GZEBM12037-0

SHOP 12037-xE-GB-0

Shop Manual

HYDRAULIC EXCAVATOR

PC8000E-6 Serial Number 12037 and up

SHOP MANUAL

SHOP 12037-xE-GB-0

HYDRAULIC EXCAVATOR PC8000E-6

Machine model PC8000E-6

Serial number 12037 and up

00 Foreword

PC8000E-6

1

1.1 CONTENTS OF VOLUME 1 BINDER

1.1

CONTENTS OF VOLUME 1 BINDER

The volume 1 binder contains the Operation and Maintenance Manual for your KOMATSU Hydraulic Mining Shovel. Manufacturer of this Product Komatsu Mining Germany GmbH Buscherhofstrasse 10 40599 Düsseldorf Germany NOTICE ● This Operation and Maintenance Manual is the Original Edition issued in February 2010.

1.1.1

SPECIFICATION AND SERIAL NUMBER PLATE

The specification and serial number plate is located on the outside of the Operator’s cab near the door.

Product Identification Number The Product Identification Number (PIN-Code) is printed in the space provided on the specification and serial number plate, illustration Z25844.

4

INTRODUCTION

INTRODUCTION

1.2

1.2 CONTENTS OF VOLUME 2 BINDER

CONTENTS OF VOLUME 2 BINDER

The volume 2 binder is being delivered with the Shovel. This Binder contains the General Assembly Procedure Manual for the Shovel, Specification Booklet, Service Literature for the Power Unit (Diesel Engine or Electric Motor) and for Special Equipment. The Electrical- and Hydraulic Diagrams are attached in the pocket of the front cover. Refer to the -TABLE OF CONTENTS VOLUME 2 BINDERfor details.

Read the Manuals before You Start the Engines. Before operating the machine, familiarize yourself with its instruments and controls. Observe the instructions in these manuals for: ●

your Personal SAFETY

●

Operating SAFETY, and

●

READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.

Periodic preventive inspections and maintenance are the surest means of keeping the machine in proper working order. Prompt detection and correction of minor irregularities, and immediate replacement of worn out or broken parts will prevent failures and avoid expenses. Replace damaged graphics and symbols. Observe safety precautions to prevent injury and damage. If you have any questions concerning this literature please contact Komatsu Mining Germany GmbH Service Information Department 8151.30 P.O. Box 18 03 61 D - 40570 Düsseldorf GERMANY

5

1.3 DESIGNATED USE OF THE SHOVEL

1.3

DESIGNATED USE OF THE SHOVEL

This machine has been manufactured in accordance with advanced and up-to-date technology standards including recognized safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other material property. The machine must only be used in technically perfect condition in accordance with its designated use and the instructions set out in the operation manual. Only trained safety-conscious operators who are fully aware of the risks involved should operate the machine. Any functional disorders, especially those affecting the safety of the machine, should, therefore, be rectified immediately. The hydraulic Shovel is designed exclusively for excavating, i.e. excavation of bulk material and natural soil structure (e.g. earth, clay, sand and stones ashore and off-shore). Observe local and national safety regulations. Special conditions at the worksite require additional safe working precautions, follow your company's safety instructions. Short traveling distances for changing the working site are considered as part of the designated use of the Shovel. Using the Shovel for purposes other than those mentioned above (such as object handling, use as a transport vehicle and towing of other machinery) is considered contrary to its designated use. The manufacturer/supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user. WARNING Special use of the Shovel beyond its designated use, e.g. object handling operations, require written agreement from the manufacturer and retrofitment of the Shovel with respective safety related equipment before such special applications are permitted.

6

INTRODUCTION

INTRODUCTION

1.4

1.4 DELIVERY OF THE SHOVEL

DELIVERY OF THE SHOVEL

The Shovel is being delivered disassembled into its main components. For assembling the Shovel refer to the separate Manual ”General Assembly Procedure” in Volume 2 Binder: WARNING Personnel entrusted with work on the machine must have read the Assembly Manual, the Operation,- Lubrication- and Maintenance Manual and in particular the section on safety before beginning work. Reading the instructions after work has begun is too late.

If there are any questions concerning the assembling procedure, contact your local Service Center. Prior to first operation, inspect the Shovel thoroughly with the Service Engineer responsible for the erection of the machine. Check all fluid levels according to the Lubrication and Maintenance Schedule. Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturers guarantee. NOTICE If the Shovel is equipped with a fire suppression system, make sure that the system is ready for operation.

SPARE PARTS For your spare part orders refer to the Parts Catalogue. The use of genuine Komatsu spare parts is recommended to assure safe mounting and operation of the machine. The use of any part other than the genuine part releases the KOMATSU MINING GERMANY GmbH from any guarantee.

SERVICE For all questions related to your Shovel please contact your local Service Center. In all your written or phoned inquiries please indicate the model and serial number of your Shovel.

7

1.5 EXPLANATION OF ABBREVIATIONS

1.5

EXPLANATION OF ABBREVIATIONS

ABB.

Definition

A

Ampere

AC

Alternating Current

API

American Petroleum Institute

cSt

Centistoke

°C

Degree Celsius

CENSE

Engine Monitoring System

CLS

Central Lubrication System

DC

Direct Current

DIN

German Institute for Standardization

EBL

Electronic Bucket Levelling System

ECM

Electronic Control Module (Engine)

FGPS

Front Guard Protective Structure

FOPS

Falling-Object Protective Structure

GL

Gear Lubricant

h

hours of operation

HPF

High Pressure Filter (Hydraulic Oil)

HT

High Tension

LED

Light Emitting Diode

LT

Low Tension

N

Newton

Nm

Newton meter

QUANTUM

Electronic Control System (Engine)

QSK

Type of Engine Fuel System

PLC

Programmable Logic Controller

PM

Planned Maintenance

ppm

parts per million

PTO

Power Take-Off (Pump Distributor Gear)

SLS

Swing circle pinion Lubrication System

V

Volt

VHMS

Vehicle Health Monitoring System

1/min

Revolutions Per Minute (RPM)

8

INTRODUCTION

SAFETY

2 SAFETY

IGNORING THE INSTRUCTIONS IN THIS MANUAL COULD LEAD TO SERIOUS INJURY OR DEATH. Please read and make sure that you fully understand the precautions described in this section and the safety labels on the machine. When operating or servicing the machine, always follow these precaution strictly.

2 -1

SAFETY

CONTENTS 2.1

SAFETY INFORMATION ................................................................................................................... 2-3

2.2

OVERVIEW......................................................................................................................................... 2.2.1 NORMAL OPERATIONS ....................................................................................................... 2.2.2 REGULAR MAINTENANCE................................................................................................... 2.2.3 TROUBLESHOOTING, ADJUSTMENTS AND REPAIR ....................................................... 2.2.4 ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR.........................................................................

2-4 2-4 2-4 2-4 2-4

2.3

SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB. .............................................................. 2-5

2.4

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR........................... 2-6 2.4.1 UNDERSTANDING THE MACHINE ...................................................................................... 2-6 2.4.2 PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR ...................... 2-6 2.4.2.1 ENSURING SAFE OPERATION............................................................................ 2-6 2.4.3 PREPARATIONS FOR SAFE OPERATION.......................................................................... 2-6 2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT........................ 2-6 2.4.3.2 INSPECTING THE MACHINE................................................................................ 2-6 2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT.................. 2-7 2.4.3.4 KEEP MACHINE CLEAN ....................................................................................... 2-7 2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT ................................... 2-7 2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ........................................ 2-8 2.4.3.7 IF A PROBLEM IS FOUND .................................................................................... 2-8 2.4.4 FIRE PREVENTION............................................................................................................... 2-8 2.4.4.1 PRECAUTIONS TO PREVENT FIRE .................................................................... 2-8 2.4.4.2 ACTION IF FIRE OCCURS.................................................................................... 2-9 2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB................................................. 2-10 2.4.5 PRECAUTIONS WHEN CLEANING CAB GLASS .............................................................. 2-10 2.4.6 PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE ....................................... 2-10 2.4.6.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE............................................................................................................. 2-10 2.4.6.2 NO JUMPING ON OR OFF THE MACHINE ........................................................ 2-10 2.4.6.3 NO PEOPLE ON THE ATTACHMENT ................................................................ 2-10 2.4.6.4 WORKING IN HIGH PLACES .............................................................................. 2-10 2.4.6.5 LEAVING OPERATOR’S SEAT WITH LOCK ...................................................... 2-11 2.4.6.6 LEAVING THE MACHINE .................................................................................... 2-11 2.4.7 BURN PREVENTION........................................................................................................... 2-11 2.4.7.1 HOT COOLANT .................................................................................................. 2-11 2.4.7.2 HOT OIL .............................................................................................................. 2-12 2.4.8 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES .......................................... 2-12 2.4.8.1 UNAUTHORIZED MODIFICATION...................................................................... 2-12 2.4.9 PRECAUTIONS AT JOBSITE.............................................................................................. 2-14 2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT ............................................................. 2-15 2.4.9.2 CAMERA SYSTEM WITH MONITORS................................................................ 2-15 2.4.9.3 ENSURE GOOD VISIBILITY................................................................................ 2-15 2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS............................................ 2-15 2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS.................................... 2-16 2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES .......................................... 2-16 2.4.9.7 WORKING ON LOOSE GROUND ....................................................................... 2-17 2.4.9.8 GAS, DUST, STEAM AND SMOKE ..................................................................... 2-17 2.4.9.9 VENTILATION OF ENCLOSED AREAS.............................................................. 2-18

2 -2

SAFETY

2.5

2.6

2.4.10 STARTING ENGINE ............................................................................................................ 2.4.10.1 WARNING TAG ................................................................................................... 2.4.10.2 CHECKS BEFORE STARTING ENGINE ............................................................ 2.4.10.3 PRECAUTION WHEN STARTING ENGINE........................................................ 2.4.10.4 PRECAUTION IN COLD AREAS ......................................................................... 2.4.11 OPERATION........................................................................................................................ 2.4.11.1 CHECKS BEFORE OPERATION ........................................................................ 2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE ............... 2.4.11.3 PRECAUTIONS WHEN TRAVELLING ................................................................ 2.4.11.4 TRAVELLING ON SLOPES ................................................................................. 2.4.11.5 OPERATIONS ON SLOPES................................................................................ 2.4.11.6 PROHIBITED OPERATIONS............................................................................... 2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES....................... 2.4.11.8 PARKING THE MACHINE ................................................................................... 2.4.11.9 TRANSPORTATION ............................................................................................

2-19 2-19 2-19 2-19 2-20 2-20 2-20 2-21 2-22 2-23 2-24 2-24 2-25 2-25 2-25

PRECAUTION FOR MAINTENANCE.............................................................................................. 2.5.1 GENERAL PRECAUTIONS ................................................................................................. 2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES ............................................................................................ 2.5.1.2 STOP ENGINE FOR MAINTENANCE ................................................................. 2.5.1.3 WARNING TAG ................................................................................................... 2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY ............................................................. 2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS ..................................... 2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING ............................................................................................................ 2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS ............................... 2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT........................................................................................................ 2.5.1.9 NOISE .................................................................................................................. 2.5.1.10 WHEN USING A HAMMER ................................................................................. 2.5.1.11 PROPER TOOLS................................................................................................. 2.5.1.12 ACCUMULATOR ................................................................................................. 2.5.1.13 PERSONNEL ....................................................................................................... 2.5.2 PRECAUTIONS FOR INSPECTION AND MAINTENANCE................................................ 2.5.2.1 PRECAUTION WHEN WELDING ........................................................................ 2.5.2.2 BATTERY HANDLING ......................................................................................... 2.5.3 PRECAUTIONS WITH HIGH PRESSURE FLUID............................................................... 2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE ................................................ 2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES .......................................... 2.5.3.3 REPLACEMENT OF HOSE LINES...................................................................... 2.5.3.4 INSPECTION OF HOSE LINES........................................................................... 2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ............................ 2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE............................................................... 2.5.3.7 AIR CONDITIONING MAINTENANCE ................................................................ 2.5.3.8 COMPRESSED AIR............................................................................................. 2.5.3.9 WASTE MATERIALS ...........................................................................................

2-26 2-26 2-27 2-28 2-28 2-29 2-30 2-30 2-30 2-31 2-31 2-31 2-32 2-32 2-32 2-32 2-32 2-33 2-34 2-34 2-34 2-34 2-35 2-35 2-36 2-36 2-36 2-37

ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS............................................................................................................................... 2-38 2.6.1 INSPECTION OF THE HYDRAULIC SYSTEM ................................................................... 2-38 2.6.2 TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING 2 -3

SAFETY

2.6.3 2.7

2 -4

ADJUSTMENTS................................................................................................................... 2-38 AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR...................................... 2-38

SPECIAL SAFETY EQUIPMENT..................................................................................................... 2.7.1 FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB ................ 2.7.2 OBJECT HANDLING ........................................................................................................... 2.7.3 LIGHTING ............................................................................................................................ 2.7.4 WARNING BEACON............................................................................................................ 2.7.5 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ........... 2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) .................................................................................. 2.7.5.2 INSTRUCTIONS FOR USE ................................................................................. 2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL ......................... 2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), .................................... 2.7.5.5 INSTRUCTIONS FOR USE .................................................................................

2-40 2-41 2-41 2-41 2-41 2-41 2-41 2-43 2-45 2-45 2-47

SAFETY

2.1

SAFETY INFORMATION

SAFETY INFORMATION

To enable you to use this machine safely, and to prevent injury to operators, service personnel or bystanders, the precautions and warnings included in this manual and the safety signs attached to the machine must always be followed. To identify important safety messages in the manual and on the machine labels, the following signal words are used. The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.

DANGER This signal word indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING This signal word indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION This signal word indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE This signal word is used to alert you to information that must be followed to avoid damage to the machine. This precaution is given where the machine may be damaged or the service life reduced if the precaution is not followed.

2 -5

OVERVIEW

2.2

SAFETY

OVERVIEW

The appropriate safety information for specific working modes on the excavator can be found in the following:-

2.2.1

NORMAL OPERATIONS

–

For normal operating procedures, refer to the OPERATION section of the Operation and Maintenance Manual.

–

For operational safety information, refer to section 2.4 on page 3-8.

–

For on site safety information, refer to section 2.4.9 on page 3-16.

2.2.2

REGULAR MAINTENANCE

–

For information on regular maintenance, including maintenance intervals, refer to the MAINTENANCE section of the Operation and Maintenance Manual.

–

For maintenance safety information, refer to section 2.5 on page 3-28.

2.2.3

TROUBLESHOOTING, ADJUSTMENTS AND REPAIR

–

For additional safety information for troubleshooting and adjustments refer to section 2.6 on page 3-40.

–

For maintenance solutions, refer to the separate manuals TROUBLESHOOTING manual. Available through Komatsu Mining Germany.

–

For servicing information and adjustments, refer to the separate SERVICE MANUAL. Available through Komatsu Mining Germany.

2.2.4 –

ADDITIONAL SAFETY PRECAUTIONS FOR ASSEMBLING, DISASSEMBLING AND TRANSPORTATION OF THE EXCAVATOR

Prior to starting assembling, disassembling and transportation of the excavator read and follow the additional safety precautions given in the ASSEMBLY PROCEDURE MANUAL.

2 -6

SAFETY

2.3

SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB.

SOUND PRESSURE LEVEL IN THE OPERATOR’S CAB.

Fig. 3-1 The sound pressure level in the operator’s cab is measured according to ISO 6396 (Dynamic test method). The sound pressure value is also shown on the decal attached to the wall inside the operator’s cab, see Fig. 3-1.

2 -7

GENERAL PRECAUTIONS COMMON TO OPERATION ON THE EXCAVATOR

2.4

SAFETY


WARNING WHEN MISUSED, THESE MACHINES ARE DANGEROUS. Mistakes in operation, inspection, or maintenance may result in personal injury or death. Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.

2.4.1

UNDERSTANDING THE MACHINE

Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not understand, ask the person in charge of safety to give an explanation.

2.4.2

PRECAUTIONS BEFORE STARTING OPERATION ON THE EXCAVATOR

2.4.2.1 ENSURING SAFE OPERATION –

Only trained and authorized personnel can operate and maintain the machine.

–

During operations, personnel are not allowed outside of the operator’s cabin.

–

Follow all safety rules, precautions and instructions when operating or performing inspection or maintenance on the machine.

–

If you are not feeling well, or are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.

–

When working with another operator or with a person on worksite traffic duty, discuss the content of the operation beforehand and use pre-determined signals when carrying out these operations.

2.4.3

PREPARATIONS FOR SAFE OPERATION

2.4.3.1 PRECAUTIONS REGARDING SAFETY RELATED EQUIPMENT –

Be sure that all guards, covers and mirrors are in their proper positions. Have guards and covers repaired immediately if they are damaged.

–

Understand the method of use of safety features and use them properly.

–

Never remove any safety features. Always keep them in good operating condition.

2.4.3.2 INSPECTING THE MACHINE Check the machine before starting operations. If any abnormality is found, do not operate the machine until repairs of the problem location have been completed.

2 -8

SAFETY


2.4.3.3 WEAR WELL FITTING CLOTHES AND PROTECTIVE EQUIPMENT –

Do not wear loose clothing and accessories. If these catch on the control levers or moving parts, there is a danger that it may cause the machine to move unexpectedly.

–

Always wear a hard hat and safety shoes when working on the machine outside of the cabin. If the nature of the work requires it, wear safety glasses, mask, gloves, ear plugs and a safety belt when operating or maintaining the machine (Fig. 3-2).

–

If you have long hair and it hangs out from your hard hat, there is a hazard that it may get caught up in the machine, so tie your hair up and be careful not to let it get caught.

–

Check that all protective equipment functions properly before using it.

Fig. 3-2

2.4.3.4 KEEP MACHINE CLEAN –

If you get on or off the machine or carry out inspection or maintenance when the machine is dirty with mud or oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the machines clean.

–

If water gets into the electrical system (Fig. 3-3), there is a hazard that it will cause malfunctions or a misoperation. If there is any misoperation, there is a danger that the machine may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical components. Fig. 3-3

2.4.3.5 PRECAUTIONS INSIDE OPERATOR’S COMPARTMENT –

When entering the operator’s compartment, always remove all mud and oil from your shoes. If you operate the pedal with mud or oil affixed to your shoes, you may slip and this may cause a serious accident.

–

Do not leave tools or machine parts lying around inside the operator’s compartment. If tools or parts get into the control devices, they may obstruct operation and cause the machine to move unexpectedly, resulting in serious personal injury or death.

–

Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.

–

Do not use a cell phone when driving or operating the machine. This may lead to mistakes in operation, which could cause serious personal injury or death.

–

Never bring any dangerous objects such as flammable or explosive items into the operator’s compartment.

2 -9


SAFETY

2.4.3.6 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT Always follow the precautions below to prepare for action if any injury or fire should occur. –

Be sure that fire extinguishers have been provided and read the labels to ensure that you know how to use them in emergencies.

–

Carry out periodic inspection and maintenance to ensure that the fire extinguisher can always be used.

–

Provide a first aid kit. Carry out periodic checks and add to the contents if necessary (Fig. 3-4).

Fig. 3-4

2.4.3.7 IF A PROBLEM IS FOUND If you find any problems in the machine during operation and maintenance (noise, vibration, smell, incorrect gauges, smoke, oil, leakage, etc., or any abnormal display on the warning devices or monitor), report to the person in charge and have the necessary action taken. Do not operate the machine until the problem has been corrected.

2.4.4

FIRE PREVENTION

2.4.4.1 PRECAUTIONS TO PREVENT FIRE Fire caused by fuel, oil, antifreeze, or window washer fluid. Do not bring any flame or fire close to flammable substances such as fuel, oil, antifreeze, or window washer fluid. There is a danger they may catch fire. To prevent fire, always observe the following: – Do not smoke or use any flame near fuel or other flammable substances. (Fig. 3-5) – Stop the engines before adding fuel. – Do not leave the machine while adding fuel or oil. – Tighten all fuel and oil caps securely. – Be careful not to spill fuel on overheated surfaces or on parts of the electrical system. – After adding fuel or oil, wipe up any spillage. – Put greasy rags and other flammable materials into a safe container to maintain safety in the workplace. – When washing parts with oil, use a non-flammable oil. Do not use diesel oil or gasoline. There is a danger that they may catch fire.

Fig. 3-5

– Do not weld or use a cutting torch to cut any pipe or tubes that contain flammable liquids. – Determine well ventilated areas for storing oil and fuel. Keep the oil and fuel in the determined place and do not allow unauthorised persons to enter. REMARKS: Before carrying out grinding or welding work on the machine, remove any flammable materials.

2 - 10

SAFETY


–

Fire caused by accumulation of flammable material. Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or affixed around the engines, exhaust manifold, muffler or battery, or inside the undercovers.

–

Fire coming from electrical wiring Short circuits in the electrical system can cause fire. To prevent fire, always observe the following: – Keep all electrical connections clean and securely tightened. – Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repair or replace any damaged wiring.

–

Fire coming from piping Check that all hose and tube clamps, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts. There is a danger that this may lead to damage to the hoses and cause high pressure oil to spurt out, leading to fire, personal injury, or death.

–

Explosion caused by lighting equipment – When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifications. – When taking the electrical power for the lighting from the machine itself, follow the instructions of this manual.

2.4.4.2 ACTION IF FIRE OCCURS –

Activate the STOP switch to stop the engine.

–

Use the access ladders and steps to get off the machine.

–

If it is impossible to escape from the rear of the cab, use the rope ladder provided for emergency escape to escape from the side of the cab. (Fig. 3-6.)

Fig. 3-6

–

After escaping with the emergency escape ladder, activate the engine stop chains (1 on Fig. 3-7) to shut down the engine if they are equipped on your shovel.

Fig. 3-7

2 - 11


SAFETY

2.4.4.3 EMERGENCY EXIT FROM OPERATOR’S CAB If the cab door does not open, use the sliding window for an emergency escape. On machines without a sliding window, use the emergency escape hammer to break the window glass and use the window as an emergency escape.

2.4.5

PRECAUTIONS WHEN CLEANING CAB GLASS

Always keep the cab glass clean to ensure good visibility when operating. Use an ethyl alcohol based washer liquid. Methyl alcohol based liquid may irritate your eyes, so do not use it. If the cab glass on the work equipment side is broken, there is a hazard that the intruding objects may contact the operator's body directly. Stop operation immediately and replace the glass.

2.4.6

PRECAUTIONS WHEN GETTING ON OR OFF THE MACHINE

2.4.6.1 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF THE MACHINE To prevent personal injury caused by slipping or falling off the machine, always do as follows. –

Always use the handrails and steps when getting on or off the machine.

–

To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot - see Fig. 3-8). with the handrails and steps to ensure that you support yourself.

–

When walking around the machine, where possible, move only in areas that have non-slip padded walkways and nonslip gratings. Extra care is to be taken when moving around outside of these areas.

–

Before getting on or off the machine, check the handrails and steps. If there is any oil, grease, or mud on the handrails or steps, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts.

Fig. 3-8

2.4.6.2 NO JUMPING ON OR OFF THE MACHINE –

Never jump on or off the machine. Never get on or off a moving machine.

–

If the machine starts to move when there is no operator on the machine, do not jump onto the machine and try to stop it.

2.4.6.3 NO PEOPLE ON THE ATTACHMENT Never let any person mount the boom, arm, bucket, or other attachment without appropriate safety equipment. There is danger of falling and suffering serious personal injury. For further information refer to section 2.7 on page 3-42.

2.4.6.4 WORKING IN HIGH PLACES When working in high places, use safety harness and fall absorber to ensure that the work can be carried out safely. For further information refer to section 2.7 on page 3-42.

2 - 12

SAFETY


2.4.6.5 LEAVING OPERATOR’S SEAT WITH LOCK –

Before standing up from the operator's seat in order to adjust the seat, always lower the work equipment to the ground, turn off the engine, relieve the pressure in the hydraulic system and set lock lever to LOCK position (L, Fig. 3-9.). If the lock is not applied, there is danger of serious personal injury if the work equipment control levers are touched by mistake and the machine moves suddenly. For information on relieving the pressure in the hydraulic system, refer to chapter ’RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM’ in the ’OPERATION’ part of this manual.

Fig. 3-9

2.4.6.6 LEAVING THE MACHINE –

When leaving the machine, always lower the work equipment completely to the ground, turn off the engine, relieve the pressure in the hydraulic system and set lock lever (1) securely to the LOCK position (L), then stop the engine. Use the key to lock all the equipment. Always remove the key, take it with you, and keep it in the specified place (Fig. 3-10). For information on relieving the pressure in the hydraulic system, refer to chapter ’RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM’ in the ’OPERATION’ part of this manual.

Fig. 3-10

2.4.7

BURN PREVENTION

2.4.7.1 HOT COOLANT –

To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap (Fig. 3-11 and Fig. 3-12) by hand before starting the operation. Even when the coolant has cooled down, loosen the cap slowly to relieve the pressure inside the radiator before removing the cap.

Fig. 3-11

2 - 13


SAFETY

2.4.7.2 HOT OIL –

To prevent burns from hot oil spurting out when checking or draining the oil, wait for the oil to cool to a temperature where it is possible to touch the cap or plug by hand before starting the operation (Fig. 3-12). Even when the oil has cooled down, loosen the cap or plug slowly to relieve the internal pressure before removing the cap or plug.

Fig. 3-12

2.4.8

PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES

On jobsites where there is a hazard that falling objects (Fig. 3-13), flying objects (Fig. 3-14), or intruding objects may hit or enter the operator's cab, consider the operating conditions and install the necessary guards to protect the operator. –

When carrying out operations in mines or quarries where there is danger of falling or flying rocks, order/use the optionally available front guard.

–

When carrying out the above operations, always ensure that bystanders are a safe distance away and are not in hazard from falling or flying objects.

–

The above recommendations assume that the conditions are Fig. 3-13 for standard operations, but it may be necessary to add additional guards according to the operating conditions on the jobsite. Always contact your Komatsu distributor for advice.

Fig. 3-14

2.4.8.1 UNAUTHORIZED MODIFICATION –

Komatsu will not be responsible for any injuries, accidents, product failures or other property damage resulting in modifications made without authorisation from Komatsu.

–

Any modifications made without authorisation from Komatsu can create hazards. Before making a modification, consult your komatsu distributor.

–

Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu.

2 - 14

SAFETY


Please continue reading on the next page.

2 - 15


2.4.9

Fig. 3-15

2 - 16

PRECAUTIONS AT JOBSITE

SAFETY

SAFETY


2.4.9.1 VISIBILITY FROM OPERATOR’S SEAT

WARNING THE AREA AROUND THE EXCAVATOR DURING OPERATION IS EXTREMELY DANGEROUS! Death and serious injury can occur. Make sure the job site is organized in such a way, that the safety of man and equipment is always ensured.

Fig. 3-15 shows an example of general blind areas of large Komatsu hydraulic mining shovels. The grey shaded areas (A) show the areas where the view is blocked when the operator is sitting in the operator’s seat, and the shovel is equipped with standard mirrors. The boundary line (B) shows the distance of 1 meter from outside surface of the shovel. Please be fully aware that there are places that can not seen when operating the machine. REMARKS: The blind areas (A) differ depending on the machine type, attachment and position of attachment. The International Standard ISO 5006 defines criteria for Operator’s visibility. This standard is not met and does not apply to large hydraulic mining shovels.

2.4.9.2 CAMERA SYSTEM WITH MONITORS Komatsu Mining Germany offers optionally camera systems and monitors to improve the overall visibility. See latest version of the OMM for typical arrangement of cameras and monitors. The camera system can be installed ex works and can also be retrofitted in the field. If you need more information, please contact your local Komatsu distributor.

2.4.9.3 ENSURE GOOD VISIBILITY When operating or travelling in places with poor visibility, if it is impossible to confirm the condition of the job side or obstacle is in the area around the machine, there is danger that the machine may suffer damage or the operator may suffer serious personal injury. When operating or travelling in places with poor visibility, always observe the following items strictly. –

If the visibility cannot be sufficiently assured, position a flagman if necessary. The operator should pay careful attention to the signs and follow the instructions of the flagman.

–

The signals should be given only by one flagman.

–

When working in dark places, turn on the working lamps and front lamps of the machine, and if necessary, set up additional lighting in the area.

–

Stop operations if there is poor visibility, such as in fog, snow, rain, or sand storms.

–

Check the mirrors on the machine before starting operations every day. Clean off any dirt and adjust the view to ensure good visibility.

–

In areas where it is impossible to confirm the area around the machine and observation cameras have been set up, clean off any dirt from the lens and make sure that the cameras give a clear view of the working area of the machine.

2.4.9.4 CHECKING SIGNS AND SIGNALMAN’S SIGNALS –

Set up signs to inform of road shoulders or soft ground. If the visibility is not good, position a signalman if necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.

–

Only one signalman should give signals.

Make sure that all workers understand the meaning of all signals and signs before starting work. 2 - 17


SAFETY

2.4.9.5 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting operations, always check the following to confirm there are no dangers on the jobsite. –

When carrying out operations near combustible materials, there is a hazard of fire, so be careful when operating.

–

Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do not operate where there is a hazard of landslides or falling rocks.

–

If water lines, gas lines, or high-voltage electrical lines may be buried under the worksite, contact each utility and identify their locations. Be careful not to sever or damage any of these lines (Fig. 3-16).

–

Take necessary measures to prevent any unauthorized person from entering the operating area.

–

If there is a fire near the machine, there is danger of sparks being sucked in and causing a fire on the machine.

–

When travelling or operating in shallow water or on soft ground, check the shape and condition of the bedrock, and the depth and speed of flow of the water before starting operations.

–

Maintain the travel path on the jobsite so that there is no obstruction to travel operations.

