaufdiagramm Flowchart 897 894 40 (Page 1 of 51)...8703
Ablaufdiagramm Flowchart 897 894 40 (Page 2 of 51)...8704
Ablaufdiagramm Flowchart 897 894 40 (Page 3 of 51)...8705
Ablaufdiagramm Flowchart 897 894 40 (Page 4 of 51)...8706
Ablaufdiagramm Flowchart 897 894 40 (Page 5 of 51)...8707
Ablaufdiagramm Flowchart 897 894 40 (Page 6 of 51)...8708
Ablaufdiagramm Flowchart 897 894 40 (Page 7 of 51)...8709
Ablaufdiagramm Flowchart 897 894 40 (Page 8 of 51)...8710
Ablaufdiagramm Flowchart 897 894 40 (Page 9 of 51)...8711
Ablaufdiagramm Flowchart 897 894 40 (Page 10 of 51)...8712
Ablaufdiagramm Flowchart 897 894 40 (Page 11 of 51)...8713
Ablaufdiagramm Flowchart 897 894 40 (Page 12 of 51)...8714
Ablaufdiagramm Flowchart 897 894 40 (Page 13 of 51)...8715
Ablaufdiagramm Flowchart 897 894 40 (Page 14 of 51)...8716
Ablaufdiagramm Flowchart 897 894 40 (Page 15 of 51)...8717
Ablaufdiagramm Flowchart 897 894 40 (Page 16 of 51)...8718
Ablaufdiagramm Flowchart 897 894 40 (Page 17 of 51)...8719
Ablaufdiagramm Flowchart 897 894 40 (Page 18 of 51)...8720
Ablaufdiagramm Flowchart 897 894 40 (Page 19 of 51)...8721
Ablaufdiagramm Flowchart 897 894 40 (Page 20 of 51)...8722
Ablaufdiagramm Flowchart 897 894 40 (Page 21 of 51)...8723
Ablaufdiagramm Flowchart 897 894 40 (Page 22 of 51)...8724
Ablaufdiagramm Flowchart 897 894 40 (Page 23 of 51)...8725
Ablaufdiagramm Flowchart 897 894 40 (Page 24 of 51)...8726
Ablaufdiagramm Flowchart 897 894 40 (Page 25 of 51)...8727
Ablaufdiagramm Flowchart 897 894 40 (Page 26 of 51)...8728
Ablaufdiagramm Flowchart 897 894 40 (Page 27 of 51)...8729
Ablaufdiagramm Flowchart 897 894 40 (Page 28 of 51)...8730
Ablaufdiagramm Flowchart 897 894 40 (Page 29 of 51)...8731
Ablaufdiagramm Flowchart 897 894 40 (Page 30 of 51)...8732
Ablaufdiagramm Flowchart 897 894 40 (Page 31 of 51)...8733
Ablaufdiagramm Flowchart 897 894 40 (Page 32 of 51)...8734
Ablaufdiagramm Flowchart 897 894 40 (Page 33 of 51)...8735
Ablaufdiagramm Flowchart 897 894 40 (Page 34 of 51)...8736
Ablaufdiagramm Flowchart 897 894 40 (Page 35 of 51)...8737
Ablaufdiagramm Flowchart 897 894 40 (Page 36 of 51)...8738
Ablaufdiagramm Flowchart 897 894 40 (Page 37 of 51)...8739
Ablaufdiagramm Flowchart 897 894 40 (Page 38 of 51)...8740
Ablaufdiagramm Flowchart 897 894 40 (Page 39 of 51)...8741
Ablaufdiagramm Flowchart 897 894 40 (Page 40 of 51)...8742
Ablaufdiagramm Flowchart 897 894 40 (Page 41 of 51)...8743
Ablaufdiagramm Flowchart 897 894 40 (Page 42 of 51)...8744
Ablaufdiagramm Flowchart 897 894 40 (Page 43 of 51)...8745
Ablaufdiagramm Flowchart 897 894 40 (Page 44 of 51)...8746
Ablaufdiagramm Flowchart 897 894 40 (Page 45 of 51)...8747
Ablaufdiagramm Flowchart 897 894 40 (Page 46 of 51)...8748
Ablaufdiagramm Flowchart 897 894 40 (Page 47 of 51)...8749
Ablaufdiagramm Flowchart 897 894 40 (Page 48 of 51)...8750
Ablaufdiagramm Flowchart 897 894 40 (Page 49 of 51)...8751
Ablaufdiagramm Flowchart 897 894 40 (Page 50 of 51)...8752
Ablaufdiagramm Flowchart 897 894 40 (Page 51 of 51)...8753
Troubleshooting Flowcharts 898 688 40 (50 Pages)...8754
Flowcharts 898 688 40 (Page 1 of 50)...8754
Flowcharts 898 688 40 (Page 2 of 50)...8755
Flowcharts 898 688 40 (Page 3 of 50)...8756
Flowcharts 898 688 40 (Page 4 of 50)...8757
Flowcharts 898 688 40 (Page 5 of 50)...8758
Flowcharts 898 688 40 (Page 6 of 50)...8759
Flowcharts 898 688 40 (Page 7 of 50)...8760
Flowcharts 898 688 40 (Page 8 of 50)...8761
Flowcharts 898 688 40 (Page 9 of 50)...8762
Flowcharts 898 688 40 (Page 10 of 50)...8763
Flowcharts 898 688 40 (Page 11 of 50)...8764
Flowcharts 898 688 40 (Page 12 of 50)...8765
Flowcharts 898 688 40 (Page 13 of 50)...8766