Fig. 3-16

2.4.9.6 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES

DANGER HIGH VOLTAGE! Do not travel or operate the machine near electric cables (Fig. 3-17). There is a hazard of electric shock, which may cause serious injury or property damage. Even going close to high-voltage cables can cause an electric shock, which may cause serious burns or even death.

Fig. 3-17

2 - 18

SAFETY


On jobsites where the machine may go close to electric cables, always do as follows. –

Before starting work near electric cables, inform the local power company of the work to be performed, and ask them to take the necessary action.

–

Always maintain a safe distance (see the table on the right) between the machine and the electric cable. Check with the local power company about safe operating procedure before starting operations.

–

To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on top of the seat, and be careful not to touch the chassis with any exposed part of your body.

–

Use a signalman to give warning if the machine approaches too close to the electric cables.

–

When carrying out operations near high voltage cables, do not let anyone near the machine.

–

If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should not leave the operator's compartment until it has been confirmed that the electricity has been shut off. Also, do not let anyone near the machine.

Voltage of Cables 100 V - 200 V 6,600 V 22,000 V 66,000 V 154,000 V 187,000 V 275,000 V 500,000 V

Safety Distance Over 2 m (7 ft) Over 2 m (7 ft) Over 3 m (10 ft) Over 4 m (14 ft) Over 5 m (17 ft) Over 6 m (20 ft) Over 7 m (23 ft) Over 11 m (36 ft)

2.4.9.7 WORKING ON LOOSE GROUND –

Avoid travelling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or after earthquakes is weak in these areas.

–

When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling.

2.4.9.8 GAS, DUST, STEAM AND SMOKE

WARNING RISK OF EXPOLSION AND FIRE! Welding, flame-cutting and grinding work on the machine increases the risk of explosion and fire which may result in serious injury or death. All relevent safety measures must be followed and only under expressly obtained authorization. Special care must be taken before welding, flame-cutting and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can create explosive gases which will accumulate in the chambers of the counterweight. These gases must be expelled before welding, flame-cutting and grinding operations are carried out on the counterweight. Follow the instructions given in PARTS & SERVICE NEWS No. AH04518 for expelling the gases from the counterweight chambers. (See Volume 2 binder)

2 - 19


SAFETY

WARNING RISK OF EXPLOSION! Substances and objects igniting can lead to fire or explosion resulting in serious injury or death. Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other inflammable substances and make sure that the premises are adequately ventilated as there is a risk of explosion.

2.4.9.9 VENTILATION OF ENCLOSED AREAS

WARNING POISONOUS FUMES! Unventilated areas where poisonous fumes can accumulate can kill. Always ensure adequate ventilation.

–

Operate internal combustion engines and fuel operated heating systems only on adequately ventilated premises. Before starting the machine on enclosed premises, make sure that there is sufficient ventilation (Fig. 3-18). Observe the regulations in force at the respective site.

–

If it is necessary to start the engine within an enclosed area, or when handling fuel, flushing oil, or paint, open the doors and windows to ensure that adequate ventilation is provided to prevent gas poisoning.

Fig. 3-18

2 - 20

SAFETY


2.4.10 STARTING ENGINE 2.4.10.1 WARNING TAG –

If there is a "DANGER DO NOT OPERATE!" warning tag displayed, it means that someone is carrying out inspection and maintenance on the machine (Fig. 3-19). If the warning sign is ignored and the machine is operated, there is a danger that the person carrying out the inspection or maintenance may be caught in the rotating parts or moving parts and suffer personal injury or death. Do not start the engine or touch the levers.

Fig. 3-19

2.4.10.2 CHECKS BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work to ensure that there is no problem with the operation of the machine. If this inspection is not carried out properly, problems may occur with the operation of the machine, and there is the danger that this could lead to serious personal injury or death. –

Remove all dirt from the surface of the window glass to ensure a good view.

–

Completely remove all flammable materials accumulated around the engine and battery, and remove any dirt from the windows, mirrors, handrails, access ladder and steps.

–

Check the coolant levels, fuel levels, and oil levels, and check for damage to the electric wiring.

–

Adjust the operator's seat to a position where it is easy to carry out operations, check the camera system functions and check that there is no damage or wear to the seat belt or mounting clamps.

–

Check the operation of the instruments and gauges, check the angle of the mirror, and check that the control levers are all at the Neutral position.

–

Before starting the engine, check that lock lever (Fig. 3-20) is in LOCK position (L).

–

Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat.

–

Check that there are no persons or obstacles above, below, or in the area around the machine.

Fig. 3-20

2.4.10.3 PRECAUTION WHEN STARTING ENGINE –

Start and operate the machine only while seated.

–

Do not short circuit the starting motor circuit to start the engine. Short circuiting can cause fire.

–

When starting the engine, sound the horn as a warning.

2 - 21


–

SAFETY

Do not let any person on the machine other than the operator and the operator's assistant (1 person). For demonstration purposes or during training, more than two people can be present in the operator’s cabin at the same time. All personnel within the cabin at such times must secure good hand-holds and be aware of sudden movements. All appropriate relevant safety measures are to be observed.

2.4.10.4 PRECAUTION IN COLD AREAS –

Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control levers or control pedals are operated, the reaction of the machine will be slow or the machine may move in a way not expected by the operator. Particularly in cold weather, be sure to carry out the warming-up operation thoroughly.

–

If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is a hazard that this will ignite the battery and cause the battery to explode.

–

Before charging or starting the engine with a different power source, melt the battery electrolyte and check that there is no leakage of electrolyte before starting.

2.4.11 OPERATION 2.4.11.1 CHECKS BEFORE OPERATION If the checks before starting are not carried out properly, the machine will be unable to display its full performance, and there is also danger that it may lead to serious personal injury or death. When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. –

Always fasten your seat belt.

–

Check that the movement of the machine matches the display on the control pattern label in the cabin. If it does not match, replace it immediately with the correct control pattern label.

–

Check the operation of the gauges and equipment, and check the operation of the bucket, arm, boom, travel system and swing system.

–

Check for any problem in the sound of the machine, vibration, heat, smell, or gauges; check also that there is no leakage of oil or fuel.

–

If any problem is found, carry out repairs immediately.

2 - 22

SAFETY


2.4.11.2 PRECAUTIONS WHEN TRAVELLING IN FORWARD OR REVERSE –

Before travelling, set the machine so that sprocket (1) is behind the operator's seat (Fig. 3-21).

–

If sprocket (1) is in front of the operator's cab, the machine moves in the opposite direction from the operation of the pedals (front and rear travel is reversed, left and right steering is reversed). Be extremely careful when operating the machine in this situation.

Fig. 3-21

–

Before travelling, check again that there is no one in the surrounding area, and that there are no obstacles (Fig. 3-22).

–

Before travelling, sound the horn to warn people in the area.

–

Always operate the machine only when seated.

–

Do not allow anyone apart from the operator to ride on the machine.

–

Check that the travel alarm works properly.

–

Secure the cab door when it is both open and closed.

–

Always keep the cab door closed when operating the machine. Fig. 3-22

–

If there is an area to the rear of the machine which cannot be seen, position a signal person. Take special care not to hit other machines, objects or people when turning or swinging the machine (Fig. 3-23)

Fig. 3-23 NOTE!

Always be sure to carry out the above precautions even when the machine is equipped with mirrors or camera systems.

2 - 23


2.4.11.3 PRECAUTIONS WHEN TRAVELLING –

When travelling on flat ground, keep the work equipment 100 to 150 cm (39 to 59 in) high above the ground (Fig. 3-24).

–

If the view to the right side is poor, raise the boom to ensure better visibility.

–

When travelling on rough ground, travel at low speed and do not operate the steering suddenly. There is danger that the machine may turn over. The work equipment may hit the ground surface and cause the machine to lose its balance, or may damage the machine or structures in the area.

–

Fig. 3-24

–

Avoid travelling over obstacles when possible. If the machine has to travel over an obstacle, keep the work equipment close to the ground and travel at low speed. Never travel over obstacles which make the machine tilt strongly to one side (Fig. 3-25).

–

When travelling or carrying out operations, always keep a safe distance from people, structures or other machines to avoid coming into contact with them.

Fig. 3-25

2 - 24

SAFETY

SAFETY


2.4.11.4 TRAVELLING ON SLOPES To prevent the machine from tipping over or slipping to the side, always do as follows. –

Keep the work equipment 100 - 150 cm (39 - 59 in) above the ground surface so that the work equipment can be lowered to the ground immediately to stop the machine in emergencies (Fig. 3-26).

–

When travel up slopes, set the operator's cab facing uphill, when travel down slopes, set the operator's cab facing downhill. Always be aware and informed about the firmness and bearing capacity of the ground under the machine when travelling. Cavaties and underground mines may cause the ground beneath the excavator to collapse. Fig. 3-26

–

When travelling up a steep slope, extend the work equipment to the front to improve the balance, keep the work equipment approximately 100 to 150 cm (39 to 59 in) above the ground, and travel at low speed (Fig. 3-27).

Fig. 3-27

–

When travelling downhill, keep the travel pedals close to the neutral position, and travel at low speed.

–

Always travel straight up or down a slope. travelling at an angle or across the slope is extremely dangerous.

–

Do not turn on slopes or travel across slopes. Always go down to a flat place to change the position of the machine, then travel on to the slope again (Fig. 3-28).

–

Travel on slippery ground with low speed. Even with slight slopes there is a hazard that the machine may slip

Fig. 3-28

2 - 25


2.4.11.5 OPERATIONS ON SLOPES –

When working on slopes, there is a hazard that the machine may lose its balance and turn over when the swing or work equipment are operated. This may lead to serious injury or property damage, so always provide a stable place when carrying out these operations, and operate carefully.

–

Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded. This operation is dangerous, and may cause the machine to tip over.

–

If the machine has to be used on a slope, pile the soil to make a platform (A on Fig. 3-29) that will keep the machine as horizontal as possible. Fig. 3-29

2.4.11.6 PROHIBITED OPERATIONS –

Never dig the work face under an overhang. There is a hazard that rocks may fall or that the overhang may collapse and fall on top of the machine (Fig. 3-30).

Fig. 3-30

–

Do not excavate too deeply under the front of the machine. The ground under the machine may collapse and cause the machine to fall (Fig. 3-31).

Fig. 3-31

2 - 26

SAFETY

SAFETY


–

To make it easier to escape if there is any problem, set the tracks at right angles to the road shoulder or cliff with the sprocket at the rear when carrying out operations (Fig. 3-32).

–

Generally speaking, the machine is more liable to overturn when the work equipment is at the side than when it is at the front or rear. – Do not suddenly lower, swing, or stop the work equipment. – Do not suddenly extend or retract the boom cylinder. There is a hazard that impact will cause the machine to tip over.

–

Do not pass the bucket over the head of other workers or over the operator's seat of dump trucks or other hauling equipment. The load may spill or the bucket may hit the dump truck and cause serious injury or property damage.

Fig. 3-32

2.4.11.7 TRAVELLING ON FROZEN OR SNOW COVERED SURFACES –

Snow-covered or frozen surfaces are slippery, so be extremely careful when travelling or operating the machine, and do not operate the pedals suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.

–

With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the machine to tip over.

–

If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be careful not to leave the road shoulder or to get trapped in a snow drift.

–

When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out operations carefully.

2.4.11.8 PARKING THE MACHINE –

Park the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low.

–

Lower the work equipment completely to the ground.

–

When leaving the machine, set lock lever (1) to the LOCK position (L), then stop the engine (Fig. 3-33).

–

Always close the operator's cab door, and use the key to lock all the equipment in order to prevent any unauthorized person from moving the machine. Always remove the key, take it with you, and leave it in the specified place.

–

If it is necessary to park the machine on a slope, always set the bucket on the downhill side, then dig it into the ground.

Fig. 3-33

2.4.11.9 TRANSPORTATION This machine must be disassembled for transportation. When transporting the machine, please consult your Komatsu distributor. Use only appropriate means of transport and lifting gear of adequate capacity. The recommissioning procedure must be strictly in accordance with the General Assembly Procedure Manual.

2 - 27

PRECAUTION FOR MAINTENANCE

2.5


2.5.1

GENERAL PRECAUTIONS

SAFETY

–

Observe the adjusting, maintenance and inspection activities and intervals set out in the Operation,- Lubrication and Maintenance Manual, including information on the replacement of parts and equipment. These activities may be executed by skilled personnel only.

–

Brief operating personnel before beginning special operations and maintenance work, and appoint a person to supervise the activities.

–

In any work concerning the operation, conversion or adjustment of the machine and its safety-oriented devices or any work related to maintenance, inspection and repair, always observe the start-up and shut-down procedures set out in the Operation,- Lubrication and Maintenance Manual and the information on maintenance work.

–

Ensure that the maintenance area is adequately secured.

–

If the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by: – locking the principal control elements and removing the ignition key and/or – attaching a warning tag to the main switch or control levers. – setting the maintenance safety switch to the 0 position and securing it with a padlock

–

Carry out maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movement and buckling.

–

To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended loads.

–

The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The marshaller giving the instructions must be within sight or sound of the operator.

–

For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders and working platforms. Never use machine parts as a climbing aid. Wear a safety harness when carrying out maintenance work at greater heights. Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.

–

Always tighten any screwed connections that have been loosened during maintenance and repair.

–

Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work.

–

Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.

–

Before starting any lubrication or maintenance work read the Fundamental Safety Instructions on page 3-1.

–

Park the Excavator at a safe place on level ground. Proceed according to the instructions ”Parking the Shovel”. Lower the attachment flat onto the ground. Move all control levers to neutral position.

–

Stop the engines and move all control levers through their shift positions to relieve the pressure in the hydraulic system. Refer to ”Stopping the Engines” for detailed description of the stopping procedure.

–

Before any maintenance work is started, set the maintenance safety switch to 0 position. Find to the location of the maintenance safety switch refer to section 2.5.1.3 on page 3-30. In the 0 position the engines can not be started. Secure this position by inserting a padlock into the holes of the switch. Up to ten padlocks can be attached to the holes provided.

–

A warning plate ”Caution Machine Maintenance” must be fixed in the Operator’s cab before any lubrication or maintenance work is started.

–

Block the machine to prevent machine movement

2 - 28

SAFETY


–

Always use safety devices to block hydraulic cylinders. Never rely on the machine hydraulic system to hold when working on the loader attachment. A hydraulic line or cylinder could fail or someone could accidently strike the control levers causing the loader to fall.

–

Relieve all pressure in the hydraulic system before servicing the hydraulic system.For information on relieving the pressure in the hydraulic system, refer to chapter ’Relieving The Pressure In The Hydraulic System’ in the ’Operation’ part of this manual.

–

Oily cloth and inflammable material must be removed from the machine. Clean the excavator before starting maintenance work.

–

Switch-off battery main switch and remove key, before working on the electrical system.

–

Wear safety clothing, goggles, respirator and other safety devices, whenever working conditions make this necessary. Observe the local safety rules.

–

Never allow unauthorized persons access to the machine during lubrication and maintenance work.

–

After servicing, remove oily cloth, inflammable material and all tools from the machine.

–

Clean the Excavator with a steam jet, especially after servicing the hydraulic system and fuel system.

WARNING BEWARE OF STEAM! Hot steam can cause serious personal injury. When using a steam cleaner, wear safety glasses and protective clothing.

–

For cleaning the Excavator and its components use only fresh water with a salt content of less than 0.05%.

–

DO NOT use steam jet, high pressure cleaning device or strong water jet for cleaning headlights, solenoid valves, sensors, cable connections and bearings.

–

Be sure to reinstall safety devices, guards or shields after adjusting and/or servicing the machine.

2.5.1.1 SELECTION AND QUALIFICATION OF PERSONNEL - BASIC RESPONSIBILITIES –

Any work on and with the machine must be executed by reliable personnel only. Statutory minimum age limits must be observed.

–

Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, set-up, maintenance and repair.

–

All personnel must be aware of the appropriate safety measures when working on or around the machine.

–

Make sure that only authorized personnel works on or with the machine.

–

Define the machine operator’s responsibilities - also with regard to observing traffic regulations - giving the operator the authority to refuse instruction by third parties that are contrary to safety.

–

Do not allow persons to be trained or instructed or persons taking part in a general training course on or with the machine without being permanently supervised by an experienced person.

–

Work on the electrical system and equipment of the machine must be carried out only by skilled electricians or by persons instructed under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations.

–

Work on the chassis, brake and steering systems must be performed only by skilled personnel who have been specifically trained for such work.

Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of hydraulic equipment.

2 - 29


SAFETY

2.5.1.2 STOP ENGINE FOR MAINTENANCE –

Stop the machine (Fig. 3-34) on firm, level ground.

–

Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low.

–

Lower the work equipment completely to the ground and stop the engine.

Fig. 3-34

–

Turn the main key switch to the ON position. Operate the work equipment control lever back and forth, left and right at the full stroke 2 to 3 times to eliminate the remaining internal pressure in the hydraulic circuit, and then push up lock lever (1) to the LOCK position (Fig. 3-35).

–

Check that the battery main switch is off and main power is not conducted. (Wait for approx. one minute after activating the engine STOP switch and press the horn switch. If the horn does not sound, it is not activated.)

Fig. 3-35

2.5.1.3 WARNING TAG –

Always attach the “DO NOT OPERATE“ warning tag (Fig. 336) to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine. Attach additional warning tags around the machine if necessary.

–

Keep this warning tag in the tool box while it is not used. If there is not the tool box, keep the tag in the operation manual pocket.

–

If any other person starts the engine, or touches or operates the control levers or control pedals while you are performing service or maintenance, you may suffer serious injury. Fig. 3-36

2 - 30

SAFETY

–

Before entering the machinery house, switch off maintenance safety switch (Fig. 3-37)

–

The maintenance safety switch is located in the machinery house, next to the entrance door (Pos. 1 on Fig. 3-38).

–

Before beginning maintenance operations, set the safety switch to "0" to prevent a starting of the engines. Secure this position by inserting a padlock into the holes of the safety switch. Up to ten padlocks can be attached.


Fig. 3-37

Fig. 3-38

2.5.1.4 KEEP WORKPLACE CLEAN AND TIDY

CAUTION HAZARD OF ACCIDENTS! If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over and injure yourself. Observe the following points.

–

Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances that will cause you to slip. Always keep the work place clean and tidy to enable you to carry out operations safely.

–

Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying 2 - 31


SAFETY

2.5.1.5 APPOINT LEADER WHEN WORKING WITH OTHERS When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his instructions during the operation.

2.5.1.6 TWO WORKERS FOR MAINTENANCE WHEN THE MACHINE IS RUNNING –

To prevent injury, do not perform maintenance or adjustments while the engine runs. If work must be carried out with the engine running, carry out the operation with at least two workers and do as follows: – One worker must always sit in the operator's seat and be ready to stop the engine at any time. All workers must maintain contact with each other and be fully aware of all relevant safety measures.

–

For safety information when working with high pressure oil in the hydraulic system, refer to section 2.6 on page 3-40.

–

When carrying out operations near rotating parts, there is a hazard of being caught in the parts, so be careful not to come close (Fig. 3-39).

–

Fig. 3-39

Do not touch any control levers or pedals. If they must be operated, always give a signal to other workers to warn them to move to a safe place.

2.5.1.7 INSTALLING, REMOVING OR STORING ATTACHMENTS –

Appoint a leader before starting removal or installation operations for attachments.

–

Place attachments that have been removed from the machine in a stable condition so that they do not fall (Fig. 3-40). And take steps to prevent unauthorized persons from entering the storage area.

Fig. 3-40

2 - 32

SAFETY


2.5.1.8 PRECAUTIONS WHEN WORKING UNDER THE MACHINE OR EQUIPMENT –

If it is necessary to go under the work equipment or the machine to carry out service and maintenance (Fig. 3-41), support the work equipment and machine securely with blocks and stands strong enough to support the weight of the work equipment and machine.

–

It is extremely dangerous to work under the machine if the track shoes are lifted off the ground and the machine is supported only with the work equipment. If any of the control levers are touched by accident, or there is damage to the hydraulic piping, the work equipment or the machine will suddenly drop. This is extremely dangerous. Never work under the work equipment or the machine. Fig. 3-41

2.5.1.9 NOISE When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers or ear plugs while working. If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.

2.5.1.10 WHEN USING A HAMMER When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury. Always do as follows. –

If hard metal parts such as pins, bucket teeth, cutting edges, or bearings are hit with a hammer, there is a hazard that pieces might be scattered and cause injury. Always wear safety glasses and gloves (Fig. 3-42).

–

When hitting pins or bucket teeth, there is a hazard that broken pieces might be sent flying and injure people in the surrounding area. Always check that there is no one in the surrounding area.

–

There is a hazard that the pin hit with strong force may fly out and injure people in the surrounding area.

Fig. 3-42

2 - 33


SAFETY

2.5.1.11 PROPER TOOLS –

Use only tools suited to the task and be sure to use the tools correctly. Using damaged, low quality, faulty, makeshift tools or improper use of the tools could cause serious personal injury (Fig. 3-43).

Fig. 3-43

2.5.1.12 ACCUMULATOR The accumulator is charged with high-pressure nitrogen gas. When handling the accumulator, careless procedure may cause an explosion which could lead to serious injury or property damage (Fig. 3-44). For this reason, always observe the following precautions. –

Do not disassemble the accumulator.

–

Do not bring it near flame or dispose of it in fire.

–

Do not make holes in it, weld it, or use a cutting torch.

–

Do not hit or roll the accumulator, or subject it to any impact.

–

When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to have this work performed.

Fig. 3-44

2.5.1.13 PERSONNEL Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area. If necessary, employ an observer.

2.5.2

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

2.5.2.1 PRECAUTION WHEN WELDING

WARNING RISK OF EXPOLSION AND FIRE! Welding, flame-cutting and grinding work on the machine increases the risk of explosion and fire which may result in serious injury or death. All relevent safety measures must be followed and only under expressly obtained authorization.

Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding.

2 - 34

SAFETY


2.5.2.2 BATTERY HANDLING

WARNING RISK OF EXPLOSION AND FIRE! Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Wrong handling can lead to serious injury or fire. For this reason, always observe the following precautions.

–

Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause an explosion. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the UPPER LEVEL line.

–

When working with batteries, always wear safety glasses and rubber gloves.

–

Never smoke or use any flame near the battery (Fig. 3-45).

Fig. 3-45

–

If you spill acid on your clothes or skin, immediately flush the area with large amount of water.

–

If acid gets into your eyes (Fig. 3-46), flush them immediately with large amount of water and seek medical attention.

–

Before working with batteries, activate the STOP switch and remove battery main switch key.

Fig. 3-46

As there is a hazard that sparks will be generated, always do as follows. –

Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or other metal objects lying around near the battery.

–

When disconnecting the battery terminals, wait for approx. one minute after activating the engine STOP switch and be sure to disconnect the grounding terminal (negative (-) terminal) first. Conversely, when connecting them, begin with the positive (+) terminal and then the grounding (-) terminal. Make sure that all the terminals are connected securely.

–

Attach the battery terminal securely.

–

Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis, take it to a well-ventilated place, and remove the battery caps before charging it.

–

Tighten the battery caps securely.

–

Install the battery securely to the determined place. 2 - 35


2.5.3

SAFETY

PRECAUTIONS WITH HIGH PRESSURE FLUID

WARNING FLUID UNDER HIGH PRESSURE! The hydraulic system is always under internal pressure and can lead to serious injury when leaking. When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has been released.

2.5.3.1 PRECAUTIONS WITH HIGH FUEL PRESSURE –

For details of the method of releasing the pressure, see the latest version of the Operation and Maintenance Manual. If the circuit is still under pressure, do not carry out any inspection or replacement operation.

–

If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping and hoses and for swelling in the hoses.

–

When carrying out inspections, wear full-face protection and penetration resistant clothing and gloves (leather).

–

There is a hazard that high-pressure oil leaking from small holes may penetrate your skin or cause blindness if it contacts your eyes directly (Fig. 3-47). If you are hit by a jet of high-pressure oil and suffer injury to your skin or eyes, wash the place with clean water, and consult a doctor immediately for medical attention.

Fig. 3-47

High pressure is generated inside the engine fuel piping when the engine is running. When carrying out inspection or maintenance of the fuel piping system, wait for at least 30 seconds after stopping the engine to let the internal pressure go down before starting inspection or maintenance.

2.5.3.2 HANDLING HIGH PRESSURES HOSES OR PIPES –

If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor.

Replace the hose if any of the following problems are found. –

Damaged or leaking hydraulic fitting.

–

Frayed or cut covering or exposed reinforcement wire layer.

–

Covering swollen in places.

–

Twisted or crushed movable portion.

–

Foreign material embedded in covering.

2.5.3.3 REPLACEMENT OF HOSE LINES Hydraulic hoses are subjected to natural aging. Hence, their usable lifetime is limited to maximum 6 years.

NOTICE The maximum permissible storage time of hydraulic hoses must be observed.

2 - 36

SAFETY


–

This storage period is part of the usable lifetime and must be considered when installing a new hose line. If, for example, a hose line with a one year storage time is to be installed, the remaining service life of the hose line must be considered. All hose lines are marked with the date of production.

–

Hose lines considered as Safety Critical Parts have to be replaced earlier. Refer to the chapter "Lubrication and Maintenance Schedule" in the MAINTENANCE section of the Operation and Maintenance Manual for further information.

All hydraulic hoses of the Shovel have to be replaced when their service life has expired, even if there is no visible damage. Refer to the chapter "Lubrication and Maintenance Schedule" in the MAINTENANCE section of the Operation and Maintenance Manual for further information.

NOTICE Repairs on hydraulic hoses are not allowed. Use ONLY GENUINE Komatsu Mining Germany replacement hose lines.

2.5.3.4 INSPECTION OF HOSE LINES

WARNING FLUID UNDER HIGH PRESSURE! The hydraulic system is always under internal pressure and can lead to serious injury when leaking. When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has been released.

Inspect all hoses, hose lines and fittings carefully during the course of the daily walk-around inspection. Check for leaks and damages. Beware of pinhole leakages. Replace damaged parts without delay. Some examples of faults on hydraulic hoses requiring replacement of the concerned part: –

Damage to the outer layer (e.g. chafed spots, cuts or scratches).

–

Brittle top layers. Flaws on the hose material

–

Distortion of the hose line (strong deviation from the original shape) under pressurized and pressureless conditions or when kinked or crushed, e.g. disintegration of hose layers or blistering.

–

Leaks.

–

Detachment of hose and fitting. Damaged hose fitting.

2.5.3.5 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS To ensure safety at all times when operating the machine, the user of the machine must always carry out periodic maintenance. In addition, to further improve safety, the user should also carry out periodic replacement of the parts given in the table. These parts are particularly closely connected to safety and fire prevention. With these parts, the material changes as time passes, or they easily wear or deteriorate. However, it is difficult to judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function completely. However, if these parts show any abnormality before the replacement interval has passed, they should be repaired or replaced immediately. If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same time as the hoses. When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.

2 - 37


–

SAFETY

Ask your Komatsu distributor to replace safety critical parts.

2.5.3.6 PRECAUTIONS FOR HIGH VOLTAGE

DANGER HIGH VOLTAGE! High voltage appliances cause serious injury or death. Authorized staff only.

–

When the engine is running and immediately after it is stopped, high voltage is generated inside the engine controller and the engine injector.

–

The headlights also operates using high voltage. Never perform maintenance on the headlights.

–

If it is necessary to touch the inside of the controller or the engine injector portion, or the headlight electrics please contact your Komatsu distributor.

–

The cab base contains high voltage electrical appliances. Access to the cab base for authorized service staff only.

2.5.3.7 AIR CONDITIONING MAINTENANCE

WARNING AIR CONDITIONING REFRIGERANT IS HARMFUL! If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frostbite. Never touch refrigerant.

2.5.3.8 COMPRESSED AIR

WARNING COMPRESSED AIR IS HAZARDOUS! When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles. Wear protective clothing.

–

When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves, and other protective equipment.

–

Never drop or insert tools or other objects into the fan or fan belt. Parts may break or be sent flying.

2 - 38

SAFETY


2.5.3.9 WASTE MATERIALS Operation –

Avoid engine idling over long periods. Long periods of idling (more than 10 minutes), will not only waste fuel, but is also harmful to the engine.

–

Avoid operation against the main relief valves of the hydraulic system. Move control lever to neutral position before the loader attachment stalls due to overload.

–

Position trucks in such a way, that loading operation can be carried out in a safe and economic manner. Avoid swing angles over 90°.

Maintenance –

Preserve our environment. To prevent environmental pollution, pay careful attention to the method of disposing waste materials.

–

Always drain fluids from your machine into containers. Never drain fluids onto the ground or dump it into the sewage system, rivers, the sea or lakes. (Fig. 3-48).

–

Dispose of harmful material, such as oil, fuel, coolant, solvent, filters and batteries in accordance with local environmental regulations and laws.

Fig. 3-48

2 - 39

ADDITIONAL SAFETY INFORMATION FOR TROUBLESHOOTING AND ADJUSTMENTS

2.6


2.6.1

INSPECTION OF THE HYDRAULIC SYSTEM

SAFETY

A hands-on approach to inspecting the hoses and pipes of the hydraulic system can only be made when the excavator is shut down and there is no oil pressure in the hydraulic system. –

Do not use your hands during inspection or move in the vicinity of the hydraulic system’s piping or tubing when the engine is running before checking for leaks, as hydraulic fluid escaping under pressure can cause serious injuries.

–

Additional to the general personal protective clothing as described on page 3-9, full face protection and penetration resistant clothing and gloves must be worn.

–

Troubleshooting and adjustments may only be performed by personnel trained by Komatsu Mining Germany in safe and correct hydraulic handling procedures.

–

Before troubleshooting or adjustments, the inspection of areas of potential dangers for damages, leaks or loose connections on the pressure lines and hydraulic components must be carried out visually only when the engine is shutdown and when there is no hydraulic pressure in the system.