Flowcharts 898 688 40 (Page 14 of 50)...8767
Flowcharts 898 688 40 (Page 15 of 50)...8768
Flowcharts 898 688 40 (Page 16 of 50)...8769
Flowcharts 898 688 40 (Page 17 of 50)...8770
Flowcharts 898 688 40 (Page 18 of 50)...8771
Flowcharts 898 688 40 (Page 19 of 50)...8772
Flowcharts 898 688 40 (Page 20 of 50)...8773
Flowcharts 898 688 40 (Page 21 of 50)...8774
Flowcharts 898 688 40 (Page 22 of 50)...8775
Flowcharts 898 688 40 (Page 23 of 50)...8776
Flowcharts 898 688 40 (Page 24 of 50)...8777
Flowcharts 898 688 40 (Page 25 of 50)...8778
Flowcharts 898 688 40 (Page 26 of 50)...8779
Flowcharts 898 688 40 (Page 27 of 50)...8780
Flowcharts 898 688 40 (Page 28 of 50)...8781
Flowcharts 898 688 40 (Page 29 of 50)...8782
Flowcharts 898 688 40 (Page 30 of 50)...8783
Flowcharts 898 688 40 (Page 31 of 50)...8784
Flowcharts 898 688 40 (Page 32 of 50)...8785
Flowcharts 898 688 40 (Page 33 of 50)...8786
Flowcharts 898 688 40 (Page 34 of 50)...8787
Flowcharts 898 688 40 (Page 35 of 50)...8788
Flowcharts 898 688 40 (Page 36 of 50)...8789
Flowcharts 898 688 40 (Page 37 of 50)...8790
Flowcharts 898 688 40 (Page 38 of 50)...8791
Flowcharts 898 688 40 (Page 39 of 50)...8792
Flowcharts 898 688 40 (Page 40 of 50)...8793
Flowcharts 898 688 40 (Page 41 of 50)...8794
Flowcharts 898 688 40 (Page 42 of 50)...8795
Flowcharts 898 688 40 (Page 43 of 50)...8796
Flowcharts 898 688 40 (Page 44 of 50)...8797
Flowcharts 898 688 40 (Page 45 of 50)...8798
Flowcharts 898 688 40 (Page 46 of 50)...8799
Flowcharts 898 688 40 (Page 47 of 50)...8800
Flowcharts 898 688 40 (Page 48 of 50)...8801
Flowcharts 898 688 40 (Page 49 of 50)...8802
Flowcharts 898 688 40 (Page 50 of 50)...8803
SMPC40008170 - Hydraulic Mining Shovel PC4000-6 Shop Manual...8804
COVER...8804
CONTENTS...8806
TABLE OF CONTENTS...8806
SAFETY...8807
FOREWARD...8810
HOISTING INSTRUCTIONS...8811
STANDARD TIGHTENING TORQUE...8813
CONVERSION TABLE...8814
1.0 MAIN ASSEMBLY GROUPS...8821
1.0 MAIN ASSEMBLY GROUPS - GENERAL LAY OUT...8823
1. GENERAL LAY OUT - LEGEND FOR ILLUSTRATION\...8823
1.1 SUPERSTRUCTURE - LEGEND FOR ILLUSTRATION...8825
1.1.1 MACHINE HOUSE - LEGEND FOR ILLUSTRATION...8827
1.1.2 HYDRAULIC OIL RESERVOIR - LEGEND FOR ILLUSTRATION...8829
1.1.3 HYDRAULIC OIL COOLER - LEGEND FOR ILLUSTRATION...8831
1.1.4 FUEL TANK (FUEL RESERVOIR) - LEGEND FOR ILLUSTRATION...8833
1.1.5 COUNTERWEIGHT - LEGEND FOR ILLUSTRATION...8835
1.1.6 CAB SUPPORT - LEGEND FOR ILLUSTRATION...8837
1.1.7 OPERATOR'S CAB - LEGEND FOR ILLUSTRATION...8839
1.1.8 CONTROL BLOCKS - LEGEND FOR ILLUSTRATION...8841
1.1.9 SWING GEARS - LEGEND FOR ILLUSTRATION...8843
1.2 UNDER CARRIAGE - LEGEND FOR ILLUSTRATION...8845
1.3 ATTACHMENT - LEGEND FOR ILLUSTRATION...8847
1.3.1 BACKHOE ATTACHMENT (BHA) - LEGEND FOR ILLUSTRATION...8847
1.3.2 FRONT SHOVEL ATTACHMENT - LEGEND FOR ILLUSTRATION...8849
2.0 PRIME DRIVE ASSEMBLY...8850
2.0 PRIME DRIVE ASSEMBLY - GENERAL LAY OUT...8850
2.0 PRIME DRIVE ASSEMBLY - LEGEND FOR ILLUSTRATION...8852
2.1 ENGINE AND PTO MOUNT...8854
2.2 COUPLING...8858
2.2 COUPLING LEGEND FOR ILLUSTRATION...8858
2.3 AIR FILTER...8860
2.3 AIR FILTER - LEGEND FOR ILLUSTRATION...8860
2.4 FAN DRIVE AND RADIATOR ASSEMBLY...8862
2.4 FAN DRIVE AND RADIATOR ASSEMBLY - LEGEND FOR ILLUSTRATION...8862
2.5 RADIATOR FAN DRIVE SPEED ADJUSTMENT...8866
2.6 PUMP DISTRIBUTOR GEARBOX (PTO)...8870
2.7 PUMP-SPLINE LUBRICATION...8872
2.8 PTO LUBRICATION AND COOLING...8874
2.8 PTO LUBRICATION AND COOLING - LEGEND OF ILLUSTRATION...8874
2.9 HYDRAULIC PUMPS - LOCATION, DRIVE SPEED AND FLOW RATES...8878
3.0 HYDRAULIC OIL RESERVOIR...8879
3.0 HYDRAULIC OIL RESERVOIR GENERAL LAYOUT...8879
3.1 MAIN OIL TANK, LOCATION OF SWITCHES, SENSORS ETC...8883