–

When the machine is running, the areas of potential danger can only be entered when no leakages or other irregularities have been noticed when the high pressure oil circulation has been brought up to maximum pressure from a safe distance (operator’s cab, machinery house roof, ladder platform).

2.6.2

TWO WORKERS ONLY WHEN THE MACHINE IS RUNNING DURING ADJUSTMENTS

To prevent injury, do not carry out adjustments with the engine running. If work must be carried out with the engine running, perform the task with, at maximum, two maintenance workers and an operator and do as follows. –

An operator that has been trained on the machine he is operating, must always sit in the operator's seat and be ready to stop the engine at any time. All workers must maintain contact with the other workers and be fully aware of all relevant safety measures.

–

When carrying out operations near the fan, fan belt, or other rotating parts, there is a hazard of being caught in the parts, so be careful not to come close (Fig. 3-49).

–

Do not touch any control levers or control pedals. If any control levers or control pedals must be operated, always give a signal to the other workers to warn them to move to a safe place. Fig. 3-49

2.6.3

AREAS OF POTENTIAL DANGER AROUND THE EXCAVATOR

General safety rules for working on the excavator –

Only trained personnel who are aware of all dangers are allowed to work on the hydraulic system

–

Visually inspect all potential danger areas for leakages before pressure build up.

–

Do not remain on or around the excavator for longer than is absolutely necessary in order to perform your tasks.

2 - 40

SAFETY


Please continue reading on the next page.

2 - 41

SPECIAL SAFETY EQUIPMENT

2.7

Fig. 3-50 2 - 42


SAFETY

SAFETY

2.7.1


FRONT GUARD PROTECTIVE STRUCTUR ’FOPS’ FOR OPERATOR’S CAB

The Shovel must be equipped with a front guard protective structure ”OPG Front Guard” if it is used for applications where there is a risk of hitting objects from the front.

2.7.2

OBJECT HANDLING

Object handling operations are not allowed.

2.7.3

LIGHTING

The Shovel must only be operated when the operator has sufficient visibility in relation to the work area. Disturbing shady areas or dazzling effects must be avoided. If necessary, the Shovel must be retrofitted with additional lighting equipment (working lights) in order to ensure sufficient visibility conditions.

2.7.4

WARNING BEACON

The Shovel can be retrofitted with a warning beacon which is fitted on the cab roof by means of a magnetic bracket. REMARKS: The above-mentioned special safety devices can be ordered as accessories together with the Shovel. They are also available as a field package for installation through our service organization.

2.7.5

SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)

The safety harness should only be used together with connectors according to EN 354, and fall arrest according to EN 355, or fall protection devices according to EN 360. See the following pages for further information.

2.7.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD)

WARNING RISK OF FALLING! Injuries can occur when working in high areas. Always use a Safety Harness (1) in conjunction with a strap type Fall Absorber (2), illust. (Fig. 3-50) before boarding the loader attachment or other unsecured areas on the Shovel.

–

The Safety Harness is located in the Cabinet in the Operator’s Cab.

–

The illustration (Fig. 3-50) shows the standard use of the safety harness with a strap type fall absorber.

2 - 43


2 - 44

SAFETY

SAFETY


Legend for Fig. 3-50 (1)

Safety Harness according to EN 361

(2)

Strap-Type Fall Absorber according to DIN EN 355

(3)

Railings (attachment points)

(4)

Walkway on the boom

(A)

Shoulder Strap

(B)

Back Plate

(C)

Catching Hook

(D)

Shoulder-Strap Fixing

(E)

Belly Strap

(F)

Holding Hook

(G)

Hold-Back Hook

(H)

Pelvis Strap

(J)

Leg Strap

2.7.5.2 INSTRUCTIONS FOR USE Open the lock, lift the harness by the catch hook (C), ensuring the leg straps hang below (J). Pull the harness over the shoulders as you would a jacket. Insert the end of the belly strap (E) through the buckle and tighten securely, as shown in the illustration (Fig. 3-50). Prevent the shoulder straps from slipping by fastening the breast strap. Pull the leg straps (J) between the legs and securely buckle them at the front as illustrated. Adjust the harness so that it snugly fits the body ensuring that the catching hook (C) is in the center of the back. The safety harness is a personal accessory and should only belong to its owner. The safety harness should only be used together with connectors acc. to EN 354, and fall arrest acc. to EN 355, or fall protection devices acc. to EN 360. The attachment point for the safety harness should be above the wearer, and the carrying capacity of the attachment point should be sufficient to correspond with the minimum carrying capacity acc. to EN 795.

2 - 45


2 - 46

SAFETY

SAFETY


2.7.5.3 PRIOR TO USING THE HARNESS (1), THE WEARER SHALL –

Carry out a visual check of the system or component; correct functioning and perfect working order have to be assured.

–

Make sure that the recommendations for use with other components of the system be observed in conformity with the instructions for use.

The system or component must no longer be used, if there are any doubts in respect of its safe condition. The equipment has to be inspected by the manufacturer or by a qualified person. It is essential for safety reasons that a fall protection system or system component which has already been subjected to fall be removed from service and sent back to the manufacturer or an authorized qualified repair shop for maintenance and renewed testing. Fall protection systems have to be treated with care and to be kept clean and ready for use. It has to be warned against bringing the systems into contact with acids or other caustic liquids and gases, oils, detergents, or sharpedged objects. Should the harness have become wet during use or cleaning, do not dry near a fire or other sources of heat, but rather in a natural way in not too warm rooms. Keep the harness freely suspended or loosely rolled up. When using the fall protection systems, the pertaining safety regulations in force and the "Rules for Use of Personal Fall Arrest Systems" have to be observed for protection against danger. At least every 12 months, the safety harness and its components have to be inspected by a competent person authorized by the manufacturer and maintained, if the manufacturer considers it necessary.

2.7.5.4 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS (1), During the holding function, the connectors may only be placed around a mast or other construction between the two holding hooks, so that free fall is limited to max. 0.5 m. It should be strictly seen to it that the connector be not slung around constructions with too small diameter or sharp edges. With the lateral holding hooks, work may only be carried out on horizontal or almost horizontal surfaces (roofs). The connectors have to be adjusted in such a way that the area, where danger of falling down prevails, cannot be reached.

2 - 47


2 - 48

SAFETY

SAFETY


2.7.5.5 INSTRUCTIONS FOR USE Strap-Type Fall Absorber acc. to DIN EN 355 (Type E.K.N.-BFD) Use Within a fall-arrest system, the strap-type fall absorber (2) has to be used in conjunction with a safety harness (1) acc. to DIN EN 361. The maximum length including the safety rope must not exceed 2.0 m. For longer ropes, a rope-shortening device has to be applied in addition. Fix the rope to the attachment point and attach the strap-type fall absorber to the catching hook in the back of the safety harness. The attachment point should be above the wearer and its minimum carrying capacity should be 10 KN, acc. to DIN EN 795. The strap-type fall absorber and the safety rope must not be damaged, e.g. never pull them over sharp edges nor get them burnt by welding sparks. Storing and maintenance The strap-type fall absorber has to be kept dry in an airy and shady room. It must not be ex-posed to acids, caustic chemicals, nor to an aggressive atmosphere, and contact with oils has to be avoided. If the strap-type fall absorber is dirty, it may be cleaned with a little water and a light-duty detergent. Dry it in a shady place (nowhere near fire or other sources of heat). Protect it from sharp-edged objects. Inspection Prior to use, all parts have to be inspected for safe condition and damages. At least once a year, the strap-type fall absorber has to be tested by a competent person. A damaged or used strap-type fall absorber has to be removed from service immediately. The strap-type fall absorber must not be changed in any way.

2 - 49


2 - 50

SAFETY

HYDRAULIC MINING EXCAVATOR PC8000E-6

Machine model

Serial numbers

PC8000E-6

12037 and up

01 Specification

® Copyright 2010 KOMATSU MINING GERMANY GmbH

PC8000E-6

1

OPERATING WEIGHT 700-720 ton 1,540,000-1,590,000 lb 42

m3

SHOVEL CAPACITY 55 yd3 SAE 2:1 heaped

BACKHOE CAPACITY 42 m3 55 yd3 SAE 1:1 heaped

PC 8000 PC

8000

SUPER SHOVEL

PC 8000

S UPER S HOVEL

WALK-AROUND Building on the technology and expertise Komatsu has accumulated since establishment, GALEO presents customers worldwide with a strong, distinctive image of technological innovation and value. Designed for high productivity, safety and environmental considerations, GALEO machines reflect Komatsu´s commitment to contributing to the creation of a better world.

Genuine Answers for Land and Environment Optimization ● Quality management ISO 9001 certified. ● Environmental Management ISO 14001 certified. ● High consistent quality through continuous investment in personnel, design and manufacturing systems and processes.

Advanced Hydraulics Extended reliability and precise control ● Comprehensive monitored filtration. ● Simple open circuit hydraulic system with high efficency swing out oil coolers.

Powerful Diesel Engine Two Komatsu SDA16V160 engines ● Rated (each) 1500 kW 2010 HP, at 1800 rpm. ● Electonic engine management. ● Low engine emission levels meet EPA regulations. ● Time saving oil management system fitted as standard; Centinel Engine Oil Management, Reserve Engine Oil Supply and Eliminator Oil Filter systems.

2

Reliability and Durability Designed for lower operating costs ● Robust structural design developed from field experience and finite element analaysis. ● Extended life undercarriage wear parts; Big diameter rollers, idlers and sprockets. Large surface area and extensive precision hardening. Hardened track link pin bores.

SUPER SHOVEL

PC 8000 MATCHED FOR TRUCKS 240 ST AND LARGER

Large Comfortable Cab Full shift comfort ● Komatsu low noise cab on multiple viscous mounts for reduced noise and vibration. ● Large volume cab with deep wide front window. ● Comprehensive climate control with pressurised filtered air ventilation and air conditioning. ● High specification multi-adjustable air suspension seat. ● Well elevated operator position giving good all round view.

SHOVEL BUCKET 42 m3 55 yd3 SAE 2:1 heaped CROWD/BREAKOUT FORCE 2320 kN 521,500 lb MAIN DRIVE DIESEL: 2 x 1500 kW 2 x 2010 HP ELECTRIC: 2 x 1450 kW

Sustained High Production Designed for more tons per hour ● Powerful digging forces. ● Ease of bucket filling. ● Proven attachment design. ● All cylinders mounted under the shovel attachment for protection. ● Buckets and Wear Packages to suit all material densities and mining conditions.

Easy Maintenance Simple, common-sense design gives quick safe access to all major components ● Generous access to all major service points from machinery house floor level. ● Enclosed, internally lit machinery house with firewall separating engine from pump area. ● Automatic central lubrication. ● ECS electronic monitoring system providing real time information about the operating status of the machine. ● Ground-level access to hydraulically powered swing down service arm with Wiggins connections.

Worldwide Experience The PC8000 is the world’s largest series built hydraulic mining shovel and proven in key mining areas. Each shovel symbol represents one or several machines in operation.

3

PC 8000

S UPER S HOVEL

SPECIFICATIONS DIESEL DRIVE Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2x Komatsu SDA16V160 Type . . . . . . . . . . . . . . . . . . . 4-cycle, water-cooled, direct injection Aspiration . . . . . . . . . . . . . . . . . . . . . Turbocharged and aftercooled Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Rated power. . . . . . . . . . . . . . . . 2x 1500 kW 2010 HP @ 1800 rpm (SAE 1995/J1349)

Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All-speed, electronic The integrated engine oil and filter system extends service intervals. This combines the oil stabilising systems Reserve and Centinel with the Eliminator self cleaning oil filter to extend, with oil analysis, the oil change interval to 4000 hours. The high capacity engine radiators are each cooled by a hydraulically driven fan for superior cooling efficiency and requiring little maintenance.

ELECTRIC DRIVE Type................................................2 x Squirrel-cage induction motor Power output ....................................................................2x 1450 kW Voltage .....................................................................................6600 V* Amperage (approximate) ......................................................2 x 155 A Frequency (standard) .............................................50 Hz @ 1500 rpm Optional frequency.................................................60 Hz @ 1800 rpm *Other voltages available on request

ELECTRIC SYSTEM (Electric Version) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V Batteries (series/parallel). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 x 12 V Standard working lights . . . . . . . . . . . . . . . . . . . . . . . 8 Xenon lights Standard service lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 lights Optional lighting upon request

ELECTRIC SYSTEM (Diesel Version) System ..........................................................................................24 V Batteries (series/parallel).........................................................8 x 12 V Alternator ..............................................................................2 x 100 A Standard working lights...............................................8 Xenon Lights Standard service lights...........................................................15 lights *Optional lighting upon request

UNDERCARRIAGE Undercarriage consists of one center carbody and two track frames, each attached by four large diameter hardened pins. Center frame .............................................................................H-type Track frame ..............................................................Steel box-section

CRAWLER ASSEMBLY Track adjustment .........................................Automatic hydraulic type Number of track shoes....................................................48 each side Number of top rollers ........................................................3 each side Number of bottom rollers ..................................................8 each side

TRAVEL AND BRAKE SYSTEMS Travel control...................................................................2 foot pedals Gradeability ........................................................................Up to 50% Travel speed (maximum) .........................................2.4 km/h 1.5 mph Service brake ..............................................................Hydraulic brake Parking brake ..........................................................Wet, multiple-disc

HYDRAULIC SYSTEM The power train consists of two main drives. Diesel engines or electric motors can be supplied. Each of the two gearboxes drives four identical pumps which draw hydraulic oil from an unpressurized hydraulic tank. Open circuit hydraulics provide maximum cooling and filtering efficiency. Rated flow (total output) ...............................8280 ltr/min .. 2190 gpm Relief valve setting ...............................................310 bar.... 4,495 psi Swing flow rate .............................................2070 ltr/min ... 547 gpm High pressure in line filters...............................................200 microns one per pump located at the valve blocks

Full flow return line filters (8 double elements) ..................10 microns at head of hydraulic tank

Case drain/by-pass return line filters ..................................3 microns The four-circuit system features a load-limiting governor with oil delivery summation to the working circuits and incorporates pressure cut-off control. Hydropilot prioritizes hydraulic flow giving smooth hydraulic response, simple hydraulic system layout, and a reduced number of components. The hydraulic system includes six large swing-out vertical air-to-oil hydraulic coolers with temperatureregulated hydraulically driven fans.

AUTOMATIC CENTRALISED LUBRICATION Two hydraulically powered Lincoln Single Line automatic lubrication systems are provided as standard, complete with time and volume variable controls. Activity and malfunction events are linked to the ECS. The central lubrication and open gear lubricant are supplied by identical pump assemblies from a refillable twin container which has a capacity of 2 x 300 litres (2 x 80 gal.). Replenishment of the containers is through the Wiggins connections on the service arm.

SWING SYSTEM Hydraulic motors and drives..............................................................3 Swing brake, service ..................................................Hydraulic brake Swing brake, parking ..............................................Wet, multiple-disc Swing ring teeth ......................................................................External Swing speed (maximum) .........................................................2.7 rpm

4

SERVICE CAPACITIES Hydraulic oil tank . . . . . . . . . . . . . . . . . .83500 ltr 2,205 U.S. gal Hydraulic system . . . . . . . . . . . . . . . . . .11500 ltr 3,040 U.S. gal Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .13500 ltr 3,564 U.S. gal Engine coolant . . . . . . . . . . . . . . . . . . .2x 475 ltr 2x 125 U.S. gal Engine oil . . . . . . . . . . . . . . . . . . . . . . .2x 290 ltr 2x 77 U.S. gal Centinel engine oil make up tank . . . . .2x 670 ltr 2x 180 U.S. gal

PC 8000

SUPER SHOVEL

CAB The large welded steel safety cab is mounted with 18 viscous damping pads and sound insulated. It is equipped with automatic climate control and is pressurised. The operator’s seat is fully adjustable, air suspended, electrically heated and has a lap seat belt. There is a trainer’s seat. Low effort joy stick controls are electric over hydraulic and foot controls are for front shovel clam, crawler and swing brake. Full instrumentation and ECS are provided. Space in the console is provided for an additional monitor. AM/FM radio is fitted. The windshield wash wiper has two speed and intermittent operation. (Water reservoir 7 litres 1.8 gal.) Amenities include a wash basin with running water, water reservoir, (50 litres 13 gal.), refrigerator and storage cabinets. Powered mirrors are adjusted from inside the cab. There are left and right hand sliding windows. All windows are tinted parsol green. External metal louvres are provided on the cab side windows.

Cab engineering standards are; • ISO 3449 Falling Objects Protection Structure • ISO 6396 Noise in operator´s cab is 76 dB(A) • ISO 2631-1/ 5349-1 Vibration and Shock • Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . .10kW 34120 Btu • Heater/Demister (Diesel version) . . . . . . . . . . . . .10kW 34120 Btu • Heater/Demister (Electric version) . . . . . . . . . . . .12kW 40940 Btu

CS

HEALTH MONITORING SYSTEM The ECS digital diagnostic system, mounted in the operator‘s console, provides a text display of real time and stored information about the status of the operating machine. Non serious and critical faults are immediately announced, and for major malfunctions the engines are also shut down. The integrated digital storage provides full event history, which can be down loaded with a laptop computer. The ability to electronically record service events provides precise service information to assist in reducing downtime.

OPERATING WEIGHTS PC 8000 Backhoe:

PC 8000 Front Shovel:

Operating weight including 11,500 mm 37’9’’ boom, 5500 mm 18’0’’ stick, 38 m3 50.0 yd3 backhoe bucket, operator, lubricant, coolant, full fuel tank and standard equipment.

Operating weight including 8150 mm 26’’9’ boom, 5750 mm 18’9’’ stick, 42 m3 55.0 yd3 shovel bucket, operator, lubricant, coolant, full fuel tank and standard equipment.

Shoe Width

Operating Weight

Ground Pressure

Shoe Width

Operating Weight

Ground Pressure

1500 mm 59’’

710 t 1,565,000 lb

26.7 N/cm2 38.7 psi

1500 mm 59’’

700 t 1,540,000 lb

26.3 N/cm2 38.1 psi

1900 mm 75’’

720 t 1,590,000 lb

21.4 N/cm2 31.0 psi

1900 mm 75’’

710 t 1,565,000 lb

21.2 N/cm2 30.7 psi

10 5 4

3 8 9

8

7 2

2 10

8 6

Diesel

10 Explanation 1 Cab 2 Diesel Engines 3 Hydraulic Pumps 4 Hydraulic Tank 5 Hydraulic Coolers

6 7 8 9 10

6

1

SKZ 8006-64

Fuel Tank Valve Blocks Swing Motors Counterweight Secondary Egress

Electric Variation for Electric Drive Version 2 Electric Motors 6 High Voltage Electric Cabinet

SKZ 8006-65

Lower-Level Walkways

Upper-Level

5

PC 8000

S UPER S HOVEL

PRODUCTIVITY-FEATURES

8006057

DIGGING FORCES Break-out force Tear-out force

2000 kN 1800 kN

449,500 lb 404,600 lb

Maximum reach at ground level . . . . . . . . . .19900 mm 65’4’’ Maximum digging depth . . . . . . . . . . . . . . . .8400 mm 27’7’’

BACKHOE BUCKET, STICK AND BOOM COMBINATION Bucket Capacity

Width

Teeth

SAE Heaped 1 : 1

Boom Length 11500 mm 37’ 9’’

including Wear package WP-1 WP-2

Stick Length 5500 mm 18’ 0’’

38 m3 50 yd3

4830 mm

15’10’’

6

–

45.5 t 100,300 lb

Material weight to 1.8 t/m3 3000 lb/yd3

42 m3 55 yd3

4780 mm

15’8’’

6

40.3 t 88,900 lb

–


Alternative buckets / wear packages are available

6

Weight

SUPER SHOVEL

PC 8000

8006058

DIGGING FORCES Break-out force Crowd force

2320 kN 2320 kN

521,500 lb 521,500 lb

Level crowd at ground level . . . . . . . . . . . . .5900 mm Maximum dumping height . . . . . . . . . . . . .13900 mm

19’4’’ 45’7’’

SHOVEL BUCKET, STICK AND BOOM COMBINATION Bucket Capacity SAE / CECE Heaped 2 : 1

Heaped 1 : 1

42 m3 55 yd3

48 m3 63 yd3

Width

5630 mm 18’6’’

Teeth

6

Weight

Boom Length 8150 mm 26’ 9’’

including Wear package-3

Stick Length 5750 mm 18’ 9’’

67.2 t 148,000 lb


Alternative buckets / wear packages are available

7

STANDARD EQUIPMENT Hydraulic Mining Shovel will comprise: FRONT SHOVEL ATTACHMENT 8.15 m 26'9" boom and 5.75 m 18'9" stick complete with cylinders. 42 m3 55 yd3 (SAE 2:1) shovel bucket with mechanical teeth and lip system. OR BACKHOE ATTACHMENT 11.5 m 37'9" boom and 5.5 m 18'0" stick with 38 m3 50 yd3 (SAE 1:1) bucket with mechanical teeth and lip system. CRAWLER UNDERCARRIAGE Heavy-duty shovel type undercarriage consisting of a center carbody and 2 heavy box-type track frames, each having 8 bottom rollers, 3 top rollers, and 1500 mm 59" cast steel track shoes. Hydraulic track adjustment and parking brake provided. SUPERSTRUCTURE A main frame mounted over an externally toothed swing circle carries the platform component modules and the counterweight.

AM-FM radio. Washbasin with running water (reservoir 50 ltr 13 gal). Refrigerator and storage cabinets. Left and right hand sliding windows, external metal sunblinds. All windows tinted parsol green. LIGHTING 8 Xenon high performance lights. 15 service lights throughout platform. LUBRICATION LINCOLN central lubrication for basic machine, attachment, and bucket. 300 ltr 80 gal refillable container. LINCOLN automatic pinion lubrication system for swing circle teeth with 300 ltr 80 gal refillable container. Service point (diesel version only as standard) on hydraulic arm carrying WIGGINS fluid receiving connectors for filling of fuel, engine oil and coolant, hydraulic oil, grease, cab water and the evacuation of coolant, and hydraulic and engine oils. ACCESSORIES ● Acoustic travel alarm ● Hydraulically actuated ground access ladder ● Electric air horn ● Engine oil management package (Centinel, Reserve & Eliminator systems)

Diesel version • Fuel tank module. • Drive module: Two Komatsu SDA16V160 diesel engines, each driving 4 identical hydraulic pumps. Electric version • Electrical cabinet module. • Drive module: 2 Squirrel cage induction motors, each with soft start and mounted with 4 identical main hydraulic pumps per motor. • Hydraulic tank module. • Oil cooler module. • Cab base module: Includes the low tension electrical cabinet. OPERATOR’S CAB Fully enclosed steel cab which incorporates the ISO 3449 standard FOPS structure and CARRIER SÜTRAK air-conditioning unit. Mounted on viscous pads. GRAMMER full suspended seat with lap-belt. Fold-away auxiliary seat. Full selection of controls, switches, and ECS (Electronic Control System). Joystick and pedal-operated controls are electric over hydraulic. Windshield wash wiper with two-speed and intermittent operation (reservoir 7 ltr 1.8 gal).

OPTIONAL EQUIPMENT ● 1900 mm 75" trackshoes ● Extra or alternative, lighting ● Fire suppression system

● Electric drive ● Cable reel (Electric version) ● Service crane

● Low temperature package (incl. KIM hot start) ● Auxiliary diesel generator

DIMENSIONS

BASIC MACHINE WITH COUNTERWEIGHT OR O

N

A 1500mm B 1900mm CA 8150mm CB 8550mm D 2830mm E 3970mm F 7945mm G 10515mm H 3470mm

59" 75" 26'9" 28'1" 9'3" 13'00" 26'00" 34'6" 11'5"

I 3550mm J 8780mm K 9500mm LA 4550mm LB 5530mm M 3750mm N 10000mm O 8410mm OR 8710mm

11'8" 28'10" 31'2" 14'11" 18'1" 12'4" 32'10" 27'7" 28'7"

K

I J H

D A B

E F G

CA CB

Ground Clearance: 1144mm 3'9"

QESS0086 01

M

LB LA

8006_63

8006_62

©2006 Komatsu Printed in Germany

KOMATSU MINING GERMANY GMBH BUSCHERHOFSTRASSE 10 D-40599 DÜSSELDORF PHONE +49 (0) 211/ 71 09-0 FAX +49 (0) 211/ 71 58 22

www.komatsumining.com

Materials and specifications are subject to change without notice. is a trademark of Komatsu Ltd. Japan.

SHOP MANUAL

SHOP 12037-xE-GB-0


Machine model PC8000E-6

Serial number 12037 and up

10 Structure, Function

PC8000E-6

1

PC8000-6-E_#12048_Contents and 00_Foreword_rev1.doc

CONTENTS TABLE OF CONTENTS

00 01 02

Safety - Foreword Technical DATA (Leaflet) Assembly PROCEDURE (Brochure)

Section 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Main assembly groups Drive Hydraulic oil tank Hydraulic oil cooling Controlling Components Main hydraulic pumps and pump regulation Operating hydraulic Hydraulic track tensioning system Hydraulic operated access ladder Cable drum Hints for the hydraulic circuit diagram Hints for the electric circuit diagram ECS-T Lubrication System

APPENDIX

• Each section includes a detailed table of contents.

02.09.09

PC8000-6-E_#12048_Contents and 00_Foreword_rev1.doc

02.09.09

SAFTEY

SAFTEY NOTICE

SAFETY SAFETY NOTICE

• IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. The following Symbols are used in this Manual to designate Instructions of particular Importance.

WARNING -

Serious personal injury or extensive property damage can result if the warning instructions are not followed. To prevent injury to workers, this symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

CAUTION -

Minor personal injury can result or a part, an assembly, or the shovel can be damaged if the caution instructions are not followed.

NOTE -

Refers to special information

GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. continued 00-1

SAFTEY

SAFTEY NOTICE

Cont'd: GENERAL PRECAUTIONS 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower bucket, hammer or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out work on the oil or water circuits. continued 00-2

SAFTEY

SAFTEY NOTICE

Cont'd: PRECAUTIONS DURING WORK 13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. 19. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

00-3

ENVIRONMENT PROTECTION

Environment NOTICE

RECOMMENDATIONS FOR ENVIRONMENTALLY FRIENDLY OPERATION AND MAINTENANCE OF HYDRAULIC MINING SHOVELS

OPERATION

•

Avoid operation against the main relief valves of the hydraulic system. Move control lever to neutral position before the loader attachment stalls due to overload.

•

Position trucks in such a way, that loading operation can be carried out in a safe and economic manner. Avoid swing angles over 90°.

MAINTENANCE • • •

Preserve our environment. To prevent environmental pollution, pay careful attention to the method of disposing waste materials. Always drain fluids from your machine into containers. Never drain fluids onto the ground or dump it into the sewage system, rivers, the sea or lakes. Dispose of harmful material, such as oil, fuel, coolant, solvent, filters and batteries in accordance with environmental regulations and laws.

FOREWORD

FOREWORD GENERAL With this SERVICE MANUAL KOMATSU provides you with the description of the construction and the function of the major systems of the Hydraulic Excavator PC8000-6-E. We describe for you all functions and how to carry out the inspections and adjustments. How do you find "your" desired information? In the table of CONTENT all the functions and components are shown in their sequence of the description. If after reading this SERVICE MANUAL you can give us suggestions and comments for improvements - please do not hesitate to contact us. Komatsu Mining Germany GmbH - Service Training Postfach 180361 40570 Düsseldorf Tel.:0211 / 7109 - 206 Fax.:0211 / 74 33 07 The editorial staff will be pleased about your co-operation. - FROM THE PRACTICE - FOR THE PRACTICE -

• This service manual corresponds to the state of development of the machine at the time the manual was produced. Variations based on special customers request and special equipment are not included in this manual

00-4

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS HOISTING • Heavy parts (25 kg or more) must be lifted with a hoist etc.

• If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1. Check for removal of all bolts fastening the part to the relative parts. 2. Check for existence of another part causing interface with the part to be removed.

WIRE ROPES 1. Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing)

Rope diameter [mm]

10,0

11,2 12,5 14,0 16,0 18,0 20,0 22,4 30,0 40,0 50,0 60,0

Allowable load [tons]

1,0

1,4

1,6

2,2

2,8

3,6

4,4

5,6

10,0 18,0 28,0 40,0

• The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used.

2. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

continued Cont'd: 00-5

FOREWORD

HOISTING INSTRUCTIONS

WIRE ROPES 3. Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. • Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150.

00-6

FOREWORD

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE (1Kgm = 9,806Nm) STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS

Bolt dia.