3.2 SUCTION OIL TANK WITH STRAINERS...8885
3.3 RETURN OIL COLLECTOR TUBE WITH STRAINER...8887
3.4 BACK PRESSURE VALVE...8889
3.5 TRANSFER PUMP (OPTIONAL EQUIPMENT)...8891
3.6 RETURN AND LEAK OIL FILTER...8893
3.7 BREATHER FILTER...8895
4.0 HYDRAULIC OIL COOLING...8896
4.1 GENERAL...8898
4.2 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT...8900
4.3 ADJUSTMENT OF THE BACK PRESSURE VALVE...8902
4.4 FAN DRIVE (TWO STAGE COOLER FAN PRM CONTROL)...8904
4.5 PRESSURE RELIEF VALVES AND SOLENOID VALVE...8906
4.6 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING...8910
5.0 CONTROLLING...8911
5.0 GENERAL LAYOUT - LEGEND FOR ILLUSTRATIONS...8913
5.1 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS (VALVES, SWITCHES, SENSORS ETC)...8915
5.2 PILOT PRESSURE SUPPLY AND ADJUSTMENTS...8919
5.3 REMOTE CONTROL VALVES ARRANGEMENT...8925
5.4 FUNCTION PRINCIPLEOF THE ELECTRO-HYDRAULIC-PROPORTIONAL CONTROL...8927
5.5 POTENTIOMETER CONTROL (LEVER, JOY STICK)...8931
5.6 POTENTIOMETER CONTROL (PEDAL)...8933
5.7 PROPORTIONAL AMPLIFIER MODULE, TYPE A...8935
5.8 PROPORTIONAL AMPLIFIER MODULE, TYPE B...8937
5.9 RAMP TIME MODULE...8939
5.10 ADJUSTMENTS OF AMPLIFIER MODULES (GENERAL)...8941
5.11 ADJUSTING THE AMPLIFIERS TYPE B, ILLUSTRATION...8943
5.12 ADJUSTING THE AMPLIFIERS TYPE B, ILLUSTRATION...8947
5.13 ADJUSTING THE RAMP TIME MODULE...8951
6.0 COMPONENTS...8956
6.1 HYDRAULIC...8956
6.1.1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER - FRONT SHOVEL ATTACHMENT...8958
6.1.2 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER BACK HOE ATTACHMENT...8960
6.1.3 DISTRIBUTOR MAINFOLD - LOCATION OF RESTRICTOR BLOCKS AND CAVITATION VALVES - FRONT SHOVEL ATTACHMENT...8962
6.1.4 DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND CAVITATION VALVES - BACKHOE ATTACHMENT...8964
6.1.5 SINGLE CONTROL BLOCKS (FLOATING) FOR STICK AND BOOM FRONT SHOVEL ATTACHMENT...8966
6.1.6 RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE...8968
6.1.7 ANTI CAVITATION VALVE BLOCK...8970
6.1.8 REMOTE CONTROL VALVE...8972
6.1.9 DIRECTIONAL SOLENOID VALVES (THREE POSITIONS / 4-WAY)...8974
6.1.10 PROPORTIONAL SOLENOID VALVE...8976
6.1.11 HIGH PRESSURE FILTER...8978
6.1.12 CONTROL BLOCKS AND VALVES...8980
6.1.13 TRAVEL BRAKE VALVE...8992
6.1.14 PRESSURE REDUCING VALVE...8994
6.1.15 DIRECTIONAL SOLENOID VALVES (TWO POSITIONS / 4-WAYS)...8996
6.1.16 PRESSURE INCREASING VALVE...8998
7.0 MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM...8999
7.0 GENERAL LAYOUT (HYDRAULIC ONLY)...9001
7.0 GENERAL LAYOUG (PUMP REGULATION SYSTEM)...9003
7.1 MAIN PUMPS...9009
7.1.1 LOCATION OF PUMPS...9009
7.1.2 PUMP BEARING FLUSHING / LUBRICATION...9011
7.1.3 OPERATING PRINCIPLES...9013
7.1.4 CHECKS / ADJUSTMENTS...9029
7.2 ELECTRONIC PUMP REGULATION SYSTEM...9039
7.2.1 ELECTRONIC LOAD LIMITING CONTROL - GENERAL...9039
7.2.2 MICROCONTROLLER MC7...9041
7.2.3 CHECKS AND ADJUSTMENTS...9043
METHOD A X1 PRESSURE WITH 24V SUPPLY...9045
METHOD B - WITH ELECTRONIC SERVICE TOOL...9047
LANGUAGE SELECTION...9047
EXCAVATOR TYPE SELECTION...9051
X1 PRESSURE (MAXIMUM CURRENT) ADJUSTMENT...9055
METHOD C - WITH A LAPTOP COMPUTER...9059
STARTING THE PROGRAM...9059
LANGUAGE SELECTION...9063
EXCAVATOR TYPE SELECTION...9065
X1 PRESSURE (MAXIMUM CURRENT) ADJUSTMENT...9067
7.3 HYDRAULIC CONSTANT REGULATION SYSTEM...9069
7.3.1 GENERAL...9069
7.3.2 X1 PRESSURE ADJUSTMENT (CONSTANT PRESSURE)...9071
7.4 DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE)...9073
8.0 OPERATING HYDRAULIC...9074
OPERATING HYDRAULIC - GENERAL...9076
8.1 HYDRAULIC FOR THE ATTACHMENT CYLINDER FSA AND BHA...9079
8.1.1 ELECTRIC/HYDRAULIC FLOWCHART "BOOM RAISING"...9081