Wrench size [mm]

Tightening torque [Nm] Quality grades

8.8

10.9

12.9

M 8

13

6

21

31

36

M 10

17

8

43

63

73

M 12

19

10

74

108

127

M 14

22

12

118

173

202

M 16

24

14

179

265

310

M 18

27

14

255

360

425

M 20

30

17

360

510

600

M 22

32

17

485

690

810

M 24

36

19

620

880

1030

M 27

41

19

920

1310

1530

M 30

46

22

1250

1770

2080

M 33

50

24

1690

2400

2800

M 36

55

27

2170

3100

3600

M 39

60

2800

4000

4700

M 42

65

3500

4950

5800

M 45

70

4350

6200

7200

M 48

75

5200

7500

8700

M 52

80

6700

9600

11200

M 56

85

8400

12000

14000

M 60

90

10400

14800

17400

M 64

95

12600

17900

20900

M 68

100

15200

21600

25500

32

35

41

46

Insert all bolts lubricated with MPG, KP2K

00-7

FOREWORD

CONVERSION TABLE

CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE Method of using the Conversion Table to convert from millimeters to inches. 1. Convert 55 mm into inches. (a) Locate the number 5 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A). (b) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). (c) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches. 2. Convert 550 mm into inches. (a) The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm. (b) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (c) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

00-8

FOREWORD

00-9

CONVERSION TABLE

FOREWORD

CONVERSION TABLE

00-10

FOREWORD

00-11

CONVERSION TABLE

FOREWORD

CONVERSION TABLE

00-12

FOREWORD

CONVERSION TABLE

Basic Values in Ohm according to DIN 43 76 For Measuring Resistor PT100

°C

-0

-1

-2

-3

-4

-5

-6

-7

-8

-9

-50

80,31

79,91

79,51

79,11

78,72

78,32

77,92

77,52

77,13

76,73

-40

84,27

83,88

83,48

83,08

82,69

82,29

81,89

81,50

81,10

80,70

-30

88,22

87,83

87,43

87,04

86,64

86,25

85,85

85,46

85,06

84,67

-20

92,16

91,77

91,37

90,98

90,59

90,19

89,80

89,40

89,01

88,62

-10

96,09

95,69

95,30

94,91

94,52

94,12

93,73

93,34

92,95

92,55

0

100,00

99,61

99,22

98,83

98,44

98,04

97,65

97,26

96,87

96,48

°C

0

1

2

3

4

5

6

7

8

9

0

100,00

100,39

100,78

101,17

101,56

101,95

102,34

102,73

103,12

103,51

10

103,90

104,29

104,68

105,07

105,46

105,85

106,24

106,63

107,02

107,40

20

107,79

108,18

108,57

108,96

109,35

109,73

110,12

110,51

110,90

111,28

30

111,67

112,06

112,45

112,83

113,22

113,61

113,99

114,38

114,77

115,15

40

115,54

115,93

116,31

116,70

117,08

117,47

117,85

118,24

118,62

119,01

50

119,40

119,78

120,16

120,55

120,93

121,32

121,70

122,09

122,47

122,86

60

123,24

123,62 124,01, 124,39

124,77

125,16

125,54

125,92

126,31

126,69

70

127,07

127,45

127,84

128,22

128,60

128,98

129,37

129,75

130,13

130,51

80

130,89

131,27

131,66

132,04

132,42

132,80

133,18

133,56

133,94

134,32

90

134,70

135,08

135,46

135,84

136,22

136,60

136,98

137,36

137,47

138,12

100

138,50

138,88

139,26

139,64

140,02

140,39

140,77

141,15

141,53

141,91

110

142,29

142,66

143,04

143,42

143,80

144,17

144,55

144,93

145,31

145,68

120

146,06

146,44

146,81

147,19

147,57

147,94

148,32

148,70

149,07

149,45

130

149,82

150,20

150,57

150,95

151,33

151,70

152,08

152,45

152,83

153,20

140

153,58

153,95

154,32

154,70

155,07

155,45

155,82

156,19

156,57

156,94

150

157,31

157,69

158,06

158,43

158,81

159,18

159,55

159,93

160,30

16067

00-13

FOREWORD

CONVERSION TABLE

TEMPERATURE Fahrenheit – Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

00-14

FOREWORD

CONVERSION TABLE

00-14

Main Assembly Groups

Section 1.0 Page 1

Table of contents section 1.0 Section 1.0

Page Main assembly groups General lay out

2

1.1

Superstructure

3

1.1.1

Machine house

4

1.1.2

Hydraulic Oil Reservoir

5

1.1.3

Hydraulic Oil Cooler

6

1.1.4

High Voltage Switch Cabinet

7

1.1.5

Counter weight

8

1.1.6

Cab support (with Medium Voltage Switch Cabinet)

9

1.1.7

Operators cab

10

1.1.8

Main pumps and Control blocks

11

1.1.9

Swing gears

12

1.2

Under carriage

1.3

Attachment

13

1.3.1.

Backhoe Attachment (BHA)

14

1.3.2.

Front Shovel Attachment (FSA)

15

PC8000-6-E_Sec_1-0_#12048_rev0.doc

28.11.05

1.0 2

PC8000-6-E_Sec_1-0_#12048_rev0.doc

28.11.05


1.0

Section 1.0 Page 2

General lay out Legend for illustration (Z 22388): (1) Superstructure (2) Under carriage (3) Front Shovel Attachment (FSA) (4) Backhoe Attachment (BHA)

PC8000-6-E_Sec_1-0_#12048_rev0.doc

28.11.05

1.0 3

PC8000-6-E_Sec_1-0_#12048_rev0.doc

28.11.05


1.1

Section 1.0 Page 3

Superstructure Legend for illustration (Z 22389): (1) Operators Cab with integrated FOP system (2) Cab support (contains the electrical switch board for low- and medium-voltage) (3) Swing ring connection (4) High-Voltage cabinet (5) Main entrance to the motor and pump compartment. (6) Hydraulic ladder (7) Counter weight (8) Hydraulic oil cooler with hydraulic driven fans (9) Hydraulic oil reservoir (10) (11) (12) (13)

Electric motor No 1 Flexible coupling, rubber type PTO gear with all hydraulic pumps Main hydraulic pumps 1 – 4

(14) (15) (16) (17) (18) (19)

Electric motor No 2 Flexible coupling, rubber type PTO gear with all hydraulic pumps Main hydraulic pumps 5 – 8 Control blocks with high pressure filters Swing gears

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Section 1.0 Page 4

Superstructure 1.1.1

Machine house

Legend for illustration (Z 22393): (A) Motor cooling air inlet (B) Motor cooling air outlet (1) Electric motor No 1 (2) Electric motor No 2 (3) Flexible coupling, rubber type (4) Protecting cover (5) PTO gear box (6) High tension terminal box (7) Cooling fan housing (8) Air duct (9) Air to air heat exchanger (10) Air outlet duct (11) Hydraulic pump for the hydraulic oil cooler fan drive (12) Main hydraulic pumps (13) Auxiliary pumps, installed at the drive through shaft of the main hydraulic pumps (piggyback pumps) (14) Suction oil reservoir

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Section 1.0 Page 5



Legend for illustration (Z 22780): (1) Breather filter (2) Temperature controlled back pressure valve (3) Transfer pump (4) Return oil filter (5) Case drain (leak oil) filter (6) Main shut-off valve (Gate valve) with compensator (7) Return oil collector tube (8) Strainer

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1.1

Section 1.0 Page 6


Hydraulic Oil Cooler

Legend for illustration (Z 22781a): (1) Hydraulic oil cooler assembly with swing out facility (2) (3) (4)

Lower radiator set (2 identical cooler elements 106.3 and 106.4) Lower fan Hydraulic motor of lower fan (driven by prime mover 1)

(5) (6) (7)

Upper radiator set (2 identical cooler elements 106.1 and 106.2) Upper fan Hydraulic motor of upper fan (driven by prime mover 2)

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1.1

Section 1.0 Page 7


High Voltage Switch Cabinet

• Access to the high voltage area for authorized personnel only. The local safety regulations must be observed. • Before opening the door of the high voltage switch cabinet, make sure that the main power supply from the power station is interrupted. Legend for illustration (Z 25296): (1) Door, high voltage switch cabinet (2) Door, medium voltage switch cabinet (cab base) (3) Key for load cut-off switch actuator. Keep in the switch cabinet (4) Flap lockable for load cut-off switch (5) (6) (7)

(8) (9)

(10) (11)

Load cut-off switch Fuses Air conditioner including electric heaters for high voltage switch cabinet. The control panel for operating the air conditioner is located in the Medium Voltage Switch Cabinet. Compressor for air conditioner in high voltage switch cabinet. Thermoswitch (6B1) for monitoring temperature in high voltage switch cabinet. If temperature exceeds a fixed value the thermoswitch sends an error signal to the fault detection systems. Electric heater (3R23). The control panel for temperature adjustment is located in the Medium Voltage Switch Cabinet. Electric heater (3R21). The control panel for temperature adjustment is located in the Medium Voltage Switch Cabinet.

• Make sure to lock up door (1) and flap (4) with padlocks to prevent unauthorized access to the high voltage area.

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1.1


Counter weight

Legend for illustration (Z 22674b): (1) Counter weight Total weight ~ 53000 kg (2)

Mounting bolts Quantity 16

Bolt size (mm)

Grade

SW* (mm)

M 48

10.9

75

*

SW = Wrench size

(3)

Washers

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Tightening torque (Nm) 7500

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Section 1.0 Page 9


Cab support (with Medium Voltage Switch Cabinet)

Legend for illustration (Z 22782c): (1) Air conditioner for cab base, located at the outside of rear cab base wall.

)

(2)

Signal horn and compressor

(3)

Entrance door of cab base

(4)

Light switch

(5)

Switch board no. 3 at the back wall of cab base (socket outlets)

(6)

Switch board medium voltage.

(7)

Monitor and control panel.

(8)

Switch board for air conditioner in cab base

(9)

Switch board (X2). See page 227 for more information

1U2 + 1U4

Battery charger for main batteries.

1U4

Battery charger for emergency lighting system.

3R25 + 3R26

Electric heater, controlled by the air conditioner in cab base.

2M3

Compressor for air conditioner in operator’s cab (including crankcase heater).

2M2

Compressor for air conditioner in cab base (including crankcase heater).

1U1

Inverted rectifier. The inverted rectifier is protected by one 1.6AT fuse at the (+) terminal and one 10A circuit breaker at the terminal no. (11). The controls and monitors of the rectifier are located on panel (6).

REMARK:

The units 1U1, 2M2, and 2M3 are located below the floor plates in the cab base.

• Refer to the operation and maintenance manual, for further information.

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Section 1.0 Page 10


Operators cab

Legend for illustration (Z 21476): (1) (2) (3) (E19)

Monitor panel Switch panel Operators seat Control lever – EURO Control

– KMG Control

(E20)

Control lever – EURO Control

– KMG Control

(E21a)

Control pedal

A - forward Left track B - reverse

(E21b)

Control pedal

A - forward Right track B - reverse

(E22) (E23) (E24)

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Control pedal Control pedal Control pedal -

Swing brake Bucket closing Bucket opening

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Section 1.0 Page 11


Main pumps and Control blocks

Legend for illustration (Z 22783a): (1) Main pumps (prime mover 1) (2) Main pumps (prime mover 2) (3) High pressure filter (4) Main control blocks (5) Remote control valves

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Section 1.0 Page 12


Swing gears

Legend for illustration (Z 22784a): (1) Oil level gauge (2) Oil filler plug (3) Breather filter (4) Oil level gauge and filler tube. (5) Breather filter (6) Oil drain plug (7) Drain plug (8) Pinion (20.1 – 20.3) Swing motors (49.1 – 49.3) Swing brake valve blocks (50.1 – 50.3) Swing gear boxes – with integrated spring loaded multi disk brakes (Released by oil pressure)

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Section 1.0 Page 13

Under carriage Legend for illustration (Z 22643): (1) Undercarriage center body (2) Crawler carrier (3) Connecting pins, center body to crawler carriers (4) Crawler tracks (5) Rotary distributor (6) Brake valves (7) Travel motors (8) Parking brakes, spring loaded disk type brakes (9) Travel gear (10) Sprocket (11) Track rollers (12) Carrier rollers (13) Valve block of the hydraulic track tensioning system (14) Pressure accumulators of the hydraulic track tensioning system (15) Hydraulic track tensioning cylinders (16) Guide wheel (Idler) (17) Slip ring unit

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Section 1.0 Page 14

Attachment 1.3.1

Backhoe attachment (BHA)

Legend for illustration (Z 21482): (1) Boom (2) Boom Cylinders (3) Stick (4) Stick Cylinders (5) Bucket (6) Bucket Cylinders (7) Control arm (8) Linkage

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Section 1.0 Page 15

Attachment 1.3.2

Front Shovel Attachment (FSA)

Legend for illustration (Z 21483): (1) Boom (2) Boom Cylinders (3) Stick (4) Stick Cylinders (5) Bucket backwall (6) Bucket Cylinders (7) Bullclam (8) Bucket Clam cylinders

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Drive

Section 2.0 Page 1


Page Prime drive assembly General

2

2.1

Flexible coupling

3

2.2

Pump distributor gearbox (PTO)

4

2.3

Pump – spline shaft lubrication

5

2.4

PTO Lubrication and cooling - Function

6

2.5

PTO Lubrication and cooling – Adjustments

7

2.6

Hydraulic pumps – location, drive speed and flow rates

8

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2.0

Section 2.0 Page 2

Prime drive assembly Legend for illustration (Z 22785): (1) Electric Motor 1 (2) Electric Motor 2 (3) Cooling air intake (4) Cooling air exhaust (5) Alignment shims (6) Alignment supports (7) Motor frame (8) Coupling (9) Pump distributor gear (PTO)

General The two electric motors are solid bolted to the motor frame (7). The thickness of alignment shims (5) has to be selected according to the results of the alignment procedure, refer to Parts & Service News AH01523, last edition for more information.

)

• The alignment procedure must also be carried out when replacing the electric motor and/or the PTO.

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Drive

2.1

Flexible coupling Legend for illustration (Z 22786): (1) Housing (Rubber support ring) (2) Input drive hub (Motor side) (3) Output drive hub (PTO side) (4) Output drive flange (5) Rubber element (Motor side) (6) Bolt Quantity Bolt size (mm) 16

(7) (8) (9)

M 27 x 60

Grade 10.9

SW* (mm) 41

Tightening torque (Nm) 960.0 +110.0

Motor drive shaft Rubber element (PTO side) Bolt Quantity Bolt size (mm) 16

(10)

M 27 x 60

22

M 16 x 310

41


Grade 10.9

SW* (mm) 24


Washer Nut Bolt Quantity Bolt size (mm) 1

(14)

10.9

SW* (mm)

Bolt Quantity Bolt size (mm)

(11) (12) (13)

Grade

M 36 x 60

Grade 8.8

SW* (mm) 55

Tightening torque (Nm) 2170.0

Bolt Quantity Bolt size (mm) 10

M 18 x 40

Grade 10.9

SW* (mm) 27

Tightening torque (Nm) 360.0

Design: VULASTIC-L – coupling type are provided with two flexible rubber elements (5 + 8). The flexible ring connect the input drive hub (2) via input drive flange (4) with the output drive hub (3) of the coupling. Function: The high flexible LULASTIC–L coupling transfers the torque without any rotational gap. They are wear-resisting and maintenance free. Because of symmetrical arrangement of the flexible rings, there are no returning forces either by the torque transfer or the centrifugal forces. VULASTIC-L couplings dampen rotating vibrations, reducing same by partial storing of the shock energy and damp noises. The coupling allows in an acceptable range axial, radial and angular misalignment of the shafts.

)

• Repair and replacement have to be carried out according to Parts & Service News AH01523, last edition.

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2.2

Section 2.0 Page 4

Pump distributor gearbox (PTO) Legend for illustration (Z 22787a): (1) Oil level gauge (2) Oil filler plug (3) Breather filter (4) Oil level sight gauge (5) Flange for heater studs (6) Main pump drive shaft housings (7) Oil level plug of pump drive shaft housing (8) Oil filler plug with breather pipe of pump drive shaft housing (9) Oil drain plug of pump drive shaft housing (10) Oil drain plug of PTO gear (11) Suction line connection for gear oil cooling (12) Gear oil temperature probe mounting bore (13) Thermostat switch mounting bore cover plate (14) Return line connection from gear oil cooler (15) Return line connection from cooling system relief valve (C) Power take off for hydraulic oil cooler fan drive pump (D) Drive flange (M) Power take off for main pumps • Detail „S“. The arrows at detail S indicates the spray direction of the jet borings. Pay attention when disassembling / assembling. Description The pump distribution gear (PTO gear) is of a spur gear design and driven by an electric motor. The PTO gear runs in antifriction bearings and has been provided with a splash lubrication system. The oil supply of the bearings and tooth contacts takes place by an injection. The gearwheels are of case-hardened steel. The hydraulic pumps are directly attached to the gearbox. O-rings included in the supply enable the unit to be reliably sealed statically. The gearbox housing is of one-piece design and made of grey cast iron. Gearbox design allows a direct attachment to the drive motor via connection flange. The gearbox has been provided with connections for a separate cooling system resp. for heating rods. For more information refer to the REPAIR MANUAL Description for the lubrication see next pages.

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2.3

Section 2.0 Page 5

Pump – spline shaft lubrication Drive shaft housings Legend for illustration (Z 22788): (1) Oil filler plug with breather pipe of pump drive shaft housing (2) Oil level plug of pump drive shaft housing (3) Oil drain plug of pump drive shaft housing (A) Configuration, main pump drives (B) Configuration, auxiliary pump drives All drive shaft housings are filled with the same gear oil as the pump distributor gear. This is done for two reasons: 1. To lubricate the multi-spline connections, to prevent wear and corrosion. 2. It makes it easier to determine a sealring leak at one of the drive shaft connections. Function: If the oil level increases the oil drops out of the breather pipe (1). If this oil is gear oil it indicates a possible leak at the gearbox side. If the oil is a mixture of gear oil and hydraulic oil it shows a possible leak at the pump side. If at an oil level check a loss of oil is found it may be due to worn or defective radial seal rings.

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2.4

Section 2.0 Page 6

PTO Lubrication and cooling The machine is equipped with two motors and gearboxes. The motor to the front is called motor 1 and the motor close to the counter weight is called motor 2. The extension of the component designation shows the mounted position. Example: Pressure filter (69.1) is the pressure filter for the PTO lubrication of motor 1 and (69.2) for motor 2. Legend for illustration (Z 22789): (1) Line to the cooler (hot gear oil) (2) Return line from valve (74.1 – 74.2) (3) Case drain line from valve (74.1 – 74.2) (4) Return line from the cooler (cooled gear oil) (5) Pressure line to hydraulic fan drive motor (6) Hydraulic fan drive motor (7) Return line to hydraulic tank (9.2 + 9.4) Gear pump PTO-gearbox lubrication (69.1+69.2) Pressure filter - PTO gear lubrication (74.1+74.2) Pressure relief valve, 7.5 bar (96) Hydraulic oil tank (114.1+114.2) Pressure reducing valve (fan speed) (116.1+116.2) Check valve (anti cavitation valve for fan drive motor) (117.1+117.2) Gear Oil cooler unit (incl. hydraulic fan motor) (B17-1+B17-2) Pressure switch, 0,5 bar (B27-1+B27-2) Maintenance switch, 5 bar (B49-1+B49-2) Temperature sensor (M21-1+M21-2) Pressure check point (fan speed) (P) Pressure port (Y201-1+Y201-2) Solenoid valve Function: Pump (9.2)/(9.4) forces the gear oil from the gear oil pan through filter (69.1)/(69.2) to pressure relief valve (74.1)/(74.2). This pressure relief valve acts as a back pressure valve causing that most of the oil passes through the gear oil coolers (117.1)/(117.2). The gear oil coolers are assemblies consisting of frame, cooler element, hydraulic motor with intake air fan and fan guard. The units are located below the catwalk in front of the PTO’s. From the coolers the oil flows to the port (P) of the gear and internally via a system of pipes to the several spray nozzles. The spray nozzles in the gear case ensure proper and adequate distribution of the lube oil. The circuit is monitored by the pressure switches (B17-1)/(B17-2). At too low lube oil pressure (0.5 bar), a fault message will be displayed on the monitor at the dash board. The gear oil temperature is monitored by the sensor unit (B49-1) (B49-2). At too high oil temperature a fault message will be displayed on the monitor at the dash board. During the warm up period solenoid valve (Y201-1) / (Y201-2) is de-energized so that the oil flow through the cooler is interrupted, which causes that the oil gets quicker its optimum operating temperature. At normal operating temperature solenoid valve (Y201-1/Y201-2) is energized and opens the oil flow through the oil coolers.

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2.5

Section 2.0 Page 7

PTO Lubrication and cooling – Adjustments Legend for illustration (Z 22790a): (1) (2) (3) (4) (5)

(6) Port for pressure check stud (7) Jet bore (8) Valve spring (9) Seal rings (A) Pressure port (T) Return from valve (74.1+74.2) Pressure relief valve, 7.5 bar (114.1+114.2) Pressure reducing valve (fan speed) (117.1+117.2) Gear Oil cooler unit (incl. hydraulic fan motor) (M8-1+M8-2) PTO lubrication pressure (M21-1+M21-2) Pressure check point (fan speed) (Y6a/b-1 / Y6a/b-2) Solenoid valve Hydr. oil cooler fan speed (max. pressure if de-energized) •

Pilot operated relief valve Plug screw Valve piston Port for pressure switch B17-1/-2 "Y"- port (external return to tank)

The adjustment of the maximum permissible PTO lube pressure, has to be carried out with warm oil.

Setting the pressure relief valve (74.x) 1. Connect a pressure gauge to check point (M8-1 / M8-2) 2. Start the respective motor 3. Required pressure: 7,5 bar. If adjustment is required: 4. Remove protection cap (1a). 5. Loosen lock nut (1b). 6. Set the pressure with set screw (1c). 7. Tighten lock nut (1b) and re-install protection cap (1a)

)

• If the pressure of 7,5 bar cannot be adj. 100 %, adj. to the lowest visible pressure.

Adjustment of the PTO cooler fan drive speed 1. Connect a pressure gauge to check point (M21-1 / M21-2) 2. Disconnect plug of solenoid valve Y6a/b-1 / Y6a/b-2 3. Start the respective motor 4. Check the fan speed with a non-contact rev counter Required fan speed: 2200 min-1 at about 100 bar 5. Correct the speed at pressure reducing valve 114.1 /114.2 if necessary 6. Reconnect plug of solenoid valve Y6a/b-1 / Y6a/b-2

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Drive

2.6

Hydraulic pumps – location, drive speed and flow rates Legend for illustration (Z 22621b): (1 - 8) Axial piston pump (swash plate type) pump volume Vg theoretical flow rate, each Qmax Drive speed* n for all working motions (9.1 + 9.3)

(9.2 + 9.4)

Gear pump pump volume theoretical flow rate Drive speed* for pilot pressure supply

Vg Qmax n

= 110.8 cm³/rev = 152 Liter/min = 1378 min-1

Gear pump pump volume theoretical flow rate Drive speed* for PTO gear lubrication

Vg Qmax n

= 110.8 cm³/rev = 152 Liter/min = 1378 min-1

(10.1 – 10.4) Axial piston pump pump volume theoretical flow rate Drive speed* for • Hydr. oil cooler fan drive • PTO cooler fan drive (13)

Gear pump pump volume theoretical flow rate Drive speed* for flushing the travel motors

)

= 750 cm³/rev = 1034 Liter/min = 1378 min-1

Vg Qmax n

Vg Qmax n

= 108 - 160 cm³ = 188 - 278 Liter/min = 1741 min-1

= 58,7 cm³/rev = 82,2 Liter/min = 1378 min-1

• * at 1800 min-1 input drive speed (60 Hz) and • 1500 min-1 input drive speed (50 Hz)

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Section 3.0 Page 1


Page Hydraulic oil reservoir General lay out

2

3.1

Main oil tank, location of switches, sensors etc.

3

3.2

Suction oil tank with strainers

4

3.3

Return oil collector tube with strainer

5

3.4

Back pressure valve

6

3.5

Transfer pump

7

3.6

Return and Leak Oil Filter

8

3.7

Breather Filter

9

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3.0

Section 3.0 Page 2

General lay out Legend for illustration (Z 22397): (1) Filter cover retainer (2) Filter cover (3) Filter element (51.1 – 51.7) - Return oil filter - 10 µm (66) - Case drain filter - 3 µm (4) Man hole cover (26) Back pressure valve (40) Suction oil tank (54) Shut off valve with S31 (Gate valve) (55) Compensator (55a) Intermediate pipe with inspection cover for strainer (56) (56) Suction oil strainer (51.1 – 51.7) Return oil filter (57.1 – 57.3) Breather filter (58.1 – 58.3) Oil drain, quick release coupling (66) Case drain filter (95) Strainer oil cooler (96) Main oil reservoir (97) Hydraulic oil level gauge (98) Filler screen (M13) Leak oil filter chamber pressure check point (M14) Return oil filter chamber pressure check point (M15) Back pressure check point The hydraulic oil tank is a welded sheet-metal construction. The capacity is about 7750 litres. The tank contains seven return oil filters (51.1 – 51.7) and one case drain filter (66). The breather filter (57.1 – 57.3) cleans the air that streams into the tank. The back pressure valve (26) and the pressure check point (M15) are located at the collector tube for return oil. The connection to the suction tank can be closed with the shut- off valve (54) to prevent oil flow during repairs on the hydraulic pumps. This unit is monitored by the switch S31, to make sure that the a motor will not start with a closed shut-off valve. Fault message ”Start blocked because of main Shut-Off (gate) valve” is displayed at the operators dash board.

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3.1

Section 3.0 Page 3

Main oil tank, location of switches, sensors etc. Legend for illustration (Z 22792b): (B4) Oil level sensor “Hydraulic oil level too low” (B15) Hydraulic oil temperature probe (B24) Breather filter pressure switch (B25) Pressure switch – Pressure leak oil chamber (B26) Pressure switch – Pressure return oil chamber (B32) Hydraulic oil temperature probe “Temp. gauge cabin” (B42) Oil level sensor “Oil level maximum” (B50) Oil level sensor “Hydraulic oil refill level” (B68) Oil level switch – Turns off transfer pump when return oil filter chamber is empty (B165) Differential pressure switch (2 bar) – Monitoring of strainer oil cooler (M8) Electric motor of transfer pump (S31) Proximity switch “Gate valve monitoring” (S35) Switch – transfer pump ON / OFF (Y101) Solenoid valve “Back pressure reduction” (1B7) Thermostat switch for pre-heating (1B15 – 1B21) Thermostat switches for heater elements (1R15 – 1R21) Pre-Heating elements

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Section 3.0 Page 4

Suction oil tank with strainers Legend for illustration (Z 22793a): (1)

Suction hose

(2)

Suction hose connection pipe

(3)

Gaskets

(40)

Suction oil reservoir

(54)

Shut off valve (Gate valve)

(55)

Compensator

(55a)

Intermediate pipe with inspection cover for strainer (56)

(56)

Main suction oil strainer

(75.1 – 75.8)

Suction strainer – one for each main pump

(96)

Main oil reservoir

(1B14)

Thermostat switch for pre-heating

(1R12 – 1R14)

Pre-Heating elements

The suction oil tank (40) is a welded sheet-metal construction. The capacity is 520 liters. The suction lines of all hydraulic pumps are connected to the suction tank.

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3.3

Return oil collector tube with strainer Legend for illustration (Z 22794b): (1) Return oil collector tube - Part 1 (2) Return oil collector tube - Part 2 (3) Return oil collector tube - Part 3 (4) Strainer (5) Bolt Quantity 8

(6)

M 20 x 70

Grade

SW* (mm)

10.9

30

Grade

SW* (mm)

10.9

30


Bolt Quantity 8

(7) (8) (86) (93) *

Bolt size (mm)

Bolt size (mm) M 20 x 90


Self locking nut Gasket Pressure switch (B165) Pulsation damper SW = Wrench size

Task: The strainer (monitored by differential pressure switch B165) is installed to prevent the hydraulic oil coolers from getting clogged up in case of contamination in the main return circuit oil. Excessive increase of the hydraulic oil temperature can be an indication for a restricted strainer, i.e. bad cooling performance due to insufficient oil flow through the coolers. In case that main components such as cylinders or motors are internal fragmentary damaged, the strainer should be inspected for metal chips.

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3.4

Section 3.0 Page 6

Back pressure valve Legend for illustration (Z 22795): (1) Back pressure valve assembly (2) Solenoid valve (Y101)

Task: The back pressure valve has to fulfill two functions in the hydraulic system: 1. To ensure a sufficient pressure within the return oil circuit, i.e. to supply oil via the anticavitaton valves to the low pressure side of cylinders, respectively motors. 2. To force the return oil through the coolers depending on the present hydraulic oil temperature, controlled by solenoid valve Y101. - Low temperature ⇒ low volume through the coolers - High temperature ⇒ high volume through the coolers

)

• Further information about the function principle and adjustments, refer to Section 4.0 this Manual.

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3.5

Section 3.0 Page 7

Transfer pump Legend for illustration (Z 22425a): (1) Shut-off valve for return oil compartment and leakage oil filter chamber (2) Shut-off valve for return oil collector pipe (3) Shut-off valve suction oil reservoir C - Closed O - Open (4) Operating switch for pump (5) (5) Transfer pump (6) Return oil compartment (7) Main oil reservoir (8) Vent plug, remove before transfusing oil from return oil compartment and leakage oil filter chamber into the main reservoir (9) Return oil collector pipe (10) Hand wheel of the main shut-off valve between main- and suction oil reservoir (11) Vent plug on top of the main oil reservoir, remove before transfusing oil from return oil compartment and leakage oil filter chamber into the main reservoir (12) Leakage oil filter (13) Return oil filters (14) Breather filters Functions of the Transfer Pump: 1 - Transfusing the oil from the return oil compartment and leakage oil filter chamber into the main oil reservoir. Necessary for filter service and for hydraulic oil change. 2 - Transfusing oil from return oil collector tube and back-pressure valve pipe into main oil reservoir. Necessary when changing the hydraulic oil and prior to servicing the high pressure filters, the main control valves, or hydraulic oil cooler (oil return system). 3 - Transfusing oil from the suction oil reservoir into the main oil reservoir. Necessary for evacuation of the suction oil reservoir, when changing the hydraulic oil. Prior servicing the main hydraulic pumps it is advisable to empty the suction oil reservoir partially.

)

• During normal operation the valves (1, 2 and 3) must be in closed position ”C”. • Refer to the operation and maintenance manual, for further information.