8.1.2 ELECTRIC/HYDRAULIC FLOWCHART "BOOM LOWERING"...9085
8.1.3 ELECTRIC/HYDRAULIC FLOWCHART "STICK EXTENDING"...9089
8.1.4 ELECTRIC/HYDRAULIC FLOWCHART "STICK RETRACTING"...9093
8.1.5 ELECTRIC/HYDRAULIC FLOWCHART "BUCKET FILLING"...9097
8.1.6 ELECTRIC/HYDRAULIC FLOWCHART "BUCKET EMPTYING"...9101
8.1.7 ELECTRIC/HYDRAULIC FLOWCHART "CLAM OPENING"...9105
8.1.8 ELECTRIC/HYDRAULIC FLOWCHARG "CLAM CLOSING"...9107
8.1.9 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES ...9109
8.1.10 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES...9113
Boom cylinder “Piston side” FSA +BHA...9115
Boom cylinder “Piston rod side” FSA +BHA...9117
Stick cylinder “Piston side” FSA...9121
Stick cylinder “Piston side” BHA...9125
Stick cylinder “Piston rod side” FSA...9129
Stick cylinder “Piston rod side” BHA...9133
Bucket cylinder “Piston side” FSA...9137
Bucket cylinder “Piston side” BHA...9141
Bucket cylinder “Piston rod side” FSA...9145
Bucket cylinder “Piston rod side” BHA...9149
Clam cylinder “Piston rod side” FSA...9153
Clam cylinder “Piston side” FSA...9155
8.1.11 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED...9157
Boom cylinder FSA...9159
Boom cylinder BHA...9163
Stick cylinder BHA...9169
Bucket cylinder FSA...9171
Bucket cylinder BHA...9173
Clam cylinder BHA...9175
8.2 HYDRAULIC FOR THE SWING CIRCUIT...9176
8.2.1 SWING CIRCUIT...9178
8.2.2 SWING MOTOR...9182
8.2.3 SWING GEAR BOX...9186
8.2.4 SWING PARKING BRAKE (GEAR HOUSE BRAKE)...9188
8.2.5 SWING BRAKE VALVE...9190
8.2.6 ELECTRIC/HYDRAULIC FLOWCHART "SWING LEFT"...9194
8.2.7 ELECTRIC/HYDRAULIC FLOWCHART "SWING RIGHT"...9196
8.2.8 SWING MONITORING SYSTEM...9198
8.2.9 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT...9202
8.2.10 FUNCTION FOR THE SWING PARKING BRAKE...9208
8.3 HYDRAULIC FOR THE SWING CIRCUIT...9209
8.3.1 TRAVEL CIRCUIT...9211
8.3.2 TRAVEL MOTOR...9215
8.3.3 ROTARY DISTRIBUTOR...9217
8.3.4 TRAVEL GEAR...9219
8.3.5 TRAVEL PARKING BRAKE (GEAR HOUSE BRAKE)...9221
8.3.6 TRAVEL BRAKE VALVE...9223
8.3.7 ELECTRIC/HYDRAULIC FLOWCHART "TRAVELING FORWARD"...9225
8.3.8 ELECTRIC/HYDRAULIC FLOWCHART "TRAVELING BACKWARD"...9227
8.3.9 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT...9229
8.3.10 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE...9231
9.0 HYDRAULIC TRACK TENSIONING SYSTEM...9232
9.0 GENERAL...9234
9.1 FUNCTIONAL DESCRIPTION...9236
9.2 PRESSURE INCREASING VALVE...9240
9.3 TENSIONING CYLINDER...9242
9.4 ADJUSTMENTS / CHECKS...9244
9.5 FUNCTIONAL TEST...9248
10.0 ACCESS LADDER HYDRAULIC OPERAGED...9249
10.0 GENERAL...9251
10.1 FUNCTION OF HYDRAULIC OPERATED ACCESS LADDER...9253
11.0 HYDRAULIC OPERATED REFILLING ARM...9256
11.0 GENERAL...9258
11.1 FUNCTION OF HYDRAULIC OPERATED REFILLING ARM...9260
12.0 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM...9261
12.0 GENERAL...9262
12.1 LEGEND FOR THE CIRCUIT DIAGRAM...9263
12.2 HOW TO READ THE CIRCUIT DIAGRAM...9271
13.0 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM...9272
13.1 DESIGNATION OF ELECTRICAL DEVICES...9274
13.2 SYMBOLS...9276
13.3 GENERAL INFORMATION...9280
13.4 READING A CIRCUIT DIAGRAM...9284
13.5 COMPONENT LIST...9288
14.0 VEHICLE HEALTH MONITORING SYSTEM...9434
DATA FLOW CONTROL OF VHMS...9435
GENERAL...9436
14.1 COLORED GRAPHIC CONSOLE (CGC) SPECS FOR OPERATORS...9413
14.1.1 GRAPHIC FLOW CHART...9415
14.1.2 INITIALIZATION SCREEN (NO. 0.0)...9417
14.1.3 OPERATOR INFORMATION SCREEN ( NO. 1.1)...9417
14.1.4 MONITORING SCREENS...9419
STANDARD MONITOR 1 (NO. 1.2)...9419
EXPANSION MONITOR 2 (NO.1.3)...9419
EXPANSION MONITOR 3 (NO. 1.4)...9419
14.1.5 BRIGHTNESS AND CONTRAST SETTING SCREEN (NO. 1.2.1)...9421
14.1.6 FUEL CONSUMPTION SCREEN (NO. 1.2.2)...9423
14.1.7 SETTINGS FOR OPERATOR, SCREEN (NO. 1.2.3)...9425
14.1.8 MAINTENANCE MONITOR (NO. 1.2.4)...9427
14.1.9 FAILURE MESSAGE ( NO. 1.2.5)...9431
14.1.10 AUTOMATIC MESSAGES...9433
14.2 COLORED GRAPHIC CONSOLE (CGC) SPECS FOR SERVICEMEN...9354
14.2.1 GRAPHIC FLOW CHART...9356
14.2.2 SERVICE ID SETUP SCREEN (NO. 2.0)...9358
14.2.3 SERVICE MENU SELECT SCREEN (NO. 3.1)...9360
14.2.4 REAL TIME MENU SELECT SCREEN (NO. 4.1.1)...9362
ENGINE 5.1.1 - 5.1.4...9362
TRANSMISSION 5.2.1...9364
HYDRAULIC 5.3.1 - 5.4.2...9366
ELECTRICAL EQUIPMENT 5.4.1 - 5.4.2...9368
EMERGENCY STOP 5.5.1...9370
MANUAL SWITCH 5.6.1 - 5.6.3...9372
CENTRAL LUBRICATION SYSTEM 5.7.1 - 5.7.2...9374
SWING LUBRICATION SYSTEM 5.8.1 - 5.8.2...9376
OTHER ITEMS 5.9.1 - 5.9.3...9378
OUTPUT SIGNALS 5.10.1 - 5.10.6...9380
14.2.5 PM-CLINIC...9382
PM CLINIC GENERAL - 4.2.1 - 4.2.2...9382
PM CLINIC POWER CHECK - 4.2.3 - 4.2.5...9384
14.2.6 SERIAL NO. SETTING ...9386
MACHINE 4.3.1...9386
ENGINE 4.3.2...9388
14.2.7 MEMORY CLEAR...9390
INPUT ID 4.3.2...9390
MEMORY CLEAR 4.4.1...9392
14.2.8 MAINTENANCE MONITOR - MAINTENANCE ACKNOWLEDGEMENT - 4.5 - 4.5.1...9394
14.2.9 FAILURE HISTORY - 4.6...9396
14.2.10 SNAPSHOT TRIGGER- 4.7...9398
14.2.11 SETTINGS...9400
CENTRAL LUBRICATION SYSTEM 4.8.1...9400
SWING LUBRICATION SYSTEM 4.8.2...9402
OTHER SETTINGS 1/2...9404
LANGUAGE...9405
OPERATING HOURS...9405
DATE...9405
TIME...9406
GMT REFERENCE...9406
OTHER SETTINGS 2/2...9408
OIL VISCOSITY HYDRAULIC...9408
OIL VISCOSITY GEAR...9408
MESSAGES ON/OFF...9410
PLC-AUTOM. ON/OFF...9410
SHUT DOWN ON.OFF 4.8.5 - 4.8.10...9412
14.4 WIRING OF THE MAIN COMPONENTS...9341
14.4.1 WIRING OF THE ENGINE...9345
14.4.2 WIRING OF THE VHMS CONTROLLER...9347
14.4.3 WIRING OF THE CGC MONITOR...9351
14.4.4 WIRING OF THE PLC...9353
15.0 LUBRICATION SYSTEMS...9441
15.1 HYDRAULICALLY DRIVEN LUBE PUMP...9441
FUNCTION...9447
ADJUSTMENTS...9451
15.2 ONE LINE SYSTEM WITH HYDRAULICALLY DRIVEN "PUMP MASTER III" PUMP...9453
FUNCTION...9455
ELECTRICAL FUNCTION...9459
SONAR SENSOR FOR GREASE LEVEL...9463
ADJUSTMENTS...9465
END LINE SWITCH...9465
INJECTORS...9467
15.3 PINION TYPE SYSTEM WITH HYDRAULIC DRIVEN "POWER MASTER III" PUMP...9469
FUNCTION...9472
ELECTRICAL FUNCTION...9475
LUBRICANT LEVEL...9479
ADJUSTMENTS...9481
END OF LINE SWITCH SETTING...9481
INJECTORS...9483
15.4 COMPONENTS...9485
HYDRAULICALLY DRIVEN "POWER MASTER III" LUBE PUMP...9487
LUBRICANT INJECTORS...9491
END-OF-LINE SWITCH...9497
FILTER...9499
VENT VALVE...9501
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SMPC40008172 - Hydraulic Mining Shovel PC4000-6 Shop Manual...9663
COVER...9663
CONTENTS...9665
TABLE OF CONTENTS...9665
SAFETY...9666
FOREWARD...9669
HOISTING INSTRUCTIONS...9670
STANDARD TIGHTENING TORQUE...9672
CONVERSION TABLE...9673
1.0 MAIN ASSEMBLY GROUPS...9680
1.0 MAIN ASSEMBLY GROUPS - GENERAL LAY OUT...9682
1. GENERAL LAY OUT - LEGEND FOR ILLUSTRATION\...9682
1.1 SUPERSTRUCTURE - LEGEND FOR ILLUSTRATION...9684
1.1.1 MACHINE HOUSE - LEGEND FOR ILLUSTRATION...9686
1.1.2 HYDRAULIC OIL RESERVOIR - LEGEND FOR ILLUSTRATION...9688
1.1.3 HYDRAULIC OIL COOLER - LEGEND FOR ILLUSTRATION...9690
1.1.4 FUEL TANK (FUEL RESERVOIR) - LEGEND FOR ILLUSTRATION...9692
1.1.5 COUNTERWEIGHT - LEGEND FOR ILLUSTRATION...9694
1.1.6 CAB SUPPORT - LEGEND FOR ILLUSTRATION...9696
1.1.7 OPERATOR'S CAB - LEGEND FOR ILLUSTRATION...9698
1.1.8 CONTROL BLOCKS - LEGEND FOR ILLUSTRATION...9700
1.1.9 SWING GEARS - LEGEND FOR ILLUSTRATION...9702
1.2 UNDER CARRIAGE - LEGEND FOR ILLUSTRATION...9704
1.3 ATTACHMENT - LEGEND FOR ILLUSTRATION...9706
1.3.1 BACKHOE ATTACHMENT (BHA) - LEGEND FOR ILLUSTRATION...9706