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3.6

Section 3.0 Page 8

Return and Leak Oil Filter Legend for illustration (Z 21500): (1) Filter cover retainer (2) Filter cover with o-ring (3) Pre-tensioning spring (4) Retainer (5) Filter assembly (6) Filter pot with machined cover (7) Main filter element, 10 micron absolute for return oil 3 micron absolute for leak oil (8) Safety filter element (200 micron strainer) same for return and leak oil (9) By pass-valve, 2.3bar (9.1) Valve cone (9.2) Valve spring (9.3) O-ring (10) Profile gasket (11) Seal ring (12) Self locking nut (13) Self locking nut Function: The returning oil flows into the filter chamber (A) of the hydraulic tank. (The sketch shows one section only). The chamber is split into two sections; one section with 4 filter elements for the return oil (10 micron) and another section with one filter element for the leak oil (3 micron). But the structure of the five filter assemblies is basically the same. The hydraulic oil enters the filter at the top and passes then on its way to the entire tank the filter-element (7). "Inside to outside filtration." The filter element condition is monitored by a pressure switch (B25, 0.5 bar for the leak oil filter) and (B26, 2 bar for the return oil filter). As soon as the pressure inside the filter chamber reaches the set pressure of those switches due to the restriction of the filter-element which is caused by foreign matters, the fault message ”Return oil filter restricted" or ”Leak oil filter restricted” is displayed at the operator's dash board The filter elements must be replaced. For safety pre-cautions the filter is equipped with a by-pass valve. As the filter chamber pressure increases the by-pass valve opens at 2.3 bar and protects the element from bursting. But the oil flows not totally unfiltered into the tank because it must flow through the strainer (8).

)

• •

The switch point of the pressure switch for the leak oil has been chosen so low with best intention to protect first of all the radial seal rings of the hydraulic motors. Refer to the maintenance manual, for further information

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9

3.7

Section 3.0 Page 9

Breather filter Legend for illustration (Z 22796): (1) Nut (2) Cover (3) Filter element (4) Filter pot (B24) Vacuum type pressure switch A breather filter is installed to clean the air that streams into the tank any time the oil level decreases while extending attachment cylinders The filter element condition is monitored by a vacuum type pressure switch (B24, 80mbar).

)

•

Refer to the maintenance manual, for further information

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Hydraulic Oil Cooling

Section 4.0 Page 1


Page Hydraulic oil cooling 4.1

General

4.2

Function of the hydraulic oil cooling circuit

4.3

4.4

4.5

2

4.2.1 Standard hydraulic oil cooling circuit

3

4.2.2 Additional hydraulic oil cooling circuit

4

Back Pressure Valve 4.3.1 Adjustment of the Back Pressure Valve

5

4.3.2 ½ Qmax adjustment

6+7

Fan drive of standard cooler 4.4.1 Two stage cooler fan RPM control

8

4.4.2 Pressure relief valves and solenoid valves

9 + 10

4.4.3 Fixed Displacement Pump, with variable setting

11

4.4.4 Adjustment of the cooler fan drive speed

12 + 13 + 14

4.4.5 Function check of fan speed control

15

4.4.6 Switch points cooler fan speed (PLC controlled)

15

Fan drive of additional cooler 4.5.1 Function of the cooler fan RPM control

16

4.5.2 Adjustment of the cooler fan drive speed

16

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4.1

Section 4.0 Page 2

General The hydraulic oil cooling system maintains the hydraulic oil at a normal operating temperature. Legend for illustration (Z 22797) (1) Standard cooler assembly with swing out facility (2) Additional oil cooler assembly with swing out facility (3) Hydraulic motor of upper fan (driven by prime mover 2) (4) Upper fan (5) Upper cooler set (4 identical cooler elements 106.1 to 106.4) (6) Hydraulic motor of lower fan (driven by prime mover 1) (7) Lower fan (8) Lower cooler set (4 identical cooler elements 106.5 to 106.8) (9) Hydraulic motor of additional fan (driven by prime mover 1) (10) Hydraulic motor of additional fan (driven by prime mover 2) (11) Additional cooler set (2 identical cooler elements 151.1 and 151.2) (12) Drive shaft (13) Shaft protecting Sleeve (14) Drive shaft seal (15) Ball bearings (16) Seeger clip ring (17) Breather filter (18) Oil level plug (19) Bearing group housing (20) Bearing group carrier Design: The hydraulic oil cooler, installed in front of the hydraulic tank is divided in two parts: A. The standard cooler assembly (1) with eight cooler elements mounted in one frame. The air stream needed for the cooling is produced by hydraulically driven fans. The air flows from inside to outside through the coolers. For easy cleaning, the coolers can be opened. ("Swing out cooler") The bearing group housing is filled with oil to lubricate the bearings. B. Additional oil cooler assembly (2) with two cooler elements mounted in one frame on top of the standard cooler assembly. The air stream needed for the cooling is produced by hydraulically driven fans. The air flows from inside to outside through the coolers. For easy cleaning, the coolers can be opened. ("Swing out cooler")

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Section 4.0 Page 3

4.2.1 Function of the hydraulic oil cooling circuit Standard circuit Legend for illustration (Z 22798) (26) Back pressure valve (93) Accumulator (Pulsation damper) (96) Main oil reservoir (106.1 – 106.8) Hydraulic oil cooler elements (107.1 – 107.4) Restrictor, shock absorbers for the hydraulic oil cooler (L20 – L22) Supply line for the anticavitation circuit of the swing motors (L23 – L27) Return line from control blocks (L28 – L32) Supply line for the anticavitation circuit of attachment cylinders (M15) Pressure check point (Y101) Solenoid valve – 4/2-directional control valve (H) Lines to cooler (hot oil) (C) Lines to tank (cold oil) Function: The returning oil from the system flows via the lines into the collector tube. On the top of it is the Back Pressure Valve (26) installed. The back pressure valve (26) causes a back pressure which forces most of the relative hot oil through the lines (H) to the cooler (106.1 – 106.8). The hydraulic oil passes first the restrictors (107.1 – 107.4) before it gets cooled in the cooler elements and flows than through and the lines (C) into the filter chamber of the main oil reservoir (96). The restrictors are acting like shock absorbers and prevent together with the pulsation damper (93) cooler cracking at pressure peaks. Besides the back pressure valve acts as an oil flow control valve as far as the oil temperature has not reached its steady temperature. During the warm up period (1/2 Qmax) the back pressure valve (26) is wide open, because solenoid valve Y101 is energized, which results in less oil flow through the cooler which causes that the oil gets quicker its optimum operating temperature. With increasing oil temperature the oil gets thinner, so that the main pumps can be shifted to Qmax position and simultaneously solenoid valve Y101 will be de-energized, so that the valve piston will be more closed by the force of the spring thus that more oil passes the cooler. (See sectional drawing on page 5.)

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Section 4.0 Page 4

4.2.2 Function of the hydraulic oil cooling circuit Additional circuit Legend for illustration (Z 22799) (10.1 + 10.3) Fan drive pumps (fixed displacement pump, with variable setting) (23.1 + 23.2) Fan drive motors (standard cooler) (68.2 + 68.4) Pressure filter with pressure differential switch (96) Main oil reservoir (151.1 + 151.2) Additional oil cooler elements (152.1 + 152.2) Fan drive motors (additional cooler) (H) Lines to cooler (hot oil) (C) Lines to tank (cold oil) Function: Oil delivery of both fan drive pumps (10.1+10.3) is directed to the additional cooler elements (151.1+151.2) after leaving the four fan drive motors (103.3+103.4 and 152.1+152.2) and flows back into the filter chamber of the main oil reservoir (96). This ensures that a constant oil volume circulates through the additional cooler, independent of the main return oil flow.

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Section 4.0 Page 5

4.3 Back Pressure Valve 4.3.1 Adjustment of the Back Pressure Valve Checks and settings only at normal operating temperature of the hydraulic oil, main pumps in maximum flow position and "Idle Time" control eliminated. 1. Connect a pressure gauge to check point (M15). 2. Disconnect plug connector (13) of solenoid valve Y101. 3. Actuate service switch S155 in to position Qmax. 4. Start both motors 5. Required pressure: 10 ±0,5 bar If adjustment is required: a) Take off protective cap (12). b) Loosen lock nut (5). c) Alter the pressure with the set screw (6). d) Tighten lock nut (5) and refit protective cap (12). 6. Disconnect the pressure gauge, reconnect solenoid valve Y101 and switch back service switch S155 in to automatic mode (center position). Legend for illustration (Z 21596b): (1) Control oil port (2) "Y"- port (external return to tank) (2a) "X"- port (external return to tank via solenoid valve Y101) (3) Poppet (4) Valve spring (5) Lock nut (6) Set screw (7) Jet bore (large) (8) Valve spring (9) Valve piston (10) Jet bore (small) (11) Plug screw (12) Protective cap (13) Plug connector (A) Return to tank (Filter chamber) (Z) Pressure oil to valve

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4.3.2

Section 4.0 Page 6

½ Qmax adjustment For efficient hydraulic oil cooling during idle time all pumps are automatically in ½ Qmax position reducing the circulating oil volume so that oil flows only through the oil coolers. If all pumps would stay in Qmax position during idle time a high amount of the circulating oil would pass the back pressure valve before returning in the oil tank this would waste energy and create adverse high oil temperatures. • Before ½ Qmax adjustment is made the back pressure valve must be correct adjusted with all pumps in Qmax position and hydraulic oil at operating temperature. • All main pumps must be correctly adjusted i.e. start of de-stroking and Qmax stop bolt setting. See section 7 in this Service Manual for adjustment procedure. Precondition • The actual PLC software with ½ Qmax idle control must run on the PLC. • Make sure that the filled in hydraulic oil viscosity is selected at the PLC. See Operation and Maintenance Manual to select the oil viscosity. Procedure: 1. 2. 3. 4. 5. 6. 7.

Connect a pressure gauge to back pressure check point (M15). Connect a pressure gauges to the X3 pressure check point (M36). Start both motors (both diesel engines must run at high idle) Warm up hydraulic oil so that the hydraulic oil cooler fans run with maximum speed, controlled by the PLC (oil temperature above T3). With all controls in neutral position the pumps should move in ½ Qmax position, because of the de-energised solenoid valve Y17a. Unplug solenoid valve Y17a to keep the valve de-energised. Check the X3 pressure at test point M36 in the ½ Qmax position of the pumps. The pressure indicated on the gauge should be 15±5 bar.

continued

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Section 4.0 Page 7

4.3.2 ½ Qmax adjustment Cont’d. 8.

Check back pressure at test point M15. – if the pressure is lower as the required normal back pressure of 10bar continue with next item Nr.9. – if the pressure shows the required normal back pressure of 10bar decrease the X3 pressure setting with pressure reducing valve (244.4) until the back pressure drop to a lower pressure as 10bar. a) Loosen lock nut. b) Correct the pressure with the set screw. - turn clock wise (cw) to increase the pressure - turn counter clock wise (ccw) to decrease the pressure c) Tighten lock nut.

9.

Increase pump delivery by increasing the X3 pressure setting of pressure reducing valve (255.4) which in turn increases the back pressure. As soon as the gauge (M15) shows 10 bar (equal to back pressure valve setting) stop adjustment. Check the resulting X3 pressure at test point M36 and record it for later checks, the values must be distinctly lower as the max X3 pressure (45 bar). Check the back pressure after activating a control lever or activate Qmax switch S155. The pumps change now to Qmax but the back pressure must stay constant at 10 bar (check point M15). Turn switch S155 back to normal operating position (center position) and remove all gauges.

10.

11.

12.

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Section 4.0 Page 8

4.4.1 Two stage cooler fan RPM control Legend for illustration (Z 22801) (10.1 + 10.3) Fan drive pumps (fixed displacement pump, with variable setting) (23.1 + 23.2) Fan drive motors (standard cooler) (45.1 + 45.2) Pressure relief valve (maximum fan speed) (48.1 + 48.2) Pressure relief valve (medium fan speed) (103.3 + 103.4) Check valve – (Anti cavitation valve for fan drive motor) (68.2 + 68.4) Pressure filter with pressure differential switch (Y6a/b-1 / -2) Solenoid valve (M6-1 / -2) Pressure check point (fan speed) Function: From pump (10.1 + 10.3) flows the oil through the filter (68.2 + 68.4) to the fan motors (23.1 + 23.2) and then back to the tank. (or through additional cooler if installed) The check valve (103.3 + 103.4) act as an anti cavitation valve and is installed, because the fan motor -driven by inertial force- is running for a short period after the oil flow is inerrupted by solenoid valve (Y6a/b-1 / -2), or if the motor has been switched off. The hydraulic circuit "Fan drive" is protected by the pilot controlled pressure relief valves (45.1 + 45.2) and (48.1 + 48.2). These valves are working together with the solenoid valve (Y6a/b-1 / -2), controlled by the ECS - system, depending on the hydraulic oil temperature: • With de-energized solenoids Y6a and Y6b the relief valve (45.1 + 45.2) is functioning and the fans are running with max. adjusted speed (1250 RPM) • With solenoid Y6a energized the relief valve (45.1 + 45.2) is not functioning and the fans are running with a very low speed caused by the flow resistance only. • With solenoid Y6b energized the relief valve (48.1 + 48.2) is controlling the relief valve (45.1 + 45.2) and the fans are running with 1000 RPM only. (See also description on next page)

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Section 4.0 Page 9

4.4.2 Pressure relief valves and solenoid valve Pressure relief valve (45.1 + 45.2) Legend for illustration (Z 21598b) (1) Valve cartridge (2) Spring (3) Spring chamber (4) "X" port (5) Jet bore, Pilot poppet (6) Jet bore, Main piston (7) Main piston (8) Valve housing (9) Pilot poppet (Y) External leak oil port (A) Pressure port (B) Return oil port Function: Pressure in line A affects the main piston (7). At the same time there is pressure via the jet bore (6) on the spring-loaded side of the main piston and via jet bore (5) at the pilot poppet (9) of the relief valve cartridge (1). If system pressure in line A exceeds the value set at the spring (2), pilot poppet (9) opens. The signal for this comes from line A via the jet bores (6) and (5). The oil on the spring-loaded side of the main piston (7) now flows via the jet bore (5) and poppet (9) into the spring chamber (3). From here it is fed internally by means of the control line (Y) to tank (port B). Due to the state of equilibrium at the main piston (7), oil flows from line A to line B, while the set operating pressure is maintained. The pressure relief valve (45.1 + 45.2) can be unloaded (Remote controlled) by means of the port "X" and the combined function of solenoid valve Y6a/b-1 / -2 with pressure relief valve 48.1 + 48.2 .( Function see next page) continued

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Section 4.0 Page 10

4.4.2 Pressure relief valves and solenoid valve, illustration (Z 21599c) Cont’d.

Function: With de-energized solenoids (Y6a and Y6b), the spool (3) keeps the "X" connection of valve (45.1 + 45.2) and port “B“ to port “P“ closed. The pressure relief valve (45.1 + 45.2) operates normal. The energized solenoid Y6b, operate the spool (3) and a connection is made between port “P“ and port “B“ and port "X" of valve (45.1 + 45.2). The system pressure now opens the main piston (7) of valve (45.1 + 45.2), because via solenoid Y6b (P to B) the oil from the rear side of piston (7) flows from the "X"port to the “P“ connection of valve (48.1 + 48.2). The normal valve function is now remote controlled by the pressure adjusted at valve (48.1 + 48.2). The energized solenoid Y6a, operate the spool (3) and a connection is made between port “P“ and port “A” and port "X" of relief valve (45.1 + 45.2). The system pressure now opens the main piston (7) of valve (45.1 + 45.2) because via the "X"-port the oil from the rear side of piston (7) flows to tank. The normal relief valve function is eliminated.

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Section 4.0 Page 11

4.4.3 Fixed Displacement Pump, with variable setting Legend for illustration (Z 21852) (1) Drive shaft (2) Bearings (3) Cylinder with pistons (4) Center pin (5) Control lens (6) Q-min adjustment bolt (7) Q-max adjustment bolt (8) Pressure port (9) Tank port Description. Pump type A7F0 is a variable displacement pump, designed to operate in open circuits. It has an internal case drain return. The rotary group is a robust self aspirating unit. External forces may be applied to the drive shaft. Changing the swivel angle of the rotary group is achieved by sliding the control lens along a cylindrical formed track by means of an adjusting screw. • With an increase in the swivel angel, the pump output increase together with necessary drive torque. • With an decrease in the swivel angel, the pump output decreases together with the necessary drive torque.

• When increasing to maximum swivel angle, there is a danger of cavitation and over-speeding the hydraulic motor!

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Section 4.0 Page 12

4.4.4 Adjustment of the cooler fan drive speed Basic Adjustment – Maximum Speed Legend for illustration (Z 22802): (a) Dust cap (b) Lock nut (c) Set screw (6) Qmin stop bolt (6.1) Lock nut (7) Qmax stop bolt (7.1) Lock nut (10) Positioning pin (mover) (L1) Measurement of Qmin stop bolt (L2) Measurement of Qmax stop bolt (10.1 + 10.3) Fan drive pumps (fixed displacement pump, with variable setting) (23.1 + 23.2) Fan drive motors (standard cooler) (45.1 + 45.2) Pressure relief valve (maximum fan speed) (Y6a/b-1 / -2) Solenoid valve (M6-1 / -2) Pressure check point (fan speed)

)

• Basic adjustment has to be carried out whenever one of the following components has been replaced: - pump - relief valve - hydraulic motor 1. Reduce the output flow of pump (10.1 and/or 10.2), by adjusting the minimum possible swivel angle, to avoid over speeding the fan: To do this, loosen both lock nuts (6.1 + 7.1) and turn out bolt (6) and turn in bolt (7) the same length. This is necessary to avoid a loose positioning pin (10), resulting in oscillating of the cylinder barrel. Tighten the lock nuts. 2. Remove protection cap (a) from relief valve (45.1 and/or 45.2), loosen lock nut (b) and turn set screw (c) fully clockwise and then a half turn counter clockwise. 3. Isolate the function of solenoid valve (Y6a/b-1 and/or Y6a/b-2), by disconnecting both plug connectors, to ensure that the full flow of pump 10.1 and/or 10.2 will be delivered to the fan motor. continued

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Section 4.0 Page 13

4.4.4 Adjustment of the cooler fan drive speed, illustration Z22802 Cont'd Basic Adjustment – Maximum Speed 4. Connect a pressure gauge to check point (M6-1 and/or M6-2). 5. Start the respective motor. 6. Check the fan speed with a non-contact rev counter Required fan speed: 1250 min-1 • Be careful not to get caught in the fan or other rotating parts 7. Increase the output flow of pump (10.1 and/or 10.2), by adjusting the swivel angle, until the fan speed will be 20 min-1 higher than required: To do this, loosen both lock nuts (6.1 + 7.1) and turn in bolt (6) and turn out bolt (7) the same length. This is necessary to avoid a loose positioning pin (10), resulting in oscillating of the cylinder barrel. Tighten the lock nuts (6.1 + 7.1). • Do not exceed the maximum permissible operating pressure of 230bar.

)

• Note down the lengths ”L1” and ”L2” as reference measurements.

8. Loosen lock nut (b) of the relief valve (45.1 and/or 45.2), and decrease the pressure with set screw (c) until the correct fan speed is obtained. 9. Tighten lock nut (b) and fix protection cap (a). continued

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Section 4.0 Page 14

4.4.4 Adjustment of the cooler fan drive speed, illustration Z22804 Cont'd Basic Adjustment – Medium Speed 10. Activate the function of pressure relief valve (48.1 and/or 48.2), by connecting the plug connector of solenoid valve Y6a/b-1 and/or Y6a/b-2. 11. In order to ensure a proper function of solenoid valve Y6b during the adjustment, energize the valve by using the manual control “Digital Outputs” of the ECS-System ( refer to section 5 of the operation manual), or activate Y6b, by connecting the solenoid plug to permanent 24 V. Use the 24V socket at the PTO *) 12. Loosen lock nut (e) of the relief valve (124), and turn set screw (f) fully counter clockwise and then clockwise until the correct fan speed is obtained. Required fan speed: 1000 min-1 13. Tighten lock nut (e) and fix protection cap (d). 14. Note down the pressure as reference value (expected ~ 150 bar) 15. Disconnect the pressure gauge from check point (M6). 16. Connect the plug connector of solenoid valve Y6a. *) Prepare a test wire with a plug ET-No. 891 039 40, and a plug ET-No. 440 305 99. Connect terminal 1 to positive (+) (center off plug 440 305 99) and terminal 2 to ground (-). 4.4.5 Function check of fan speed control Switch manually the output signals to Y6a/b and check the fan speed:

)

}

Y6a Y6b

0 0

Y6a Y6b

0 1

Y6a Y6b

1 0

nmaximum ≈ 1250 min-1

}

nmedium ≈ 1000 min-1

}

nminimum ≈ 0 - 50 min-1

• For operating instructions of the ECS system refer to section 3.4 of the operation manual

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Section 4.0 Page 15

4.4.6 Switch points of cooler fan speed (PLC controlled) Switch points with hysteresis: 30°C 39°C 48°C 56°C 65°C

VG22: VG32: VG46: VG68: VG100:

46°C 57°C 67°C 73°C 73°C

Switch point: Speed decrease

Fan speed Maximum

Medium

Minimum Temperature Switch point: Speed increase

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67°C 58°C 50°C 41°C 32°C

VG100: VG68: VG46: VG32: VG22:

75°C 75°C 69°C 59°C 48°C

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4.5

Section 4.0 Page 16

Fan drive of additional cooler Legend for illustration (Z 22806) (10.1 + 10.3) Fan drive pumps (fixed displacement pump, with variable setting) (23.1 + 23.2) Fan drive motors (standard cooler) (103.3 + 103.4) Check valve – (Anti cavitation valve for fan drive motor) (152.1 + 152.2) Fan drive motors (additional cooler) (154.1 + 154.2) Pressure reducing valves – Fan drive additional oil cooler (Y6a/b-1 / -2) Solenoid valve (M21-3 / -4) Pressure check point (fan speed)

4.5.1

Function of the cooler fan RPM control Since the oil delivery of the fan drive pumps (10.1 + 10.3) is used for the standard fan motors 23.1 + 23.2 and for the additional fan motors 152.1 + 152.2, the speed of the additional fans depends on the speed control of the standard fans. Therefore only the maximum speed of the additional fans can be adjusted with the cooler standard fans running at maximum speed. The maximum speed adjustment of the additional fans must be carried out to ensure the intended cooling performance of the system.

4.5.2

)

Adjustment of the cooler fan drive speed • Precondition for this adjustment is the correct setting of the standard cooler fan drive. Procedure: 1. Connect a pressure gauge to check point (M21-3 and/or M21-4). 2. Unplug solenoid valve (Y6a/b-1 and/or Y6a/b-2). to ensure max. speed of the standard fan drive. 3. Start the respective motor. 4. Adjust* at valve (154.1 and/or 154.2.3) a fan speed of approx. 1550 rpm. 5. Re-plug solenoid valve (Y6.1 and/or Y6.2). • Be careful not to get caught in the fan or other rotating parts!

How to change the valve adjustment: Remove dust cap (a). Loosen lock nut (b). Adjust the pressure with set screw (c). Tighten lock nut and install dust cap.

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Controlling


Page Controlling General lay out

2

5.1

Control and filter panel location of components (valves, switches, sensors etc.)

3+4+5

5.2

Pilot Pressure Supply and Adjustments

6+7+8

5.3

Remote control valves arrangement

9

5.4

Function principle of the Electro-Hydraulic- Proportional Control

10 + 11

5.5

Potentiometer Control (Lever, Joy Stick)

12

5.6

Potentiometer Control (Pedal)

13

5.7

Proportional amplifier module, Type A (for swing brake only)

14

5.8

Proportional amplifier module, Type B (for Boom, Stick, Bucket, Swing and Travel)

15

5.9

Ramp Time Module (Analogue command value module for Boom, Stick, Travel and Swing function)

16

5.10

Adjustments of Amplifier Modules (General)

17

5.11

Adjusting the Amplifiers Type B

18 + 19

5.12

Adjusting the Amplifiers Type A

20 + 21

5.13

Adjusting the Ramp Time Modules

22 + 23 + 24

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General lay out Legend for illustration (Z 22736b): (E19) Electro proportional joy stick control (E20) Electro proportional joy stick control (E21a) Electro proportional pedal control, travel left crawler (E21b) Electro proportional pedal control, travel right crawler (E22) Electro proportional pedal control, swing brake (E23) Electro proportional pedal control, bucket closed (E24) Electro proportional pedal control, bucket open (9.1) Gear pump for Pilot pressure (Motor 1) (9.3) Gear pump for Pilot pressure (Motor 2) (36) Central control and filter panel (37.1) Control and filter panel (PTO - and Hydraulic oil cooling) Motor 1 (37.2) Control and filter panel (PTO - and Hydraulic oil cooling) Motor 2 (68.1) Pressure filter of pilot pressure pump with pressure differential switch B22-1 (Motor 1) (68.7) Pressure filter of pilot pressure pump with pressure differential switch B22-2 (Motor 2) (85) Pressure accumulator (Bladder Accumulator 10 Liter, 10 bar precharge pressure) (102) Remote control valve blocks General The controlling includes the pilot pressure system and the pump regulation system. The pumps (9.1 / 9.3) forcing the oil through the filters (68.1 / 68.7) to all involved valves. The pressure accumulator (85) ensures that under any circumstances enough pilot pressure oil is available. The accumulator (85) is also functioning as a hydraulic battery for a certain time when the engine was shut down or to pressure relieve the system for repair works. When the operator is using his controls an electrical signal causes energizing of the selected solenoid valve of the remote control valves(102). By the function of the remote control valves pilot pressure oil is send to the relevant control block spools which in turn allows operating hydraulic oil to the users.

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Section 5.0 Page 3

Control and filter panel location of components Central control and filter panel Legend for illustration (Z 22737c): Solenoid valves (Y5) Swing parking brake operating pressure (Y16) Travel parking brake operating pressure (Y17) „Idle time“ control, (Pump control system) (Y17a) ½ Q-max (reduced oil flow at too cold oil) (Y61-1) „X1“ pressure, pumps 1 – 4 (Motor 1) (Y61-2) „X1“ pressure, pumps 5 – 8 (motor 2) (Y100) Reserve (Y120) Hydraulic swing brake, maximum operating pressure (Y123a) Hydraulic access ladder “raise” (Y123b) Hydraulic access ladder “lower” (Y125) Hydraulic access ladder “fast” movement (Y127) Proportional pressure to hydraulic swing brake (Y200) Hydraulic flow heating for attachment (pressure increasing valve “boom”) Filter: (68.1) (68.7)

Pressure filter of pilot pressure pump 9.1 (Motor 1) Pressure filter of pilot pressure pump 9.3 (Motor 2)

Pressure switches: (B16) Swing parking brake operating pressure (B22-1) Pilot pressure pump 9.1 (Motor 1) - Filter element monitoring (B22-2) Pilot pressure pump 9.3 (Motor 2) - Filter element monitoring (B48) Travel parking brake operating pressure (B85-1) Pressure transducer – X1 pressure (Motor 1) (B85-2) Pressure transducer – X1 pressure (Motor 2) (B86) Pressure transducer – X2 pressure continued

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Control and filter panel location of components Cont'd: Central control and filter panel Legend for illustration (Z 22738c): Miscellaneous: (85) Pressure accumulator (10 Liter, 10 bar pre-charge pressure) (147) Pressure reducing valve – Track tensioning system (35bar) (252.1) Pressure reducing valve for pilot pressure X2 (45bar) (252.2) Pressure relief valve for pump support pressure X4 (60bar) (252.3 Check valve (pilot oil from pump 9.1 – motor1) (252.4) Check valve (pilot oil from pump 9.3 – motor2) (253.1) Change over valve – Electronic pump regulation or hydraulic. constant regulation Motor 1 (253.2) Pressure reducing valve – hydraulic constant regulation (Motor 1) (254.1) Change over valve – Electronic pump regulation or hydraulic constant regulation Motor 2 (254.2) Pressure reducing valve – hydraulic constant regulation (Motor 2) (255.4) Pressure reducing valve – ½ Qmax (~ 15 bar) (257.1) Pressure relief valve – Safety valve for Travel brake / Track tensioning system (55 bar) (258.3) Pressure relief valve – Hydraulic access ladder (70 bar) Pressure check points: (M1.1) X4, Pump support pressure, Pump bearing lubrication (60bar) (M1.2) X2 pressure, pilot pressure (45bar) (M2) Bladder Accumulator, pilot pressure (45bar) (M3.1) X1 pressure, hydraulic constant regulation Motor 1 (M3.2) X1 pressure, hydraulic constant regulation Motor 2 (M5.1) X1 pressure – general Motor 1 (M5.2) X1 pressure – general Motor 2 (M9.1) Travel parking brake operating pressure (45 bar) (M9.2) Travel parking brake supply pressure (35 bar) (M10) Swing parking brake operating pressure (45 bar) (M12) Option operating pressure: “fast motion for travel” not used (M30.1) X4, (60bar) of pump 9.1 only (Motor1) (M30.2) X4, (60bar) of pump 9.3 only (Motor2) (M33) Reduced “X3” pressure – to pump No 1 – ½ Qmax (~ 15 bar) (M34) not used (M36) “X3” pressure – pumps No 2 to No 8 (M37.1) Hydraulic cylinder access ladder “piston side” (M37.2) Hydraulic cylinder access ladder “rod side” (M39) Proportional pressure to hydraulic swing brake

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Section 5.0 Page 5

Control and filter panel location of components Legend for illustration (Z 22739c): (37.1) Control and filter Panel mounted on front PTO for motor 1 circuit (37.2) Control and filter Panel mounted on rear PTO for motor 2 circuit Solenoid valves (Y6a-1) Cooler fan RPM control minimum speed (Motor 1) (Y6a-2) Cooler fan RPM control minimum speed (Motor 2) (Y6b-1) Cooler fan RPM control medium speed (Motor 1) (Y6b-2) Cooler fan RPM control medium speed (Motor 2) Filter: (67) Oil filter for flushing circuits of travel motors. (68.2) Pressure filter of Oil cooler fan drive pump 10.1 (Motor 1) (68.3) Pressure filter of Oil cooler fan drive pump 10.2 (Motor 1) (68.4) Pressure filter of Oil cooler fan drive pump 10.3 (Motor 2) (68.5) Pressure filter of Oil cooler fan drive pump 10.4 (Motor 2) (69.1) Pressure filter – PTO 1 gear lubrication pump 9.2 (Motor 1) (69.2) Pressure filter – PTO 2 gear lubrication pump 9.4 (Motor 2) Pressure switches: (B17-1) Monitoring the PTO 1 gear lubrication pressure (lowest permissible pressure) (B17-2) Monitoring the PTO 2 gear lubrication pressure (lowest permissible pressure) (B21-1) Filter element monitoring – Oil cooler fan drive pump 10.2 (Motor 1) (B21-2) Filter element monitoring – Oil cooler fan drive pump 10.4 (Motor 2) (B27-1) Filter element monitoring – PTO 1 gear lubrication pump 9.2 (Motor 1) (B27-2) Filter element monitoring – PTO 2 gear lubrication pump 9.4 (Motor 2) (B28-1) Filter element monitoring – Oil cooler fan drive pump 10.1 (Motor 1) (B28-2) Filter element monitoring – Oil cooler fan drive pump 10.3 (Motor 2) (B200) Filter element monitoring – (13) for flushing circuit pump. (Motor 2) Miscellaneous: (45.1+45.3) Pressure relief valve – Max. operating pressure – cooler fan drive (Motor 1) (45.2+45.4) Pressure relief valve – Max. operating pressure – cooler fan drive (Motor 2) (48.1) Pressure relief valve –Medium speed cooler fan (Motor 1) (48.2) Pressure relief valve –Medium speed cooler fan (Motor 2) (74.1) Pressure relief valve – PTO 1 gear lubrication - oil cooler (74.2) Pressure relief valve – PTO 2 gear lubrication - oil cooler (114.1) Pressure reducing valve – Operating pressure – fan drive PTO 1 oil cooler (114.2) Pressure reducing valve – Operating pressure – fan drive PTO 2 oil cooler Pressure check points: (M6.1) Fan drive pressure hydraulic oil cooler (Motor 1) (M6.2) Fan drive pressure hydraulic oil cooler (Motor 2) (M8.1) PTO 1 gear lubrication pressure (M8.2) PTO 2 gear lubrication pressure (M21.1) Fan drive pressure PTO 1 cooler (Motor 1) (M21.2) Fan drive pressure PTO 2 cooler (Motor 2) (M30) Flushing circuit pressure for travel motors.

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Section 5.0 Page 6

Pilot Pressure Supply and Adjustments Pilot Pressure Circuit, illustration (Z 22747) The pilot pressure oil is used for the following functions. To move the control block spools, to supply the main pump regulation system, to lubricate the main pump bearings, to release the travel- and swing gear house brakes (spring loaded multi disk brakes), to operate the hydraulic access ladder, to drive the grease pumps and to supply the hydraulic track tensioning system.

Function: Study together with the hydraulic circuit diagram The pumps (9.1 + 9.3) are delivering the oil through the filters (68.1 + 68.7) and via check valves (252.3 + 252.4) to port A of pressure relief valve (252.2). The pressure relief valve (252.2) maintains the adjusted pressure of 60 bar, called „X4“-pressure. X4 - pressure: Pump support pressure Pump bearing lubrication Actuation of refilling arm and ladder Lubrication system The pressure reducing valve (252.1) maintains the adjusted pressure of 45 bar, called „X2“-pressure. X2 – pressure: Pilot pressure system Pump regulation system Travel- and Swing parking brakes (spring loaded multi -disk brakes) The pressure accumulator (85) holds an amount of oil under pressure to provide sufficient pilot pressure during normal operation and to ensure a limited number of lowering operations with the main drive motor at standstill. The check valve (256.6) prevents return flow of the pilot pressure oil. continued

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Section 5.0 Page 7

Pilot Pressure Supply and Adjustments Cont'd: Pilot Pressure Circuit Legend for illustration (Z 22748a): (85) Bladder Accumulator – (10 Liter, 10 bar pre-charge pressure) (96) (PX2) (LX2)

Main oil reservoir Pilot pressure line Leak / return oil line from the remote control blocks

Function: The pilot pressure oil flows via line (PX2) to port (P) of each remote control block and is present via a gallery at all proportional and directional solenoid valves. These solenoid valves are energized by the function of the Electro proportional controls (Joy sticks or pedals) and direct the pilot pressure oil to the respective spools of the main control blocks with a variable pilot pressure proportional to the deflection of the controls.

)

• For the location and designation of the proportional and directional solenoid valves of the remote control blocks refer to page 9 in this section. continued

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Section 5.0 Page 8

Pilot Pressure Supply and Adjustments Cont'd: Checks and Adjustment of Pilot Pressure Legend for illustration (Z 22749): (85) Bladder Accumulator – 10 liter, 10bar pre-charge pressure (252.1) Pressure reducing valve for pilot pressure X2 (45bar) (252.2) Pressure relief valve for pump support pressure X4 (60bar) (M1.1) Pressure check point X4, pump support pressure (60bar) (M1.2) Pressure check point X2 pressure, pilot pressure (45bar) (M2) Pressure check point for accumulator

)

• Since the “X2” and the “X4” pressure are influencing each other it is always necessary to adjust both valves 252.1 + 252.2 alternately. 60 bar pressure „X4“, valve 252.2: 1. Connect pressure gauge to check point (M1.1) 2. Start both motors. 3. Read pressure, required = 60-2 bar If readjustment is required proceed as follow: a) Loosen lock nut (1). b) Set pressure with set screw (2). c) Tighten lock nut (1). 45 bar pressure „X2“, valve 252.1: 1. Connect pressure gauge to check point (M1.2) 2. Start both motors. 3. Read pressure, required = 45+3 bar If readjustment is required proceed as follow: a) Loosen lock nut (3). b) Set pressure with set screw (4). c) Tighten lock nut (3). Checking of Accumulator Function 1. Connect pressure gauge to check point (M2). 2. Start both motors. 3. After build-up of pressure stop the drive motors, but do not turn the key switch to zero position. 4. Watch pressure gauge. Pressure should remain constant for at least 5 minutes.

)

• If the pressure droops the system must be checked for leakages. • To check the accumulator charging pressure refer to PARTS & SERVICE NEWS “AH01531a” latest edition.

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Controlling

5.3

Remote control valves arrangement Legend for illustration (Z 21636c) Remote control unit Schematic code

(102.1)

(102.2)

(102.3)

(102.4)

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Directional solenoid

Proportional solenoid

Y20a Y20b Y21a Y21b Y22a Y22b Y23a Y23b

Y20


Y24


Y28


Y32

Y21 Y22 Y23

Y25 Y26 Y27

Y29 Y30 Y31

Y33 Y34 Y35

Function BHA FSA L.H. Crawler reverse L.H. Crawler forward Stick extending Stick retracting Bucket filling (curl) Bucket emptying (dump) Boom raising Boom lowering R.H. swing L.H. swing not used Boom lowering Stick extending Stick retracting Bucket filling (curl) Bucket emptying (dump) R.H. Crawler reverse R.H. Crawler forward Boom raising Boom lowering Bucket filling (curl) Bucket emptying (dump) Stick extending Stick retracting Clam opening Clam closing Bucket filling (curl) Bucket emptying (dump) Boom raising Stick extending Boom lowering Stick retracting Stick retracting Boom raising Stick extending Boom lowering not used

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Section 5.0 Page 10

Function principle of the Electro-Hydraulic- Proportional Control Legend for illustration (Z 21637) (1) Pump (2) Filter (3) Pressure relief valve (4) Check valve (5) Pressure Accumulator (6) Directional Solenoid valve, a side (7) Directional Solenoid valve, b side (8) Proportional Solenoid valve (9) Control valve block (10) Battery (11) Electronic units with amplifiers etc. (12) Control lever (Potentiometer control) Function: The electric-hydraulic control system is used to control the direction and volume of oil flow to the operating cylinders and motors via the control valve blocks. Hydraulically: The oil volume of pump (1) flows through filter (2) into the pilot pressure system. The pressure is limited by the pressure relief valve (3). With the pressurized oil stored in accumulator (5), a limited number of spool movements can be carried out with the main drive motor at standstill. When a lever (or pedal) is actuated, proportional solenoid valve (8) and one of the directional solenoid valves (either 6 or 7) are energized, and allows the pilot pressure oil to flow to the spools of the control blocks. Electrical Whenever a lever or a pedal is moved out of its neutral position, an amplifier will created a current between 0 and 1000 mA. (For detailed information refer to page 10 in this section) Depending on the lever direction, simultaneously one of the directional solenoid valves (either 6 or 7) is energized. The proportional solenoid valve alters the pilot pressure, proportional to the lever deflection, this results a spool movement between neutral and full stroke position. continued

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Section 5.0 Page 11

Function principle of the Electro-Hydraulic- Proportional Control Cont'd: (Exemplary illustration of the function of two axis with one Amplifier only) Legend for illustration (Z 21638c) (1) Control lever (joystick) (2) Capacitor-Module (3) Ramp time module (4) Proportional-Amplifier-Module (5) Relay (Supply Voltage) (6) Proportional solenoid valve-(Pressure-Reducing Valve) (7) Directional solenoid valve (8) Control block spool General Function Control lever (1) is supplied with 24 VDC battery voltage for the switch contacts and with 24 VDC capacitor supported to create the signal voltage. When moving lever (1) out of its neutral position, 24 VDC battery voltage arrives at relay (5) and energizes the Proportional Amplifier (4) with capacitor supported 24 VDC via terminal 1. Depending on the function of the control lever, 1 to 4 Amplifiers can be involved for the „Y-axis“ (forward/ backwards direction) and 1 to 4 Amplifiers for the „Xaxis“ (left/right direction.) The polarity of the Output Signal from joystick (1), either positive or negative, between 0 and 10 VDC indicates the direction of the lever movement and is proportional to the lever deflection. This is the Input Signal to the ramp time module (3) at terminal 5 which will arrive after the adjusted ramp time delay via terminal 7 to the proportional amplifier (4) at terminal 5. This Input Signal (between 0 and 10 VDC) is amplified to an Output Signal between 0 to 1000 mA and is send via terminal 7 (negative) or terminal 8 (positive) to the Proportional Solenoid valve (6) . Simultaneous a 24V signal is send to the Directional solenoid valve (7) via terminal 3 (negative) or terminal 9 (positive) to the “a” or “b”-side. The proportional Solenoid valve (6) alters the pilot pressure (“X2”) of 45 bar to a value proportional to the Current Signal. This pressure controls the movement of the control block spool (8) between neutral and full stroke position.

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Section 5.0 Page 12

Potentiometer Control (Lever, Joy Stick) Legend for illustration (Z 21639b) (1) Push button * (2) Toggle switch * (3) Inductive linear transmitter (4) Universal joint (5) Electronics (6) Push pin (7) Shaft seal (8) Reset spring (9) Coil core (10) Coil * Alternative application The non-contacting lever control (inductive linear transmitter) contains both the electronic and mechanical components which converts the lever movement into a proportional electrical voltage. The lever can be operate in two axes: Axis "Y", splitted into the half axis Y- and Y + (backward and forward) Axis "X", splitted into the half axis X- and X + (left and right) Of course the lever can be moved in any other direction (Joy stick function) In order to be able to monitor the direction of the lever movement and the neutral position, the electronics (8) sends a 24V signal as soon as the lever gets moved out of its neutral position. For one axis are used two inductive linear transmitter (3). The motion of the coil core (9) connected to the push pin (6) causes a variation of the induction in the coils (10). The electronics convert this inductive signal into a proportional output signal of –10...0...+10 V for the amplifiers. The electronic part of the lever is equipped with a internal fault detector. In case of a internal electronic fault the electronic send a 24V signal to the test output. The test input is used for a lever system check before engine start. The inductive system is designed as a redundant system with two separate coils.

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5.6

Section 5.0 Page 13

Potentiometer Control (Pedal) Legend for illustration (Z 21300a) (1) Potentiometer Control Unit (2) Pedal (3) Standard cable (4) Connection cable for combined operation (5) Push pin (5.1) Coil (6) Switch actuator (7) Direction monitoring (7.1) Directional contacts (8) Neutral position monitoring (8.1) Neutral position contacts (9) Electronic Application for: (A) Swing foot brake (B) Clam Opening/closing (C) Travelling The Potentiometer Control (inductive, linear travel transmitter) contains both the electronic and mechanical components which converts the pedal movement into a proportional electrical voltage. In order to be able to electrically monitor the pedal (2) action a neutral position switch is fitted. This switch closes when the pedal is moved out of the rest position. When using the double unit (B) (combined operation) only the signal output from one unit is used for the Clam Operation. Due to the cross lined connection via the connection cable (4) the signal is once positive and once negative (inverted), depending on the Pedal used. In order to be able to monitor the direction of the pedal movement and the neutral position of travel unit (C), two switches (5 and 6) are fitted; which are actuated by the actuator (4) as soon as the lever gets moved out of its neutral position. For the Output Signal generation are used two coils (3.1), in series connected. The push pin motion causes a variation of the induction and this in turn causes a signal variation at the AC voltage bridge. The AC voltage gets rectified and becomes the DC-Signal Voltage for the amplifiers.

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Section 5.0 Page 14

Proportional Amplifier Module, Type A Legend for illustration (Z 21516) Type A (for swing brake only) (LED) LED for Solenoid A or B (P) Set Potentiometer R1 for the lowest current value R2 for the highest current value The amplifier module contains the necessary electronics for the control of two proportional solenoids. Depending on the input polarity, either solenoid A or solenoid B is operated. The solenoid current (solenoid A - solenoid B) is measured and compared with the external input value. Differences between feed-back and input values, for example caused by changes in solenoid temperature or supply voltage, are compensated. The module also generates a direction-dependent voltage signal (solenoid A solenoid B) as soon as the solenoid current reaches the lowest set value. The lowest and highest values are set externally via the potentiometer R1 + R2. The brightness of the LED's changes with the current. This function should not be used for setting.

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5.8

Section 5.0 Page 15

Proportional Amplifier Module, Type B Legend for illustration (Z 21640) Type B (for Boom, Stick, Bucket, Clam, Swing and Travel) (LED) (P) Set Potentiometer: AX: Proportional output AX active - 10% for the lowest current value AS: Switched output AS active - J2 for the highest current value BX: Proportional output BX active (Pt) Set Potentiometer for the „Ramp BS: Switched output BS active Time“ Power: Internal supply voltage Fault: Fault indication The amplifier module contains the necessary electronics for the control of two proportional solenoids and two directional solenoids. The amplifier outputs for proportional solenoids Ax and Bx and the switched outputs As and Bs are activated by connecting a minimum of approx. 10% signal voltage at the amplifier input. A positive signal voltage controls outputs A, a negative signal voltage controls output B. A signal voltage of approx. 10% with respect to +/- 10 V input voltage at the amplifier, produces a stepped output voltage. The height of this 10% jump may be set separately for proportional outputs Ax and Bx via external potentiometer. As the signal voltage rises the solenoid current for the proportional outputs increases linearly. A further step in output current occurs at approx. 90% signal voltage. The maximum current or the 90% jump may be set separately for outputs Ax and Bx via external potentiometers and hence the gradient of the output curve may be influenced. LED`s indicate the current output to each proportional and switched output, whereby the brightness is approx. proportional to the solenoid current in Ax and Bx. This function should not be used for setting. A Ramp Time function is included in the amplifier which may be externally changed by a set potentiometer. The setting range for the ramp time is approx. from 80ms to 1s. The time setting applies to both up and down ramps and to both proportional solenoids. A fault is indicated by the LED „Fault“.

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Section 5.0 Page 16

Ramp Time Module (Analogue command value module for Boom, Stick, Travel and Swing function) Legend for illustration (Z 21518) Potentiometer: "t1" to "t5" ⇒ Ramp times "w1" to "w4" ⇒ Command value call-ups "G" ⇒ Zero point matching "Z" ⇒ Amplitude attenuation for the differential input LED displays: (1) green ⇒ Operational power (2) "4-Q" ⇒ Quadrant recognition (3) "INV" ⇒ Inversion active (4) (5) (6)

yellow ⇒ display for potentiometer t1 to t4 yellow ⇒ display for potentiometer w1 to w4 Measurement sockets: "t" ⇒ Actual ramp time "w" ⇒ Internal adjustment variable "⊥" ⇒ Reference potential / GND

General The Ramp Time Module is snapped onto mounting rails inside the X2-box. The electrical connection is done via screw terminals. The module is operated with 24 VDC. A power supply provides the internally required positive and negative supply voltages. As soon as the power supply is in operation the green LED (power) lights up. Internal command values The internal command value signal is generated from the external command value signal which is being applied to the differential input, a called-up signal and an offset signal (zero point potentiometer "Z"). The external command value signal can, via potentiometer "G", changed from 0% to approx. 110%. Command value call-ups The call-up signals w1 to w4 also have an adjustment range of 0% to 110%. No settings required. (factory set to 100%). Ramp time call up If the quadrant recognition is not activated, then each command value call-up "w1" to "w4" is allocated its own ramp time "t1" to "t4". As long as there is a signal change, the LED allocated to the actual ramp time is alight.

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Controlling

5.10 Adjustments of Amplifier Modules (General) Legend for illustration (Z 21641) (1) Potentiometer control (2) Terminal with a separating possibility (3) Ramp time module (4) Amplifier (5) Solenoid valve (6) Service module Introduction: The illustration shows simplified the route of the signal voltage from Potentiometer Control (1) to Solenoid-Valve (5): A. With ramp time module, i.e. Boom,- Stick,- Travel,- and Swing Function. B. Without ramp time module, i.e. Bucket,- Clam,- and Swing Brake Function. The ramp time modules (3) and the amplifiers (4) are adjustable. Adjustments are required: Ramp time modules • When commissioning the machine • When replacing a module

Amplifiers • When replacing a solenoid valve • When replacing an amplifier

For Checking and Setting the Signal Current at the Proportional-Amplifier (4), both separating terminal (2) before and behind the Amplifier (4) must be opened. For the setting procedure the signal voltage from the potentiometer control (1) can be simulated with the potentiometer of Service-Module (6),which is installed on the X2-panel. Accessories required for the adjustments: a) A multimeter, good readable for values between 0 and 1000 mA. b) More convenient is a second meter for reading voltage simultaneously. c) A simple wire, 1m length, or better a prepared test lead same length d) Four test leads, 1m length, with banana type connectors on each end.

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"a"

"b"

mA

VDC

"c" "d"

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Section 5.0 Page 18

5.11 Adjusting the Amplifiers Type B, illustration (Z 21642) Procedure applicable for all amplifiers except the one for the swing brake: (Do not start the motor, turn only the key switch in ON – position.) 1. Open* the respective separating terminal (T1) between the lever unit and the amplifier module to be set. 2. Open* the respective separating terminal (T2) between the amplifier module to be set and the proportional solenoid valve. 3. Disconnect the wire from terminal five. 4. Connect the positive output of the service module with terminal five of the amplifier module, using test lead (2). 5. Attach a multimeter for voltage reading to the service module, using test lead (3). 6. Attach a multimeter (in series) for Amp reading to the terminal between amplifier module and solenoid valve, using test leads (3). 7. Move the lever of the Potentiometer Control into its final position; or override manual the relay which allows 24 V operating voltage to the amplifier module; thus the amplifier gets 24 V operating voltage. The power LED and simultaneously LED A(+) or B(-) lights up, depending on the polarity. 8. Turn the potentiometer (P) of the Service-Module until the multimeter shows 1 VDC (it may be either positive or negative); the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 330 mA. (The first step (10 %) value) If necessary correct the value with potentiometer (R1). 9. Turn the potentiometer (P) of the Service-Module further until the multimeter shows 9 VDC; the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 660 mA. (The second step (90 %) value). If necessary correct the value with potentiometer (R2). 10. Repeat settings of item 8 and 9 until both mA values are stabilized, because R1 and R2 influence each other.

* How to open and close the terminal: Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. A spring pushes then the stud outwards and the contacts are either open or closed. continued PC8000-6-E_Sec_5-0_#12048_rev0.doc

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Section 5.0 Page 19

5.11 Adjusting the Amplifiers Type B, illustration (Z 21642) Cont'd: 11.

12. 13.

If the setting with either positive or negative potential was successful, turn the potentiometer (P) of the service module into the opposite direction and check the settings with the other polarity i.e. if the first setting was done with positive potential then turn the pot into negative direction; otherwise vice versa. Repeat the setting as described under item 7 to 10. Remove multimeter, test wire, close* the terminals and reconnect the wire to terminal 5 of the amplifier module.

Adjusting the Ramp Time 1. 2.

Turn potentiometer (Rt) 30 revolutions counter clockwise, to guarantee the correct start position at the complete left side. Turn potentiometer (Rt) so many revolutions clockwise as shown in the table below (part of the electrical circuit diagram).

* How to open and close the terminal: Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. A spring pushes then the stud outwards and the contacts are either open or closed.

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Section 5.0 Page 20

5.12 Adjusting the Amplifiers Type B, illustration (Z 21643)

The amplifiers for the crawler foot pedals are adjustable in the same way as the amplifiers for the joy sticks.(refer to page 17 and 18 in this section) The amplifier for the swing foot brake is similar. Procedure for the swing foot brake: 1. Open* the respective separating terminal (T1) between the pedal unit and the amplifier module to be set. 2. Open* the respective separating terminal (T2) between the amplifier module to be set and the proportional solenoid valve. 3. Disconnect the wire from terminal five. 4. Connect the positive output of the service module with terminal five of the amplifier module, using test lead (2). 5. Attach a multimeter for voltage reading to the service module, using test lead (3). 6. Attach a multimeter (in series) for Amp reading to the terminal between amplifier module and solenoid valve, using test lead (3). 7. Press the pedal fully down ; or manual override the relay which allows 24 V operating voltage to the amplifier module; thus the amplifier gets 24 V operating voltage. 8. Turn the potentiometer (P) of the Service-Module until the multimeter shows 1 VDC ; the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 10 mA. (10 % value) If necessary correct the value with potentiometer (R1).

* How to open and close the terminal: Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. A spring pushes then the stud outwards and the contacts are either open or closed. continued

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Section 5.0 Page 21

5.12 Adjusting the Amplifiers Type B, illustration (Z 21643) Cont'd: 9.

) 10. 11.

Turn the potentiometer (P) of the Service-Module further until the multimeter shows 10 VDC; the multimeter for the current reading will show a value which should correspond to the value giving in the circuit diagram e.g. 500 mA. (100 % value). If necessary correct the value with potentiometer (R2). • It is important that the pilot pressure for the pressure increasing valve is 24 +/- 1 bar. For more information refer to section 8.2 „Swing Circuit“ Repeat settings of item 8 and 9 until both mA values are stabilized, because R1 and R2 influence each other. Remove multimeter, test wire, close* the terminals and reconnect the wire to terminal 5 of the amplifier module.

* How to open and close the terminal: Push the yellow stud (1) down with a screw driver and turn it 90° to the left to open or to the right to close the terminal. A spring pushes then the stud outwards and the contacts are either open or closed.

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5.13 Adjusting the Ramp Time Module Legend for illustration (Z 21644) (2) Capacitor-Module (3) Ramp time module (6) Service module (P) Potentiometer

)

• The following adjustments have to be done when commissioning the machine and whenever the Ramp Time Module has been replaced. • Do not start the motor, turn only the key switch in ON – position.

Basic Adjustment: 1.

2.

Connect 0VDC with a test lead from the red positive terminal of the service module (6) to terminal 5 of the Ramp Time Module (3) and adjust with "Pot Z" a value of 0 VDC measured at terminal 7. Disconnect the test lead after the setting is done. Connect +10VDC with a test lead from the red positive terminal of the service module (6) to terminal 5 of the Ramp Time Module (3) and adjust with "Pot G" a value of 10 VDC measured at terminal 7. Check the negative voltage as well(- 10 VDC). Disconnect the test lead after the setting is done.

)

• Repeat settings of item 1 and 2 until both values are stabilized, because "Pot Z" and "Pot G" influence each other. • The factory setting of potentiometer "w1" to "w4" for the command value call-ups must not be adjusted. continued

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Section 5.0 Page 23

5.13 Adjusting the Ramp Time Module Cont'd: Legend for illustration (Z 21645) (1) Control lever (joystick) (2) Capacitor-Module (3) Ramp time module (4) Proportional-Amplifier-Module (5) Relay (Supply Voltage) Ramp time adjustment in relation to the operating movements: 3.

Disconnect the cables at terminal 3 and terminal 5 of the respective module. Connect 24Volt with a test lead to terminal 9, 10, 11 and 12 one after another and adjust with the respective "Pot t1, t2, t3 and t4" the values giving in the table on the next page. (Measure the voltage only at the Measurement socket "t" of the ramp time module)

4.

To check the adjustments under operating conditions reconnect terminal 3 and terminal 5 and measure the ramp time with a stopwatch.

5.

If the above mentioned values are not suitable for the local working conditions, for example due to, different Attachments or different operation feeling of the operator, the ramp time can be changed according to the NOTE on illustration Z 21645, to ensure smooth and efficient working cycles. continued

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Section 5.0 Page 24

5.13 Adjusting the Ramp Time Module Cont'd: E48 Stick 24 Volt at

Joy stick Signal

Pot

Value to be measured at socket "t"

Terminal 9

Neutral ⇒ Stick out

0V to +10V

t1

0,10 Volt = 1000ms

Terminal 10

Stick out ⇒ Neutral

+10V to 0V

t2

5,00 Volt = 20ms

Terminal 11

Neutral ⇒ Stick in

0V to -10V

t3

0,10 Volt = 1000ms

Terminal 12

Stick in ⇒ Neutral

-10V to 0V

t4

5,00 Volt = 20ms

Pot


E49 Boom 24 Volt at

Joy stick Signal

Terminal 9

Neutral ⇒ Lower

0V to +10V

t1

0,10 Volt = 1000ms

Terminal 10

Lower ⇒ Neutral

+10V to 0V

t2

5,00 Volt = 20ms

Terminal 11

Neutral ⇒ Lift

0V to -10V

t3

0,10 Volt = 1000ms

Terminal 12

Lift ⇒ Neutral

-10V to 0V

t4

5,00 Volt = 20ms

Pot


E50 Swing 24 Volt at

Joy stick Signal

Terminal 9

Neutral ⇒ Swing R

0V to +10V

t1

0,20 Volt = 500ms

Terminal 10

Swing R ⇒ Neutral

+10V to 0V

t2

0,10 Volt = 1000ms

Terminal 11

Neutral ⇒ Swing L

0V to -10V

t3

0,20 Volt = 500ms

Terminal 12

Swing L ⇒ Neutral

-10V to 0V

t4

0,10 Volt = 1000ms

Pot


E50b Swing brake 24 Volt at

Joy stick Signal

Terminal 9

Neutral ⇒ Swing R

0V to +10V

t1

0,10 Volt = 1000ms

Terminal 10

Swing R ⇒ Neutral

+10V to 0V

t2

5,00 Volt = 20ms

Terminal 11

Neutral ⇒ Swing L

0V to -10V

t3

0,10 Volt = 1000ms

Terminal 12

Swing L ⇒ Neutral

-10V to 0V

t4

5,00 Volt = 20ms

E51 Left crawler 24 Volt at

Pot


Terminal 9

t1

0,10 Volt = 1000ms

Terminal 10

t2

0,10 Volt = 1000ms

Terminal 11

t3

0,10 Volt = 1000ms

Terminal 12

t4

0,10 Volt = 1000ms

E52 Right crawler 24 Volt at

Pot


Terminal 9

t1

0,10 Volt = 1000ms

Terminal 10

t2

0,10 Volt = 1000ms

Terminal 11

t3

0,10 Volt = 1000ms

Terminal 12

t4

0,10 Volt = 1000ms

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Components

Section 6.0 Page 1


Page Components 6.1

Hydraulic 6.1.1

Main Control Blocks and High Pressure Filter

2

6.1.2

Distributor Manifold – Location of Restrictor blocks

3

6.1.3

Restrictor Block with Pressure Relief Valve (Type 131)

4

6.1.4

Restrictor Block with Pressure Relief Valve (Type 132)

5

6.1.5

Anti Cavitation Valve Block (Type 109)

6

6.1.6

Anti Cavitation Valve Block (Type 142 - 145)

7

6.1.7

Remote Control Valves

8

6.1.8

Directional Solenoid Valves (Three positions / 4-ways)

9

6.1.9

Proportional Solenoid Valves

10

6.1.10

High Pressure Filter

11

6.1.11

Control Blocks and Valves

6.1.12

Travel Brake Valve

17

6.1.13

Pressure Reducing Valve

18

6.1.14

Directional Solenoid Valves (Two positions / 4-ways)

19

6.1.15

Pressure Increasing Valve

20

6.1.16

Hydraulic Cylinder

21

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Section 6.0 Page 2

6.1.1 Main Control Blocks and High Pressure Filter Legend for illustration (Z 22727d): Circuit No. I (14 / I) Main Control block (Travel L.H. / Stick / Bucket / Boom) (18.2) High pressure filters for main pumps 2 + 6 (double unit), with differential pressure switches B6-1 and B6-2. (32.1+32.2) Anti Cavitation Valve (ACV) – Travel motors (32.3) ACV – Stick cylinder piston side (32.4) ACV – Bucket cylinder rod side (32.5) ACV – Bucket cylinder piston side (33.1) Service-line Relief Valve (SRV) – Stick cylinder rod side (33.2) Service-line Relief Valve (SRV) – Bucket cylinder rod side Circuit No. II (15 / II) Main Control block (Swing / Boom / Stick / Bucket) (18.1) High pressure filters for main pumps 4 + 8 (double unit), with differential pressure switches B5-1 and B5-2. (32.6) ACV – Stick cylinder piston side (32.7) ACV – Bucket cylinder rod side (32.8) ACV – Bucket cylinder piston side (33.3) Service-line Relief Valve (SRV) – Bucket cylinder rod side Circuit No. III (16 / III) Main Control block (Travel R.H. / Boom / Bucket / Stick) (18.3) High pressure filters for main pumps 3 + 7 (double unit), with differential pressure switches B7-1 and B7-2. (32.9+32.10) Anti Cavitation Valve (ACV) – Travel motors (32.11) ACV – Bucket cylinder rod side (32.12) ACV – Bucket cylinder piston side (262) SRV (pressure increasing valve) – Boom cylinder rod side Circuit No. IV (17 / IV) Main Control block (Clam / Bucket / Stick / Boom) (18.4) High pressure filters for main pumps 1 + 5 (double unit), with differential pressure switches B8-1 and B8-2. (32.14) ACV – Clam cylinder piston side (32.15) ACV – Clam cylinder rod side (32.16) ACV – Bucket cylinder rod side (32.17) ACV – Bucket cylinder piston side (32.18) ACV – Stick cylinder piston side (33.6) SRV – Bucket cylinder rod side (33.7) SRV – Stick cylinder rod side (33.8) SRV – Boom cylinder rod side

)

• There is one Main Relief Valve in each control block

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Section 6.0 Page 3

6.1.2 Distributor Manifold - Location of restrictor blocks and anti cavitation valves Front Shovel Attachment Legend for illustration (Z 22728): (SB) Synchronization (Equalization) block (SL)

Synchronization (Equalization) lines Pressure check point

(73)

Distributor manifold

(142) cylinder

Section A – B,

Anti Cavitation Valve (ACV) Block , Boom

(132.1+.2)

Section B

Restrictor blocks, Boom cylinder piston side with SRVs and check points M16.1 + M16.2

(131.1)

Section C

Restrictor block, Bucket cylinder piston side with SRV and pressure check point M17.1

(131.4)

Section E

Restrictor block, Bucket cylinder piston side with SRV and pressure check point M17.2

(92)

Section F

Valve block SRVs, Clam cylinder piston side with check points M20.1 + M20.2 + M20.3

(109.2)

Section G

ACV Block, Stick cylinder rod side

(131.5+.6)

Section H

Restrictor blocks, Stick cylinder piston side with SRVs and check points M19.1 + M19.2

(143)

Section H – J,

Anti Cavitation Valve (ACV) Block , Stick cylinder

(131.7+.8)

Section K

Restrictor blocks, Stick cylinder piston side with SRVs and check points M19.3 + M19.4

(131.9)

Section L

Restrictor block, Clam cylinder rod side with SRV and pressure check point M19.5

(144)

Section M – N, Anti Cavitation Valve (ACV) Block, Bucket cylinder

(131.11+.12) Section N

Restrictor blocks, Bucket cylinder piston side with SRVs and check points M17.3 + M17.4

(132.3+.4)

Section P

Restrictor blocks, Boom cylinder piston side with SRVs and check points M16.3 + M16.4

(145)

Section P – Q,

Anti Cavitation Valve (ACV) Block, Boom cylinder

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Section 6.0 Page 4

6.1.3 Restrictor Block with Pressure Relief Valve (Type 131.1 – 131.13 of the hydraulic circuit diagram)

)

• A restrictor block is used for limiting cylinder lowering speeds. • A Service Line Relief Valve is installed to limit the maximum system pressure due to external forces.