1.3.2 FRONT SHOVEL ATTACHMENT - LEGEND FOR ILLUSTRATION...9708
2.0 PRIME DRIVE ASSEMBLY...9709
2.0 PRIME DRIVE ASSEMBLY - GENERAL LAY OUT...9709
2.0 PRIME DRIVE ASSEMBLY - LEGEND FOR ILLUSTRATION...9711
2.1 ENGINE AND PTO MOUNT...9713
2.2 COUPLING...9717
2.2 COUPLING LEGEND FOR ILLUSTRATION...9717
2.3 AIR FILTER...9719
2.3 AIR FILTER - LEGEND FOR ILLUSTRATION...9719
2.4 FAN DRIVE AND RADIATOR ASSEMBLY...9721
2.4 FAN DRIVE AND RADIATOR ASSEMBLY - LEGEND FOR ILLUSTRATION...9721
2.5 RADIATOR FAN DRIVE SPEED ADJUSTMENT...9725
2.6 PUMP DISTRIBUTOR GEARBOX (PTO)...9729
2.7 PUMP-SPLINE LUBRICATION...9731
2.8 PTO LUBRICATION AND COOLING...9733
2.8 PTO LUBRICATION AND COOLING - LEGEND OF ILLUSTRATION...9733
2.9 HYDRAULIC PUMPS - LOCATION, DRIVE SPEED AND FLOW RATES...9737
3.0 HYDRAULIC OIL RESERVOIR...9738
3.0 HYDRAULIC OIL RESERVOIR GENERAL LAYOUT...9738
3.1 MAIN OIL TANK, LOCATION OF SWITCHES, SENSORS ETC...9742
3.2 SUCTION OIL TANK WITH STRAINERS...9744
3.3 RETURN OIL COLLECTOR TUBE WITH STRAINER...9746
3.4 BACK PRESSURE VALVE...9748
3.5 TRANSFER PUMP (OPTIONAL EQUIPMENT)...9750
3.6 RETURN AND LEAK OIL FILTER...9752
3.7 BREATHER FILTER...9754
4.0 HYDRAULIC OIL COOLING...9755
4.1 GENERAL...9757
4.2 FUNCTION OF THE HYDRAULIC OIL COOLING CIRCUIT...9759
4.3 ADJUSTMENT OF THE BACK PRESSURE VALVE...9761
4.4 FAN DRIVE (TWO STAGE COOLER FAN PRM CONTROL)...9763
4.5 PRESSURE RELIEF VALVES AND SOLENOID VALVE...9765
4.6 FIXED DISPLACEMENT PUMP, WITH VARIABLE SETTING...9769
5.0 CONTROLLING...9770
5.0 GENERAL LAYOUT - LEGEND FOR ILLUSTRATIONS...9772
5.1 CONTROL AND FILTER PANEL LOCATION OF COMPONENTS (VALVES, SWITCHES, SENSORS ETC)...9774
5.2 PILOT PRESSURE SUPPLY AND ADJUSTMENTS...9778
5.3 REMOTE CONTROL VALVES ARRANGEMENT...9784
5.4 FUNCTION PRINCIPLEOF THE ELECTRO-HYDRAULIC-PROPORTIONAL CONTROL...9786
5.5 POTENTIOMETER CONTROL (LEVER, JOY STICK)...9790
5.6 POTENTIOMETER CONTROL (PEDAL)...9792
5.7 PROPORTIONAL AMPLIFIER MODULE, TYPE A...9794
5.8 PROPORTIONAL AMPLIFIER MODULE, TYPE B...9796
5.9 RAMP TIME MODULE...9798
5.10 ADJUSTMENTS OF AMPLIFIER MODULES (GENERAL)...9800
5.11 ADJUSTING THE AMPLIFIERS TYPE B, ILLUSTRATION...9802
5.12 ADJUSTING THE AMPLIFIERS TYPE B, ILLUSTRATION...9806
5.13 ADJUSTING THE RAMP TIME MODULE...9810
6.0 COMPONENTS...9815
6.1 HYDRAULIC...9815
6.1.1 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER - FRONT SHOVEL ATTACHMENT...9817
6.1.2 MAIN CONTROL BLOCKS AND HIGH PRESSURE FILTER BACK HOE ATTACHMENT...9819
6.1.3 DISTRIBUTOR MAINFOLD - LOCATION OF RESTRICTOR BLOCKS AND CAVITATION VALVES - FRONT SHOVEL ATTACHMENT...9821
6.1.4 DISTRIBUTOR MANIFOLD - LOCATION OF RESTRICTOR BLOCKS AND CAVITATION VALVES - BACKHOE ATTACHMENT...9823
6.1.5 SINGLE CONTROL BLOCKS (FLOATING) FOR STICK AND BOOM FRONT SHOVEL ATTACHMENT...9825
6.1.6 RESTRICTOR BLOCK WITH PRESSURE RELIEF VALVE...9827
6.1.7 ANTI CAVITATION VALVE BLOCK...9829
6.1.8 REMOTE CONTROL VALVE...9831
6.1.9 DIRECTIONAL SOLENOID VALVES (THREE POSITIONS / 4-WAY)...9833
6.1.10 PROPORTIONAL SOLENOID VALVE...9835
6.1.11 HIGH PRESSURE FILTER...9837
6.1.12 CONTROL BLOCKS AND VALVES...9839
6.1.13 TRAVEL BRAKE VALVE...9851
6.1.14 PRESSURE REDUCING VALVE...9853
6.1.15 DIRECTIONAL SOLENOID VALVES (TWO POSITIONS / 4-WAYS)...9855
6.1.16 PRESSURE INCREASING VALVE...9857
7.0 MAIN HYDRAULIC PUMPS AND PUMP REGULATION SYSTEM...9858
7.0 GENERAL LAYOUT (HYDRAULIC ONLY)...9860
7.0 GENERAL LAYOUG (PUMP REGULATION SYSTEM)...9862
7.1 MAIN PUMPS...9868
7.1.1 LOCATION OF PUMPS...9868
7.1.2 PUMP BEARING FLUSHING / LUBRICATION...9870
7.1.3 OPERATING PRINCIPLES...9872
7.1.4 CHECKS / ADJUSTMENTS...9888
7.2 ELECTRONIC PUMP REGULATION SYSTEM...9898