Legend for illustration (Z 21834): (1) (2 + 3) (4) (5 + 6) (7) (8) (9) (10) (11 (12) (13) (14) (15) (16) A+B M Y T

Adjustment spindle O-ring with back-up ring Retainer O-ring with back-up ring Spring Spring cup Throttle sleeve O-ring Housing Return line port, T Pressure relief valve Allen bolt Clip ring Lock nut Line ports Pressure check point Control oil drain port Return line port

Function: Setting of the maximum permissible cylinder speed (flow B to A) is carried out by spindle (1). Depending on the spindle setting, the radial holes (9.1) in the valve poppet (9) will be partially opened to achieve the required throttling of the oil flow. The extra holes (fixed throttle 9.2) prevents the valve from becoming completely closed. For the lifting operation (flow A to B), the valve poppet (9), which is guided by the spindle (1), is pressed against spring (7) so that the valve will be completely open.

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Section 6.0 Page 5

6.1.4 Restrictor Block with Pressure Relief Valve (Type 132.1 – 132.4 of the hydraulic circuit diagram)

)

• A restrictor block is used for limiting cylinder lowering speeds. • A Service Line Relief Valve is installed to limit the maximum system pressure due to external forces.

Legend for illustration (Z 21315): (1)

Adjustment spindle

(2 + 3) (4) (5 + 6) (7) (8) (9) (10) (11) (12) (13) (14) (15 + 16)

O-ring with back-up ring Flange O-ring with back-up ring Spring Spring cup Throttle sleeve Lock nut Housing Clip ring Allen bolt Jet bore, 1 mm O-ring with back-up ring

(17 + 17.1) Pressure relief valve, pilot operated (18) Jet bore, 1.2 mm (19) Flange (20) Allen bolt (21 Correction shim(s) (22) Valve housing (23) Valve spring 24 + 25) O-ring with back-up ring (26) O-ring A+B Line ports T Return line port M Pressure check point Y Control oil drain port

Function: Setting of the maximum permissible cylinder speed (flow B to A) is carried out by spindle (1). Depending on the spindle setting, the radial holes (9.1) in the valve poppet (9) will be partially opened to achieve the required throttling of the oil flow. The extra holes (fixed throttle 9.2) prevents the valve from becoming completely closed. For the lifting operation (flow A to B), the valve poppet (9), which is guided by the spindle (1), is pressed against spring (7) so that the valve will be completely open.

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Section 6.0 Page 6

6.1.5 Anti Cavitation Valve Block (Type 109.1 + 109.2 of the hydraulic circuit diagram)

)

• ACVs are installed to avoid cavitation damages on users (hydraulic cylinders), by compensating a possible lack of oil, when the SRV at the opposite side of the cylinder opens (see circuit diagram).

Legend for illustration (Z 21835): (1) (2) (3) (4) (5) (6) S A and B

Housing Valve cone Spring O-ring Control and leak oil bore Cap screw (torque 900 Nm) Supply line (Return oil pressurized to approximately 10 bar by back pressure valve) Line connections

Function: The circuit pressure in the line A and B hold the valve cone (2) closed. The pressure of the supply line S forces onto the valve cone. The valve cone opens, whenever the pressure at the A and B side is lower than the back pressure at return oil port S, to allow necessary oil supply into the circuit.

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Section 6.0 Page 7

6.1.6 Anti Cavitation Valve Block (Type 142 -145 of the hydraulic circuit diagram)

)

• ACVs are installed to avoid cavitation damages on users (hydraulic cylinders), by compensating a possible lack of oil, when the SRV at the opposite side of the cylinder opens (see circuit diagram).

Legend for illustration (Z 22729): (1) (2) (3) (4) (5) (6) (7) S A and B

Housing Valve cone Spring O-ring Support ring Cap screw (torque 900 Nm) Control and leak oil bore Supply line (Return oil pressurized to approximately 10 bar by back pressure valve) Line connections

Function: The circuit pressure in the line A and B hold the valve cone (2) closed. The pressure of the supply line S forces onto the valve cone. The valve cone opens, whenever the pressure at the A and B side is lower than the back pressure at return oil port S, to allow necessary oil supply into the circuit.

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Section 6.0 Page 8

6.1.7 Remote control valves

)

• Remote control valves are part of the electric-hydraulic control system

Legend for illustration (Z 22730): (1 - 8) (9) (10) (11) (12) (13) (14)

Pilot pressure lines to the control block Pilot pressure supply port Return to tank port Manifold block Double directional solenoid valve Single proportional solenoid valve Plug-in orifice for A / B ports

Function: The electric-hydraulic control system is used to control the direction and volume of oil flow to the operating cylinders and motors via the main control valve blocks. When a lever (or pedal) is actuated, a proportional solenoid valve (13) and one of the directional solenoid valves (12 either a or b) are energized, and allows the pilot pressure oil to flow to the spools of the main control blocks. The proportional solenoid valve alters the pilot pressure, proportional to the lever deflection, this results a spool movement between neutral and full stroke position.

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Section 6.0 Page 9

6.1.8 Directional Solenoid Valves (Three positions / 4-ways)

)

• This solenoid operated directional spool valves are installed to control the start, stop and direction of an oil flow.

Legend for illustration (Z 21839a): (1) (2) (3) (4) (5) (6) (7)

Housing Solenoids Control spool Reset springs Plunger End cover Plug-in orifice

Function: In un-operated condition the control spool (3) is held in the neutral or starting position by the reset springs (4). Operation of the control spool is by means of oil immersed solenoids (2). The force of the solenoid (2) acts via the plunger (5) on the control spool (3) and pushes its from its resting position into the required end position. This results in the required free flow from P to A and B to T or from P to B and A to T. When the solenoid (2) is de-energised, the control spool (3) is returned to its original position by the reset springs (4). Where necessary restriction orifices are installed into the valve ports, to reduce the oil flow.

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Section 6.0 Page 10

6.1.9 Proportional Solenoid Valve

)

• This valves are responsible for the creation of a variable control pressure proportional to the electrical signal output of an amplifier.

Legend for illustration (Z 21697): (1) (2) (3) (4)

Proportional solenoid Control piston Valve housing Pressure measuring spool

(5) (6) (7) (8)

Pressure measuring spool Connection plug Return spring Bleed screw

Function: In unoperated condition the control spool (2) is held in the neutral or starting position by reset springs. The control spool (2) is directly operated by the proportional solenoid (1). If the solenoid is energized, it produces a force to operate the control spool (2) via the pressure measuring spool (4) and moves the spool to the left. Oil flows from P to A. As pressure in A increases, it passes via the radial borings in the control spool (2) to the inner end of the pressure measuring spool (2). The force generated by the pressure now works against the solenoid force and pushes the control spool (2) to the right (closing direction) until a balance is achieved between the two forces. In order to achieve this, the pressure measuring spool (2) moves to the left until it is supported by the pin (5). When the force balance is achieved, the connection between P and A is interrupted and the pressure in line A is held constant. Any reduction in the solenoid force leads to the pressure force exceeding the solenoid force on the control spool (2). The control spool is then moved to the right causing a connection from A to T allowing the pressure to fall until a balance is re-established at a lower level. At rest, when the solenoid is de-energized, ports A and B are open to tank, whilst port P is blocked from both ports A and B. • In order to achieve optimum functioning of the valve, it must be bleed when commissioning: - Supply pressure to the valve - Remove plug 8 - When no more air bubbles appear screw in plug 8.

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Section 6.0 Page 11

6.1.10 High Pressure Filter

)

• There is one filter in each pump line installed.

Legend for illustration (Z 22731): (1) (2) (3) (4) (5) (6)

Filter housing Drain plug O-ring Back-up ring Filter element O-ring

(7) (8) (9) (10) (11)

P1 P2 a b c d e

Higher static pressure Lower static pressure Electrical connection REED contact Permanent magnet piston Spring Plug screw

Spring Differential pressure switch O-ring Allen bolt Lock washer

Function: High-pressure in-line filters prevent contamination from entering the hydraulic circuits. The spin-on filters are installed between the main hydraulic pumps and multi-valve control blocks. All hydraulic components, behind the pumps, are effectively protected from damage and undue wear. Each filter is equipped with a differential pressure switch to monitor the filter flow restriction. If the pressure reaches an unsafe difference of 8.5 bar, a message appears on the display in the cab. Example: Fault No. 674: (677) Help:

$h: High pressure filter #5 or pump #5 restricted. Stop Motor 2 Differential pressure switch B5-2 not closed. - Clean or replace filter element. - Check pump

or Fault No. 644: (647) Help:

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$h: Start of motor 2 blocked due to contamination of pump #5 Differential pressure switch B5-2 not closed. - Check cables to differential pressure switch B5-2.

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Components

Section 6.0 Page 12

6.1.11 Control Blocks and Valves

)

• This is a principle drawing, showing valve block I to IV.

Legend for illustration (Z 22436): (1) (2) (3) (4) (5) (6) (7)

Control block housing Cab ("A side) Cap ("B" side) Spool "B" side service line ports Centering springs MRV, main relief valve

(8) (9) (10) (11) (12) (13)

Port B, to cylinder/motor Port A, to cylinder / motor Fine controlling grooves Port P, from pumps Port T, to tank Load holding valves

Control blocks with "Open Center and Closed Ports". Control blocks I, II, III and IV are 4-spool blocks and V is a 1-spool block. See hydraulic circuit diagram for spool details. Each spool is provided with "Fine Controlling Grooves" and ring grooves for hydraulically centering of the spool. Between 8 and 19 bar pilot pressure the spools are moved in their fine control range. The 4-spool blocks are equipped with different spools, depending on function and priority.

a2 / a3

Spools without a symbol (standard) are connecting the rod side of the cylinders with the pump supply line and the piston side with the tank. Spools with #-symbol are connecting the piston side of the cylinders with the tank only. (lowering with free pump circulation, i.e. the pressure channel is connected to the center channel, so that pump flow is available for other functions.) Spools with $-symbol (floating) are connecting the piston side of the cylinders with the rod side and also with the tank. The Load Holding Valves are installed inside of the spool, for each port to the cylinder or motor one valve. The hydraulic diagram shows only one. The MRV is a pilot operated pressure relief valve. continued

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Components

Section 6.0 Page 13

6.1.11 Control Blocks and Valves Cont'd: Legend for illustration (Z 22733): (1) (2) (3) (4)

Main relief valve (MRV)Control block housing Check valve (Load holding valve) Anti cavitation valve (ACV) Service line relief valve (SRV)

Explanation of the schematic drawing of the control block: The hydraulic oil flows through the control block from port P to T, if all spools are in neutral position ("pressure-less circuit" or “Free circulation“). (A) 4-spool valve block Example 1: Spool #1 moves up when pilot pressure is build up in the control pipe line a1. (Imagine the upper symbol box moves to the center position.) Now pump oil flows through check valve (2) to the user port A1 (travel motors) because the free flow circulation to the hydraulic reservoir is closed. The main relief valve (1) limits the maximum operation pressure in this circuit. Via port B1 the return oil from the travel motors is flowing back to the hydraulic oil reservoir. During down hill travel motion and stopping procedure the ACV’s (3) prevents cavitation on the hydraulic motors. Because during these short periods of time the hydraulic motor needs a higher oil supply than the pump can deliver. Example 2: Spool #2 moves up when pilot pressure is build up in the control pipe line a2. (Imagine the upper symbol box moves to the center position.) Now pump oil flows through check valve (2) to the user port A2 (stick cylinder rod side) because the free flow circulation to the hydraulic reservoir is closed. The main relief valve (1) limits the maximum operation pressure in this circuit. Via port B2 the return oil from the stick cylinder piston side is flowing back to the hydraulic oil reservoir. SRV (4) is installed to limit maximum possible pressure peaks in the service line.. Shortly high pressure closes check valve (2) which secures the hydraulic pump from pressure peaks. The check valves (2) have also the function of load holding valves because during the fine controlling period all lines are connected together (negative overlapping). The load pressure is for a moment higher than the pump pressure. (B) 1-spool valve block The "C" port is used for combined operation with a second pump circuit if the swing function is not used. (see circuit diagram). continued PC8000-6-E_Sec_6-0_#12048_rev0.doc

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Components

Section 6.0 Page 14

6.1.11 Control Blocks and Valves Cont'd: Legend for illustration (Z 22441): (1) (2) (3)

Spool Centering springs Load holding valve

Function: Reset springs (2) moves the spool (1) in neutral position. Fine control grooves provide for sensitive controlling, because a motion is started always while the pressure oil and the return oil first passes this fine control grooves before spool (1) is inter connecting the entire groove to the user channel.

Upper picture: In neutral position of spool (1) the pump oil is flowing back via port PU to the tank. Lower picture: Example. The spool is moved by pilot pressure on the left spool side to right position: Port PU is closed and the connection through the holding valve (3) to the user (port A) is open. Also the connection from the other user side (port B return) is connected to the port T (return line to tank). continued

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Section 6.0 Page 15

6.1.11 Control Blocks and Valves Cont'd: Legend for illustration (Z 21705): (01) (02) (03) (04) (5) (6) (7) (8)

Service -Line Relief Valve Anti Cavitation Valve Main Relief Valve Closing plate Plug screw Spring Valve cone Dust cap

(9) (10 (11) (12) (13) + 16) (14) (15) (17)

Set screw Lock nut Spring, pilot part Poppet Jet bore Spring, main cone Main valve cone Pilot oil dump line to tank

MRVs and SRVs are pilot operated relief valves. The MRV limits the max. Pump supply line pressure. The SRV limits the max. possible pressure peak in the service-line. The valves have an „opening characteristic“. That means, that in case of contamination after the response procedure no further pressure increasing is possible and damages are avoided. Function: The circuit pressure P forces with the force F1 on the piston surface A of the main valve cone (15). Because there is via the jet bore (16) the same pressure on the back side of the main cone, this results together with the spring (14) force in a force F2 that keeps the main cone closed. Via the jet bore (13) the circuit pressure is in front of the poppet (12). Exceeds the circuit pressure the setting value of the spring (11), the poppet opens against the force of the spring (11). This causes that the force F2 decreases and there is no more balance condition between F1 and F2. Valve cone (15) is moved upwards by the greater force F1. That means there is now a direct connection from port P to T (tank). ACVs serve for compensation possible lack of feed when the SRV at the opposite port is actuated (see circuit diagram) and for avoiding cavitation damages. In addition, to supply a user in case it is continuously moved by acceleration forces at zero position of the control spool. Function: The circuit pressure inside the spring chamber closes the valve cone (7). The back pressure of the return line acts on the surface of the valve cone (7). Whenever the pressure in the service-line is lower than the springs force the valve cone opens by the force of the back pressure and hydraulic oil is additional supplied. continued

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Section 6.0 Page 16

6.1.11 Control Blocks and Valves Cont'd: Load Holding Valve Legend for illustration (Z 22441): ((1) (2) (3)

Spool Centering springs Load holding valve

Control Blocks I to IV (4-spool blocks) Two load holding valves are fitted into each spool of the control blocks, one valve for each port (A and B). They have three tasks: 1. When circuit pressure due to attachment weight is higher than pump pressure these valves prevent dropping of the attachment, within their sensitive (fine controlling) range. 2. Due suddenly pressure peaks in the service lines the valves also protect the pump. 3. When two pumps flows are used for one user they ensure that at least the flow of one pump reaches the user in case one MRV is defect or not more correct adjusted. That means: Up to the max. Pressure of the defective valve both load holding valves are open allowing the flow of both pumps to the user, then one valve will be closed by the higher pressure and the flow of one pump only flows to the user. Function: In neutral position (upper picture) of the spool (1) both valve cones (3) are closed by the springs (2). In switched position (lower picture) forces the circuit pressure onto the front area of the valve piston (3). This force moves the piston against spring (2) and allows the oil to flow from the pump supply port (P) to the user port (A) and from port B to the return oil passage (T). If due to an external force the pressure directed to the pump overcomes the pressure in the pump line; this pressure (force) closes the valve (direction P to A).

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Section 6.0 Page 17

6.1.12 Travel Brake Valve Illustration Z 21695 Task: Travel brake valves control the oil flow from the hydraulic motor to the tank depending on operating pressure. This braking action prevents the motors from overspeeding. Function: Spring force keeps the spool in the lowest flow position. with increasing operating pressure the opening for the return oil flow becomes larger. On its way to the hydraulic motor the oil flows from A to A1 respectively from B to B1 depending on the selected travel motion. Example: Operating pressure at port A moves spool (1) against the force of the spring (2) and opens the way for the return oil (B1 to B). Check valve (3) prevents a direct oil flow from B1 to B. If the operating pressure decreases to such an extend that the spring force overcomes the pressure, the flow to the tank becomes restricted, resulting in braking of the machine.

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6.1.13 Pressure Reducing Valve

)

• Pressure reducing valves are installed to reduce the common 45 bar pilot pressure to a lower pressure for other systems, e.g. the hydraulic track tensioning system.

Legend for illustration (Z 21844): (1) (2) (3) (4) (5) (6) (7) (8)

Set screw Spool Compression spring Threaded sleeve Non return valve Boring Spring chamber Control land

Function: Pressure reducing valves type DR & DP are direct operated valves of 3 way design, e.g. with a pressure relief function on the reduced pressure side. At rest, the valve is normally open, and fluid can flow unhindered from port P to A. Pressure in port A is also present on the end of the spool (2), via control line (6), opposing the compression spring (3). When the pressure in port A reaches the pressure level set at spring (3), spool (2) moves to the control position and holds the pressure in port A constant. Fluid to control the valve is taken from port A via the boring (6). If the pressure in port A rises still further due to external forces, the spool (2) is moved still further towards the compression spring (3). This causes a flow path to be opened over control land (8) in the control spool (2) to tank. Sufficient fluid then flows to tank to prevent any further rise in pressure. An optional non return valve (5) is available to allow free flow from A to P.

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6.1.14 Directional Solenoid Valves (Two positions / 4-ways)

)

• This solenoid operated directional spool valves are installed to control the start, stop and direction of an oil flow.

Legend for illustration (Z 21845): (1) (2) (3) (4) (5) (6)

Housing Solenoid Control spool Return spring Plunger Dust cap with stem for manual operation

Function: When there is no flow through the valve, control spool (3) is held in neutral or output position by means of the return springs (4). The control spool (3) is operated by means of oil immersed solenoid (2). The force of the solenoid (2) effects control spool (3) by means of the plunger (5) and pushes it from its resting position to the required end position. This results in free flow from or P to B and A to T. When solenoid (2) is de-energized, control spool (3) is moved back to its resting position by means of return springs (4). An optional hand emergency (6) allows movement of the control spool (3) without energizing the solenoid.

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6.1.15 Pressure Increasing Valve

)

• The pressure increasing valve is a remote controlled pressure relief valve, actuated by hydraulic pressure. The individual pressure is in such a way determined by the pilot pressure.

Legend for illustration (Z 21846): (1) (2) (3) (4) (5) (6) (7+8) (9) (10) (11+12) (13+14)

Pilot valve with valve seat Valve poppet Compression spring Main valve with sleeve Main piston Closing spring Set screws Piston Pin Jet bore Lock nut

Function: The valve poppet (2) is connected via the jet bores (11) and (12) with the P port. If static pressure increase above the set pressure value, the valve poppet (2) opens and allows oil to flow freely to tank (T1). This oil generates a pressure drop in the spring chamber of the main spool, the closing force of the spring (6) is cancelled, and the main piston (5) opens to allow the pump flow to flow to tank (T2). Damped opening and closing is obtained by the throttled volumetric change. By applying external pressure of Pst max = 45 bar to the main spool (9) via port X, the pre-tensioning of the pressure spring (3) is increased by the amount of the piston stroke "S" and system pressure is increased correspondingly. The possible pressure increase p is 440 bar max. or 440 bar minus the basic setting. The setting is fixed by means of the setting screw (7) and lock nut (13); 1 turn of the screw = 150 bar.

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6.1.16 Hydraulic Cylinder Legend for illustration (Z 22735): General (1) Piston rod (2) Rod eye bushing (3) Piston (4) Cylinder tube (5) Piston fitting key (6) Piston nut (7) Piston nut lock (threaded pin) (8) Foot end eye bushing

B Flange bushing: Clam cylinder B1 Scraper ring B2 „BD“ seal (Dynamic Seal)

A Flange bushing: Boom-, Stick-, Bucket-Cylinder A1 Scraper ring A2 Support bushing A3 Hard-plastic back-up ring A4 Back-up ring A5 Chevrons A6 Header ring A7 Scraper retainer ring A8 Cover A9 Steel shims (splitted)

C = Piston rings C1 Piston seal ring C2 Piston guide rings, hard C3 Piston guide, soft C4 O-ring with back-up rings

Explanation of the cylinder markings 430/290X3150

Piston diameter / Rod diameter X Stroke

430630 40

Cylinder drawing number (identical with part No.).

11 / 97

Assembling Month and year (final figure).

261

Internal counting number.

DB 55.

Assembling crew personal code

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Main Hydraulic Pumps and Pump Regulation System

Section 7.0 Page 1


Page Main hydraulic pumps and pump regulation system General 7.1

7.2

7.3

7.4

Main Pumps 7.1.1 Location of Pumps, drive speed and flow rates 7.1.2 Pump bearing flushing / lubrication 7.1.3 Operating Principles 7.1.4 Checks and Adjustments Electronic Pump Regulation System 7.2.1 Electronic load limiting control - General 7.2.2 Components:- Electronic Power Module EPM - Electronic Signal rectifier ESR - Microcontroller MC7 7.2.3 Checks and adjustments - General Method A - With 24V supply to terminals - X1-Pressure - Demanded power - PID - Factor Method B - With the electronic service tool BB-3 - Language selection - Adjustment mode SET1 and SET2 - Number of motor selection - X1-pressure (max. current) adjust. - Demanded power adjustment - PID – Factor adjustment - Storage new settings Method C - With a laptop and BODEM software - Starting the program - Language selection - Entering of the password - Number of Motor selection - X1-pressure (max. current) adjust. - Demanded power adjustment - PID – Factor adjustment Hydraulic Constant Regulation System 7.3.1 General 7.3.2 X1-pressure adjustment (constant-pressure) Energy efficiency

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2–5

6 7 8 – 15 16 – 20 21 22 23 + 24 25 26 27 28 + 29 30 31 + 32 33 34 35 36 37 38 39 - 40 41 42 43 44 45 + 46 + 47 48 49 50 51

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Main Hydraulic Pumps and Pump Regulation System 7.0

Section 7.0 Page 2

Main hydraulic pumps and pump regulation system General lay out (Hydraulic only)

Legend for illustration (Z 22408a): (1 - 8) Main hydraulic pumps (9.1 + 9.3) Pilot pressure pumps (68.1 + 68.7) Pilot pressure filter unit (252.1) (252.2) (252.3) (252.3)

45 bar pressure reducing valve 60 bar pressure relief valve Check valve Check valve

(253.1) (253.2) hydraulic

Change over valve: "Electronic or Hydraulic regulation" Motor1 Pressure reducing valve: "Pump regulation pressure X1 at

(Y61-1)

(254.1) (254.2) hydraulic (Y61-2)

(255.4) (Y17) (Y17a) (Y100)

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pump regulation" (Hydraulic constant regulation mode) Motor1 Proportional solenoid valve: "Pump regulation pressure X1 at electronic pump regulation " (Standard operation mode) Motor1 Change over valve: "Electronic or Hydraulic regulation" Motor2 Pressure reducing valve: "Pump regulation pressure X1 at pump regulation" (Hydraulic constant regulation mode) Motor2 Proportional solenoid valve: "Pump regulation pressure X1 at electronic pump regulation " (Standard operation mode) Motor2 Pressure reducing valve: "Remote control pressure" ½ Q-max flow reduction for the warming-up period. Solenoid valve: "Remote control pressure" Q-min flow for all main pumps Solenoid valve: "Remote control pressure" ½ Q-max flow reduction for all main pumps Solenoid valve: Option only "Remote control pressure" ½ Q-max flow reduction for pump #1 only

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Section 7.0 Page 3

Main hydraulic pumps and pump regulation system Pump regulation system General Controlled output flow of the main pumps is necessary: • To utilize the available motor power most efficiently in every operating mode. • To limit the power consumption of the hydraulic pumps depending on the load of the motor. (Electronic pump regulation with micro-controller MC7) • For additional functions, such as rotating dependent or temperaturedependent flow reduction. Function: X1 – pump regulation pressure (0 – 34 bar): The power controller of the main pumps can be remotely controlled by applying an external pilot pressure (X1 ) at port X LR to the spring chamber of the power control valve. The start of destroking can be varied in proportion to the applied X1 - pressure.

X2 – pilot pressure (45 bar): Constant pilot pressure to regulate the main pumps at special circumstances, e.g. to fix the pumps in Q-max position while servicing the machine.

X3 – remote control pressure (0 / 15 / 45bar): Basic setting Q-min (0 bar), the flow rate increases with the pilot pressure X3 at port Pst, up to Q-max (45 bar). The hyperbolic power control is superimposed on the pilot pressure signal and keeps the specified drive power constant. (p x Vg = constant). The flow rates are: Q-min.: X3 = 0 bar ½ Q-max.: X3 = 15 bar Q-max.: X3 = 45 bar

X4 – pump support pressure (60 bar): Constant pilot pressure to support the regulation function at low operating pressure and to lubricate the main pump bearings.

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Section 7.0 Page 4

Main hydraulic pumps and pump regulation system Pump regulation system general Function: Solenoid valve Y17: If de-energized pumps #1-8 are in Q-min position. It gets energized as soon as one of the control levers/pedals has been operated and stays energized as long as the temperature state is above T3. It gets de-energized whenever all controls are in neutral position for more than 20 seconds and a temperature state between T1 and T3. Solenoid valve Y17a: The solenoid is de-energized as long as the temperature state is below „T2“ (depending on the filled in hydraulic oil) shown in the table. ( pumps #1-8 are in ½ Q-max. position for warm up) It gets energized at a temperature state between T2 and T4 as soon as one of the control levers/pedals has been operated and gets de-energized without delay whenever all controls are in neutral position.