7.2.1 ELECTRONIC LOAD LIMITING CONTROL - GENERAL...9898
7.2.2 MICROCONTROLLER MC7...9900
7.2.3 CHECKS AND ADJUSTMENTS...9902
METHOD A X1 PRESSURE WITH 24V SUPPLY...9904
METHOD B - WITH ELECTRONIC SERVICE TOOL...9906
LANGUAGE SELECTION...9906
EXCAVATOR TYPE SELECTION...9910
X1 PRESSURE (MAXIMUM CURRENT) ADJUSTMENT...9914
METHOD C - WITH A LAPTOP COMPUTER...9918
STARTING THE PROGRAM...9918
LANGUAGE SELECTION...9922
EXCAVATOR TYPE SELECTION...9924
X1 PRESSURE (MAXIMUM CURRENT) ADJUSTMENT...9926
7.3 HYDRAULIC CONSTANT REGULATION SYSTEM...9928
7.3.1 GENERAL...9928
7.3.2 X1 PRESSURE ADJUSTMENT (CONSTANT PRESSURE)...9930
7.4 DETERMINATION OF THE PEAK POINT (ENGINE PERFORMANCE)...9932
8.0 OPERATING HYDRAULIC...9933
OPERATING HYDRAULIC - GENERAL...9935
8.1 HYDRAULIC FOR THE ATTACHMENT CYLINDER FSA AND BHA...9938
8.1.1 ELECTRIC/HYDRAULIC FLOWCHART "BOOM RAISING"...9940
8.1.2 ELECTRIC/HYDRAULIC FLOWCHART "BOOM LOWERING"...9944
8.1.3 ELECTRIC/HYDRAULIC FLOWCHART "STICK EXTENDING"...9948
8.1.4 ELECTRIC/HYDRAULIC FLOWCHART "STICK RETRACTING"...9952
8.1.5 ELECTRIC/HYDRAULIC FLOWCHART "BUCKET FILLING"...9956
8.1.6 ELECTRIC/HYDRAULIC FLOWCHART "BUCKET EMPTYING"...9960
8.1.7 ELECTRIC/HYDRAULIC FLOWCHART "CLAM OPENING"...9964
8.1.8 ELECTRIC/HYDRAULIC FLOWCHARG "CLAM CLOSING"...9966
8.1.9 CHECKS AND ADJUSTMENTS OF THE MAIN RELIEF VALVES ...9968
8.1.10 CHECKS AND ADJUSTMENTS OF THE SERVICE LINE RELIEF VALVES...9972
Boom cylinder “Piston side” FSA +BHA...9974
Boom cylinder “Piston rod side” FSA +BHA...9976
Stick cylinder “Piston side” FSA...9980
Stick cylinder “Piston side” BHA...9984
Stick cylinder “Piston rod side” FSA...9988
Stick cylinder “Piston rod side” BHA...9992
Bucket cylinder “Piston side” FSA...9996
Bucket cylinder “Piston side” BHA...10000
Bucket cylinder “Piston rod side” FSA...10004
Bucket cylinder “Piston rod side” BHA...10008
Clam cylinder “Piston rod side” FSA...10012
Clam cylinder “Piston side” FSA...10014
8.1.11 CHECKS AND ADJUSTMENTS OF THE LOWERING SPEED...10016
Boom cylinder FSA...10018
Boom cylinder BHA...10022
Stick cylinder BHA...10028
Bucket cylinder FSA...10030
Bucket cylinder BHA...10032
Clam cylinder BHA...10034
8.2 HYDRAULIC FOR THE SWING CIRCUIT...10035
8.2.1 SWING CIRCUIT...10037
8.2.2 SWING MOTOR...10041
8.2.3 SWING GEAR BOX...10045
8.2.4 SWING PARKING BRAKE (GEAR HOUSE BRAKE)...10047
8.2.5 SWING BRAKE VALVE...10049
8.2.6 ELECTRIC/HYDRAULIC FLOWCHART "SWING LEFT"...10053
8.2.7 ELECTRIC/HYDRAULIC FLOWCHART "SWING RIGHT"...10055
8.2.8 SWING MONITORING SYSTEM...10057
8.2.9 CHECKS AND ADJUSTMENTS FOR THE SWING CIRCUIT...10061
8.2.10 FUNCTION FOR THE SWING PARKING BRAKE...10067
8.3 HYDRAULIC FOR THE SWING CIRCUIT...10068
8.3.1 TRAVEL CIRCUIT...10070
8.3.2 TRAVEL MOTOR...10074
8.3.3 ROTARY DISTRIBUTOR...10076
8.3.4 TRAVEL GEAR...10078
8.3.5 TRAVEL PARKING BRAKE (GEAR HOUSE BRAKE)...10080
8.3.6 TRAVEL BRAKE VALVE...10082
8.3.7 ELECTRIC/HYDRAULIC FLOWCHART "TRAVELING FORWARD"...10084
8.3.8 ELECTRIC/HYDRAULIC FLOWCHART "TRAVELING BACKWARD"...10086
8.3.9 CHECKS AND ADJUSTMENTS FOR THE TRAVEL CIRCUIT...10088
8.3.10 FUNCTION CHECK FOR THE TRAVEL PARKING BRAKE...10090
9.0 HYDRAULIC TRACK TENSIONING SYSTEM...10091
9.0 GENERAL...10093
9.1 FUNCTIONAL DESCRIPTION...10095
9.2 PRESSURE INCREASING VALVE...10099
9.3 TENSIONING CYLINDER...10101
9.4 ADJUSTMENTS / CHECKS...10103
9.5 FUNCTIONAL TEST...10107
10.0 ACCESS LADDER HYDRAULIC OPERAGED...10108
10.0 GENERAL...10110
10.1 FUNCTION OF HYDRAULIC OPERATED ACCESS LADDER...10112
11.0 HYDRAULIC OPERATED REFILLING ARM...10115
11.0 GENERAL...10117
11.1 FUNCTION OF HYDRAULIC OPERATED REFILLING ARM...10119
12.0 HINTS FOR READING THE HYDRAULIC CIRCUIT DIAGRAM...10120
12.0 GENERAL...10121
12.1 LEGEND FOR THE CIRCUIT DIAGRAM...10122
12.2 HOW TO READ THE CIRCUIT DIAGRAM...10130
13.0 HINTS FOR READING THE ELECTRIC CIRCUIT DIAGRAM...10131
13.1 DESIGNATION OF ELECTRICAL DEVICES...10133
13.2 SYMBOLS...10135
13.3 GENERAL INFORMATION...10139
13.4 READING A CIRCUIT DIAGRAM...10143
13.5 COMPONENT LIST...10147
14.0 VEHICLE HEALTH MONITORING SYSTEM...10293
DATA FLOW CONTROL OF VHMS...10294
GENERAL...10295
14.1 COLORED GRAPHIC CONSOLE (CGC) SPECS FOR OPERATORS...10272
14.1.1 GRAPHIC FLOW CHART...10274
14.1.2 INITIALIZATION SCREEN (NO. 0.0)...10276
14.1.3 OPERATOR INFORMATION SCREEN ( NO. 1.1)...10276
14.1.4 MONITORING SCREENS...10278
STANDARD MONITOR 1 (NO. 1.2)...10278
EXPANSION MONITOR 2 (NO.1.3)...10278
EXPANSION MONITOR 3 (NO. 1.4)...10278
14.1.5 BRIGHTNESS AND CONTRAST SETTING SCREEN (NO. 1.2.1)...10280
14.1.6 FUEL CONSUMPTION SCREEN (NO. 1.2.2)...10282
14.1.7 SETTINGS FOR OPERATOR, SCREEN (NO. 1.2.3)...10284
14.1.8 MAINTENANCE MONITOR (NO. 1.2.4)...10286
14.1.9 FAILURE MESSAGE ( NO. 1.2.5)...10290
14.1.10 AUTOMATIC MESSAGES...10292
14.2 COLORED GRAPHIC CONSOLE (CGC) SPECS FOR SERVICEMEN...10213
14.2.1 GRAPHIC FLOW CHART...10215
14.2.2 SERVICE ID SETUP SCREEN (NO. 2.0)...10217
14.2.3 SERVICE MENU SELECT SCREEN (NO. 3.1)...10219
14.2.4 REAL TIME MENU SELECT SCREEN (NO. 4.1.1)...10221
ENGINE 5.1.1 - 5.1.4...10221
TRANSMISSION 5.2.1...10223
HYDRAULIC 5.3.1 - 5.4.2...10225
ELECTRICAL EQUIPMENT 5.4.1 - 5.4.2...10227
EMERGENCY STOP 5.5.1...10229
MANUAL SWITCH 5.6.1 - 5.6.3...10231
CENTRAL LUBRICATION SYSTEM 5.7.1 - 5.7.2...10233
SWING LUBRICATION SYSTEM 5.8.1 - 5.8.2...10235
OTHER ITEMS 5.9.1 - 5.9.3...10237
OUTPUT SIGNALS 5.10.1 - 5.10.6...10239
14.2.5 PM-CLINIC...10241
PM CLINIC GENERAL - 4.2.1 - 4.2.2...10241
PM CLINIC POWER CHECK - 4.2.3 - 4.2.5...10243
14.2.6 SERIAL NO. SETTING ...10245
MACHINE 4.3.1...10245
ENGINE 4.3.2...10247
14.2.7 MEMORY CLEAR...10249
INPUT ID 4.3.2...10249
MEMORY CLEAR 4.4.1...10251
14.2.8 MAINTENANCE MONITOR - MAINTENANCE ACKNOWLEDGEMENT - 4.5 - 4.5.1...10253
14.2.9 FAILURE HISTORY - 4.6...10255
14.2.10 SNAPSHOT TRIGGER- 4.7...10257
14.2.11 SETTINGS...10259
CENTRAL LUBRICATION SYSTEM 4.8.1...10259
SWING LUBRICATION SYSTEM 4.8.2...10261
OTHER SETTINGS 1/2...10263
LANGUAGE...10264
OPERATING HOURS...10264
DATE...10264
TIME...10265
GMT REFERENCE...10265
OTHER SETTINGS 2/2...10267
OIL VISCOSITY HYDRAULIC...10267
OIL VISCOSITY GEAR...10267
MESSAGES ON/OFF...10269
PLC-AUTOM. ON/OFF...10269
SHUT DOWN ON.OFF 4.8.5 - 4.8.10...10271
14.4 WIRING OF THE MAIN COMPONENTS...10200
14.4.1 WIRING OF THE ENGINE...10204
14.4.2 WIRING OF THE VHMS CONTROLLER...10206
14.4.3 WIRING OF THE CGC MONITOR...10210
14.4.4 WIRING OF THE PLC...10212
15.0 LUBRICATION SYSTEMS...10300
15.1 HYDRAULICALLY DRIVEN LUBE PUMP...10300
FUNCTION...10306
ADJUSTMENTS...10310
15.2 ONE LINE SYSTEM WITH HYDRAULICALLY DRIVEN "PUMP MASTER III" PUMP...10312
FUNCTION...10314
ELECTRICAL FUNCTION...10318
SONAR SENSOR FOR GREASE LEVEL...10322
ADJUSTMENTS...10324
END LINE SWITCH...10324
INJECTORS...10326
15.3 PINION TYPE SYSTEM WITH HYDRAULIC DRIVEN "POWER MASTER III" PUMP...10328
FUNCTION...10331
ELECTRICAL FUNCTION...10334
LUBRICANT LEVEL...10338
ADJUSTMENTS...10340
END OF LINE SWITCH SETTING...10340
INJECTORS...10342
15.4 COMPONENTS...10344
HYDRAULICALLY DRIVEN "POWER MASTER III" LUBE PUMP...10346
LUBRICANT INJECTORS...10350
END-OF-LINE SWITCH...10356
FILTER...10358
VENT VALVE...10360
FLOWCHART 942 107 40 ...10370
FLOWCHART 942 107 40 PAGE 1 OF 70...10370
...
ELECTRICAL PLAN 942 106 40 PAGE 73 OF 73...10521
Komatsu Hydraulic Mining Shovel PC4000 Repair Service Manuals