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Section 7.0 Page 5

Main hydraulic pumps and pump regulation system Pump regulation system general Function: Proportional Solenoid valve Y61-1: This valve, connected to the MC7 micro-controller (electronic pump regulation), creates a X1-pressure depending on the load of the motor 1. This X1-pressure is the information to reduce pump delivery, in order to keep the motor at rated power. Pressure reducing valve 253.2: Pump regulation pressure X1 at "hydraulic pump regulation" (Hydraulic constant regulation mode) by the function of change over valve (253.1) for motor 1. Proportional Solenoid valve Y61-2: This valve, connected to the MC7 micro-controller (electronic pump regulation), creates a X1-pressure depending on the load of the motor 2. This X1-pressure is the information to reduce pump delivery, in order to keep the motor at rated power. Pressure reducing valve 254.2: Pump regulation pressure X1 at "hydraulic pump regulation" (Hydraulic constant regulation mode) by the function of change over valve (254.1) for motor 2. Pressure reducing valve 255.4: "Remote control pressure" (X3) ½ Q-max flow reduction during the warming-up period for all pumps by the function of solenoid valve Y17a. Change over valve 253.1 and 254.1: Change over three way cock valve to select "Electronic or constant regulation mode", one for each motor.

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7.1

Section 7.0 Page 6

Main Pumps 7.1.1. Location of Pumps Legend for illustration (Z 22621a): (1 – 8) Axial piston pump (swash plate type) theoretical flow rate, each 1033 Liter/min Drive speed* n = 1378 min-1 for all working motions (9.1 + 9.3)

(9.2 + 9.4)

Gear pump theoretical flow rate Drive speed* for pilot pressure supply

152 Liter/min n = 1378 min-1

Gear pump theoretical flow rate Drive speed* for PTO gear lubrication

152 Liter/min n = 1378 min-1

(10.1 – 10.4) Axial piston pump theoretical flow rate Drive speed* for • Hydr. oil cooler fan drive • PTO cooler fan drive

)

188 – 278 Liter/min n = 1741 min-1

• * at 1800 min-1 input drive speed (60Hz) • 1500 min-1 input drive speed (50 Hz)

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Section 7.0 Page 7

Main Pumps 7.1.2. Pump bearing flushing / lubrication The installed main pumps are provided with an external cooling and lubrication system for flushing of drive shaft bearing and shaft seal. Oil supply is provided from the X4-pressure circuit. To reach the restricted guidance of the coolant for external bearing flushing, the throttle screw (located behind the union at port U) must be screwed in all the way. An information sign is fixed at the pump. Legend for illustration (Z 22622): (1 – 8) Main pumps (94.1 – 94.8) Orifice (one for each main pump) (68.1 + 68.7) Filter for pilot pressure (U) Port for the pump bearing flushing / lubrication

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Section 7.0 Page 8

Main Pumps 7.1.3 Operating Principles Main hydraulic pump A4VSLO 750 LR3DN / 30L Type code explanation: A4VSLO 750 LR 3 D N / 30 L Rotation Series Basic adjustment for minimum displacement With pressure control Hydraulic remote adjustment facility Constant power with hyperbolic curve Displacement in cm3 at one (1) revolution Axial piston pump series 4, variable displacement ,swash plate design for open circuits with charge pump

Function and characteristics: • The A4VSLO variable displacement axial piston pump in swash plate design is intended for drives in open circuit operation. • The flow volume is proportional to the drive speed and the displacement. By adjusting the swash plate a infinitely variable flow adjustment is possible. • Pumps of the same nominal size can be built onto the trough drive. Combinations with gear pumps are also possible. Legend for illustration (Z 21549): (1) Drive shaft (2) Cylindrical roller bearing (3) Slipper pad (4) Swivel angle indicator (5) Positioning piston (6) Swivel pin (7) Cylinder with pistons (8) Final connecting plate (9) Cylindrical roller bearing (10) Impeller (charging pump) (11) Splints for the through drive coupling (Aux. pump drive) (12) Swivel cradle (13) Q-min stop bolt (14) Power control valve (15) Pressure balance valve (16) Power curve correction (17) Pressure cut off valve (18) Q-max. stop bolt (19) Remote control valve continued

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Section 7.0 Page 9

Main Pumps 7.1.3 Operating Principles Cont'd: Symbol of main hydraulic pump A4VSLO 750 LR3DN / 30L Legend for illustration (Z 21550): (1) Main pump (swash plate pump, variable displacement) (2) Charging pump (impeller type pump) (3) Pump bearing group (4) Drive shaft (5) Non return valves (6) Remote control valve (6.1) Mechanical stroke limitation* (6.2) Remote pressure (PST) operated piston for item 6 (6.3) Mechanical stroke limitation* (7) Spool valve (pressure balance valve) (8) Nozzle (9) Power control valve (10) Nozzle (11) Pressure cut-off valve (12) Auxiliary pump (Gear pump, fixed displacement (13) Positioning piston (14) Slipper pad piston (15) Lever (16) Cam (17) Through drive shaft • * Factory side adjusted, no field adjustment required

)

B/B1 S MB ML MST R T P PST U XLR

Pressure port Oil intake (suction port) Operating pressure check point Charging pressure check point Control pressure check point Filler and bleeder port Connection port for chip indicator Pump support pressure (”X4”-pressure) Remote control pressure port (”X3”-pressure) Bearing flushing port Regulating pressure port (”X1”-pressure) continued

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Section 7.0 Page 10

Main Pumps 7.1.3 Operating Principles Cont'd: Sectional drawing of Power Controller LR3DN / 30L Legend for illustration (Z 21551): (6) Remote control valve (6.1) Mechanical stroke limitation (6.2) Remote pressure (PST) operated piston for item 6 (6.3) Mechanical stroke limitation (7) Spool valve (pressure balance valve) (9) Power control valve (11) Pressure cut-off valve (13) Positioning piston (14) Slipper pad piston (15) Lever

)

• Refer also to illustration Z 21550 on the previous page.

continued

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7.1

Section 7.0 Page 11

Main Pumps 7.1.3 Operating Principles, illustration (Z 21552) Cont'd: Q-min position: (remember Q means volume) When are the pumps in Q-min position? A: Motor at standstill B: Motor running and the controls are not used for 20 sec. or longer at normal operating temperature C: Motor running and service switch S155 activated (Qmin-position) Example C with the following conditions: • Motor running • Pump pressure smaller than X4 = 60 bar (pump support pressure) • X1 = 34 bar (pump regulation pressure), this pressure will not influence the Q-min position under these conditions. • X3 = 0 bar (remote control pressure); Y17 de-energized (S155 Qmin activated) for all pumps. • X4 = 60 bar (pump support pressure) Pump support pressure is present at valve #7, the slipper pad of piston #14 and the small area side of the positioning piston #13 Response of pump control mechanism: Valve #7 moves to position "b" because the X4-pressure will overcome the spring force, since the oil behind nozzle (8) flows through valve #6 (which is in position "a", due to the missing remote control pressure X3) back to tank. Pump support pressure X4 passes valve #7 position "b" and flows via power control valve #9 position "a" to the large area side of positioning piston #13 Because the large area side of positioning piston #13 is approximately three times larger as the small area side, the pump support pressure X4 of 60 bar present on both sides, resulting in stronger force at the large area side, keeps the pump in Q-min position. The pump remains in Q-min position continued

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Main Pumps 7.1.3 Operating Principles, illustration (Z 21553) Cont'd: Q-max position: (remember Q means volume) When does the pumps move into Q-max position? and and and

Motor running hydraulic oil at normal operating temperature (> T2) the controls frequently used within 20 sec. (or Service switch S155 activated – Qmax-position) a pump pressure below start of de-stroking.

Example with the following conditions: • Motor running • Pump pressure between 60 bar and 300 bar, present at the slipper pad of piston #14 and the small area side of the positioning piston #13 • X1 = 34 bar (pump regulation pressure) • X3 = 45 bar (remote control pressure); Y17 and Y17a energized for all pumps. • X4 = 60 bar (pump support pressure), present at valve #7. Response of pump control mechanism: Valve #7 moves to position "a" because the spring force is supported by the X4-pressure, since the oil flow back to tank is blocked at valve #6 (which is in position "b", due to the 45 bar remote control pressure X3). The large area side of positioning piston #13 is connected, via power control valve (9) position "a" and pressure balance valve (7) position "a", to the return oil line. The pump moves into Q-max position, because the pump pressure acts only at the small area side of positioning piston #13.

The pump moves into Q-max position

continued

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Main Pumps 7.1.3 Operating Principles, illustration (Z 21554) Cont'd: ½ Q-max position: (remember Q means volume) When does the pumps move into half Q-max position? and and or and

Motor running hydraulic oil below normal operating temperature (< T2) the controls frequently used. the controls not used at a temperature state between T2 and T4 a pump pressure below start of de-stroking.

Example with the following conditions: • Motor running • Pump pressure between 60 bar and 300 bar, present at the slipper pad of piston #14 and the small area side of the positioning piston #13 • X1 = 34 bar (pump regulation pressure) • X3 = 15 bar (remote control pressure); Y17 energized and Y17a deenergized for all pumps. • X4 = 60 bar (pump support pressure), present at valve #7. Response of pump control mechanism: Valve #7 moves to an intermediate position (in-between "a" and "b"), since a certain amount of oil behind nozzle (8) flows through valve #6 (which is also in an intermediate position, due to the 15 bar remote control pressure X3) back to tank. The large area side of positioning piston #13 is connected, via power control valve (9) position "a" and pressure balance valve (7), to the return oil line. The pump moves into ½ Q-max position, because the return oil flow through pressure balance valve (7) is restricted (due to its intermediate position), resulting in a pressure at the large area side of the positioning piston (13). The pump moves into ½ Q-max position continued

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Main Pumps 7.1.3 Operating Principles, illustration (Z 21555) Cont'd: Destroking: (Pump moves from Q-max. into of Q-min. direction) When does the pumps start to destroke Motor running and hydraulic at normal operating temperature (> T2) and Service switch S155 deactivated and The hydraulic load is higher than the rated power of the motor ⇒ (The electronic pump regulation system will reduce the X1-pressure) or With pump pressure above ≈ 180 bar (Hydraulic constant regulation) (Constant X1-pressure of approximately 13 bar) Example with the following conditions: • Motor running • Pump pressure 180 bar adjustable at main relief valves, present at the slipper pad of piston #14 and the small area side of the positioning piston #13 • X1 = 13 bar (constant regulation pressure adjustable at pressure reducing valves 253.2 /254.2) Change over valves switched to hydraulic mode • X3 = 45 bar (remote control pressure); Y17 energized and Y17a energized for all pumps. • X4 = 60 bar (pump support pressure), present at valve #7. Response of pump control mechanism: Valve #7 moves to position "a" because the spring force is supported by the X4-pressure, since the oil flow back to tank is blocked at valve #6 (which is in position "b", due to the 45 bar remote control pressure X3). The operating pressure (with the value for start of de-stroking) at the slipper pad of piston #14 moves the power control valve (9) into position "b" (against the spring force supported by the X1-pressure). This in turn connects the operating pressure to the large area side of positioning piston #13. Because the large area side of positioning piston #13 is approximately three times larger as the small area side, the operating pressure present on both sides, resulting in stronger force at the large area side, moving the pump in Q-min direction. The pump de-strokes until the forces at positioning piston #13 are balanced continued

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Main Pumps 7.1.3 Operating Principles, illustration (Z 21556) Cont'd: Pressure cut-off valve: (DR control valve, Pump moves into Q-min. position) When is the pressure cut-off valve active? Motor running and With pump pressure above ≈ 300 bar Example with the following conditions: Motor running Pump pressure 300 bar X1 = 34 bar (pump regulation pressure) X3 = 45 bar (remote control pressure) X4 = 60 bar (pump support pressure) Response of pump control mechanism: Independent of the position of power control valve #9 the pressure cut-off valve #11 causes the pump to de-stroke to the pre-adjusted Q-min position. The operating pressure moves the pressure cut-off valve #11 (at set pressure) into position "b" and flows to the large area side of positioning piston #13. Because the large area side of positioning piston #13 is approximately three times larger as the small area side, the operating pressure present on both sides, resulting in stronger force at the large area side, moving the pump in Qmin position. The pump moves into Q-min position

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Main Pumps 7.1.4 Checks / Adjustments Location of Adjustments Legend for , illustration (Z21557) (1) Remote control valve (2) Q-min. stop bolt (3) Pressure balance valve (4) Start of destroking (5) Power curve correction (6) Pressure cut-off valve (7) Q-max. stop bolt (8) Angle indicator The average length of the measurement "L" is: set crews (bolts ) location 1 2 3 4 5 6 7

)

length (mm) 13.8 26.9 8.0 8.1 ---6.0 34.4

• The measurement "L" is an orientation only if the adjustment is totally out of requirements. They must not be used for final adjustments. The detail for (5) shows the position of the housing edge and the edge of the eccentric set bolt. The example shows them in parallel position which is mostly not the case. The adjustment should never be altered.

Further information see next pages

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Main Pumps 7.1.4 Checks / Adjustments Pressure balance valve (Δ P 20bar), illustration (Z21558) 1.

Connect a 60 bar pressure gauge to check point MST.

2.

Eliminate "Idle Time Control" by using the switch ”S155” of the X2-panel, if necessary see Operation Manual.

3.

Unplug solenoid valve Y17a (this causes a remote control. pressure (X3) of approx. 15 bar)

4.

Start the motor.

5.

Gauge reading at MST must be 40 bar (20bar less than the pump support pressure of 60bar Loosen lock nut #4 and adjust with the set bolt #5

6.

Plug-on Y17a

7

Remove the pressure gauge and set S155 for "Idle Time" elimination into normal position.

continued

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Main Pumps 7.1.4 Checks / Adjustments Cont'd: Start of destroking(LR valve), illustration (Z21559) The reason of this check is to make sure, the pump starts destroking at an operating pressure of 180 bar with a pump regulation pressure X1 of 13 bar. 1. 2.

3. 4. 5. 6.

Connect a 400 bar pressure gauge to the pressure check point at the respective high pressure filter for the pumps being checked. Connect a suitable pressure gauge (pressure can be 34 bar in electronic mode) to pressure check point M5-1/2 at the control and filter panel (X1-pressure). Move the change over valve into position “Hydraulic” (constant regulation mode). Insert an Allen key into the angle indicator bolt (see illustration) for better visibility of the start of destroking. Start the motor and adjust at pressure reducing valve (253.2 – motor1 respectively 254.2 – motor2) the X1-pressure to 13 bar. Stall the hydraulic for the pump to be checked and alter the operating pressure with the MRV up and down between 160 and 200 bar. Start of destroking should be at an operating pressure of 180 bar, shown at the gauge connected to the high pressure filter.

If readjustment is required proceed as follow: a) Adjust with the MRV an operating pressure of 180 bar. b) Loosen lock nut #6 (Power control valve). c) Turn set bolt #7, so that the pump is still in Q-max. position, but just at the beginning of destroking. d) Tighten lock nut #6. 7.

Re-adjust the operating pressure at the MRV to 310+10 bar and the X1-

8.

pressure at the pressure reducing valve (253.2 – motor1 respectively 254.2 motor2) to approx. 12bar. (For exact values refer to the final test report.) Remove Allen key and gauges. continued

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Main Pumps 7.1.4 Checks / Adjustments Cont'd: Pressure cut-off valve (DR control valve), illustration (Z21560) The reason of this check is to make sure that the pump is in Q-min. position at an operating pressure between 300 bar and 310 bar. 1. 2. 3.

4.

Connect a 400 bar pressure gauge to the pressure check point at the respective high pressure filter for the pumps being checked. Insert an Allen key into the angle indicator bolt (see illustration) for better visibility of the start of destroking. Start the motor, stall the hydraulic for the pump to be checked and alter the operating pressure with the MRV up and down between 280 and 310 bar. The angle indicator must indicate Q-min. position at a pressure of 300 bar shown at the gauge connected to the high pressure filter.

If readjustment is required proceed as follow: a) Loosen lock nut #8. b) Turn set bolt #9, so that the pump is in Q-min. position at the required value. c) Tighten lock nut #8. 5.

Re-adjust the operating pressure at the MRV to 310+10 bar

6.

Remove Allen key and gauges.

continued

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Main Pumps 7.1.4 Checks / Adjustments Cont'd: Q-max. and Q-min. stop bolt, illustration (Z21561) 1. 2. 3.

Unscrew box nut (10 or 14). Loosen the lock nut (11 or 13) Turn the stop (12 or 15) in or out until required length Length "X" or "Y" Tighten the lock nut and screw on box nut (12).

5.

• Turning the Q-min. stop bolt too much out can cause serious damage to the pump. The pump moves over 0 (zero) position into the opposite drive direction: (suction line becomes pressure line and pressure line becomes suction line)

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Electronic Pump Regulation System

7.2.1 Electronic load limiting control - general, illustration (Z 22407d) The drive train of the excavator consists of two electric motors, several hydraulic pumps, which supply cylinders and hydraulic motors. The load limiting control ensures optimum use of the power required for the excavator under varying operating conditions and avoiding overload of the motors. Illustration Z22407d shows the principle of the electronic load limiting control. The MC7 (E32) processes the following input signals: • Voltage (Pin 47) from electronic signal rectifier (A32) • Current motor 1 (Pin 45) from electronic signal rectifier (A33-1) • Current motor 2 (Pin 46) from electronic signal rectifier (A33-2) The MC7 (E32) processes the following output signals: • Signal value to control the proportional solenoid valve Y61-1 (Pin 28) Motor 1 • Signal value to control the proportional solenoid valve Y61-2 (Pin 30) Motor 2 • Switch signals (Pin 32 and 33), diagnostic of the MC7 (E32) Each electric motor drives four variable displacement pumps by means of a PTOgearbox. Each pump is equipped with a hydraulic power controller (HPC). This controller limits the input torque of the pump to an adjusted command value (X1pressure, for start of destroking). The command value (X1-pressure) is present via proportional solenoid valves Y61-1 respectively Y61-2 at the hydraulic power controllers of each pump.

)

• The auxiliary hydraulic pumps and other consumers can be operated without being directly affected by the load limiting control.

Function: The ESR-Module (A32) transforms an AC Voltage, which is proportional to the net voltage, into a proportional DC Voltage and transfers it into the MC7 (E32). The ESR-Module (A33-1 + A33-2) transforms an AC Voltage, which is proportional to the respective motor current, into a proportional DC Voltage and transfers it also into the MC7 (E32). These input signals are the information about the actual load to the motors and serves the MC7 (E32). The control algorithm of the load limiting control (MC7) always compares the actual required power with the rated power. With increasing load the motor torque will rise and in turn the required power. For this reason the electronic load limiting control will be initiated when the required power is higher than the rated power, i.e. the torque of the main pumps will be lowered (by reducing the X1-pressure) until the rated power is attained again.

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7.2.2 Electronic Power Module EPM – Module , illustration (Z 22624b) The power – Module A31a transforms the 24 VDC battery voltage into positive/negative 15 VDC and the power Module A31b into positive 5 VDC which is the supply voltage for the ESR Modules.

Function check: Measure the supply voltage. (24 VDC; GND = 0 V). If the supply voltage is not there, check the supply cable and the circuit breaker. If the circuit breaker always trips there may be a short within the cables to the Power Module or a short in the unit itself. If the supply voltage is ok. the Output Voltages have to be checked. Check pos. 15 VDC, neg. 15 VDC, 5 VDC to GND. If the supply voltages are not ok. the short circuit monitoring system of the Power Modules might be activated, therefore disconnect the cables at the terminals (+15 VDC, -15 VDC and +5 VDC) and repeat the voltage check. If now (with disconnected cables) the voltages are as they should be there is either a short within the cables or in the other modules itself. To determine the fault connect the entire modules in sequence. If the voltage is not ok., even when the cables are disconnected from the Power Module, the Module is defect.

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7.2.2 Electronic Signal Rectifier ESR – Modules, illustration (Z 22625c) Function: The ESR-Module transforms an AC signal-voltage, which is proportional to the network voltage respectively the motor current, into a proportional DC Voltage and transfers it into the MC7. Testing the ESR-Module, A32 + A33.1 + A33.2 Testing the ESR input/output voltage For a transformer function test the AC-Input Voltage and the DC-Output Voltage must be tested. • The potentiometer settings are under no circumstances allowed to be altered, because the setting is possible only with a HFGenerator and an Oscilloscope. • If the potentiometer set-positions have been altered, a new Module, with sealed potentiometers, must be ordered. Procedure: Same procedure for all three Modules 1.

Disconnect the wire from terminal 23 of the ESR Module.

2.

Start the motor and let it run without an extra load on it.

3.

Measure the AC-Voltage between the terminals 21 and 41 and record it.

4.

Measure the DC-Voltage between the terminals 23 and 11 and record it.

5.

The measured DC-Voltage must be 1/4 of the AC-Voltage. Example:

2.5 VDC ----------- = 0,25 (1 % plus/minus is ok) 10 VAC

Small variations are based on amplitude variations of the AC-Input voltage while measuring the DC-Output voltage. Greater variations denotes a faulty ESR Module. continued

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7.2.2 Electronic Signal Rectifier ESR – Modules, illustration (Z 22626d) Cont'd: The DC-Output Voltage (UaDC ) can be compared with a calculated Voltage Value. The calculation can be done with the ratios of the intermediate transformers given in the circuit diagram, and by the Voltmeter and Ammeter readings of the cab gauges.

)

• The picture shows a schematic design only and not the actual circuit diagram, the voltage- and current values may vary, therefore they are exemplary used.

With the below shown formulas the exact Output Voltages UaDC of an ESR can be calculated. Small variations are caused by the transformers. Variations greater than 20% denotes a faulty transformer. Example for ESR 1: U ESR1 ----------------T1 x T2 x T3

6240 V --------------- = 2,476 VDC 63 x 10 x 4

Voltage

Example for ESR 2: I ESR2 ----------------T1 x T2 x T3

150 A ----------------35 x 0.5 x 4

= 2,142 VDC

Current Motor 1

Example for ESR 3: I ESR3 ----------------T1 x T2 x T3

100 A ----------------35 x 0.5 x 4

= 1,428 VDC

Current Motor 2

The AC Input Voltage for an ESR-Module can be calculated with the same formula but without the value for T3. Example for ESR 2: I ESR2 ----------T1 x T2

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150 ----------35 x 0.5

= 8,571 VAC

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7.2.2 Microcontroller MC7, illustration (Z 21716) The MC7 microcontroller is used for the programmable control of a maximum of four proportional solenoids and two additional switching functions. As input signals, the microprocessor processes analog voltages in the 0V to 5V range and switching information. All inputs are protected against overvoltage and electrical interference. As output signals, the output stages of the MC7 deliver closed loop controlled currents for the connection of proportional solenoids. The analog voltage output is suitable for the simple forwarding of analog information to other electronic circuits. Characteristics • Closed loop control of solenoid currents, i.e. independent of voltage and temperature. • Pulse width modulated (PWM) solenoid currents for minimal hysteresis. • Internal buzzer for programmable monitoring of functions or errors. Setting and Display Facilities All calibration operations and the display of functions, faults and system variables are connected via the serial interface to the BB-3 control panel or to a PC running the BODEM software. MC7 - Unit Dimensions

Plug Contacts

8 junior power timer contacts 47 micro timer I contacts MC7 - Block Circuit Diagram

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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22623) The adjustment of the X1-pressure can be done with three different methods: A. With 24V supply to separating terminals at the X2-switch board or B. With the electronic service tool (EST) BB-3 connected to the serial interface X13-1 (located in the operators cab) or C. With a laptop, running the BODEM software, connected to the serial interface X13-1 (located in the operators cab)

)

• Procedure B and C should only be carried out by authorized personnel. [ Dealer or KMG-factory staff ] Because it is possible to influence the behavior of the pump regulation system. On the following pages are only the necessary setups described. If additional information is required, please contact KMG-Service department.

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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22628c) Method A - X1-pressure adjustment with 24V supply to separating terminals at the X2-panel. Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. Make sure the change over valves (253.1 – motor 1 respectively 254.1– motor 2) are in position “Electronic Pump Regulation” 2. Connect a pressure gauge to the respective check points (M5.1 or M5.2), using a long pressure gauge hose to be able reading the pressure in front of the X2-panel. 3. Selection of adjusting mode: Turn the main key switch in on position and activate the adjusting mode as follows: Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using two test leads and disconnect the voltage thereafter. 4. Selection of the motor and the required proportional solenoid valve : With the main key switch still in on position, select the applying terminal for proportional solenoid valve Y61-1 or Y61-2 as follows: Motor1 →Y 61-1 → No connection to 24V required. Motor2 →Y 61-2 → Connect permanent 24V to terminal 53, using a test lead. 5. Adjusting the X1-pressure: Start the motor. Read the pressure, required = 34± 0,5 bar If necessary increase the X1-pressure as follows: Connect 24V to terminal 54. • As long as voltage is supplied, the X1-pressure drops to zero. After interrupting the voltage supply, the gauge pointer will move slowly to the new present X1-pressure. • Example: Keeping voltage supply for two seconds , will increase the X1-pressure of approximately 1bar. • The adjusted value will be saved immediately and will be available after power off. 6. To decrease the X1-pressure connect 24V to terminal 55 and proceed as described under item 5, keeping voltage supply for two seconds , will decrease the X1-pressure of approximately 1bar. 7. After the adjustment is finished, remove the test leads and pressure gauge and turn the main key switch in OFF position to deactivate the adjusting mode. continued

)

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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22629b) Cont'd: Method A - Demanded power adjustment

)

• The adjustment has to be carried out separately for each motor

Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. Connect pressure gauges to check points M11.1, M11.2, M11.3 and M11.4 at the high pressure filters. 2. Connect pressure gauges to the X1 pressure check points M5.1 and M5.2. 3. Unplug solenoid valves Y6a-1, Y6b-1 and Y6a-2, Y6b-2 to ensure that the hydraulic oil cooler fans are running with maximum speed. 4. Start one motor. 5. Set the MRV individually to approx. 120 bar *, to prevent the motor from overloading during the adjustment. 6. Shift the three way cock valves (253.1 and 254.1) to position “Hydraulic (constant) Regulation Mode”. 7. Set the X1-pressure at pressure reducing valves (253.2 and 254.2) > 34 bar **, to ensure that the pumps remain in Q-max. flow position during the adjustment. 8. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position until the hydraulic system stalls), and increase the pressure at all 4 MRV’s * equally until the motors draw ≅ 128 Ampere. (reading of text display) Expected system pressure at 128 Ampere = 4 times 172 bar (peak point). Record this pressure for other tests.

)

• If the operating pressure is higher respectively the motor current is lower than required there is probably not the full volume available. *Altering the MRV-Setting: − Remove dust cap (a). − Loosen lock nut (b). − Turning the set screw (c) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. **Altering the X1-Setting: − Loosen the lock nut (e). − Turning the set screw (f) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. continued

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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22629b) Cont'd: Method A - Demanded power adjustment 9.

)

Store the demanded power (peak point) into the MC7 as follows: a) Activate the adjusting mode: Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using test leads and disconnect the voltage thereafter. b) Select the demanded power adjusting mode (Motor 1): Connect 24V, simultaneously to terminal 50 and 52 permanent. c) Select the demanded power adjusting mode (Motor 2): Connect 24V, simultaneously to terminal 50, 52 and 53 permanent. d) Stall the hydraulic with the values of item 8 (Peak point) 4 times ≅ 172 bar (all pumps Qmax position and cooler fans with max. speed). => ≅ 128 Ampere (each motor) e) Save the actual measured power: Connect 24V to terminal 55 for 1 second and disconnect the voltage thereafter. • The actual measured power will be saved immediately as the demanded power

10. Re-set the X1-pressure at pressure reducing valves (253.2 and 254.2) as recorded**. 11. Shift the three way cock valves (253.1 and 254.1) to position “Electronic Regulation Mode” 12. Reset the MRV’s to 310 bar+5bar , and remove the gauges. 13. After the adjustments are finished, remove the test leads and pressure gauges, stop the motors and turn the main key switch in OFF position to deactivate the adjusting mode.

*Altering the MRV-Setting: − Remove dust cap (a). − Loosen lock nut (b). − Turning the set screw (c) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. **Altering the X1-Setting: − Loosen the lock nut (e). − Turning the set screw (f) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. continued

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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22636) Cont'd: Method A - PID - Factor adjustment to obtain the most efficient pump regulation characteristic. Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. • With the PID-Factor adjustment (proportional, integral and differential factors) it is possible to influence the regulation dynamics. • The PID-Factor adjustment range is between 80% and 120% • The voltage at the analogue output (terminal 60) represents the actual adjusted value. (80% = 0VDC / 100% = 2,5VDC / 120%= 5VDC) • This factor is multiplied with all PID parameters.

) 1.

Jerky movements while lifting and swinging at the same time: a) Activate the adjusting mode: Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using two test leads and disconnect the voltage thereafter. b) Select the PID-factor adjusting mode: Connect 24V, to terminal 50 permanent, using a test lead. c) Connect a multi-meter to terminal 60 (reading DC-voltage) and note down the value (represents the actual adjusted value) d) Reduce the voltage in steps of 250mV until the system works smoothly, by connecting 24V to terminal 55. (As close as possible to the boarder line)

2.

No Jerky movements: a) Activate the adjusting mode: Connect 24V, simultaneously to terminal 54 and 55 for 10 seconds, using two test leads and disconnect the voltage thereafter. b) Select the PID-factor adjusting mode: Connect 24V, to terminal 50 permanent, using a test lead. c) Connect a multi-meter to terminal 60 (reading DC-voltage) and note down the value (represents the actual adjusted value) e) Increase the voltage in steps of 250 mV until the system jerks, by connecting 24V to terminal 54. (As close as possible to the boarder line) f) Now reduce the voltage in steps of 250mV until the system works smoothly again, as described under item 1d.

3.

After the adjustments are finished, remove the test leads and multi-meter, stop the motors and turn the main key switch in OFF position to deactivate the adjusting mode.

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7.2 Electronic Pump Regulation System 7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22357d) Method B -

With the electronic service tool (EST) BB-3 connected to the serial interface X13 (located in the operators cab) Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. 2. 3. 4.

Make sure the respective change over valve is in position “Electronic Pump Regulation” Connect a pressure gauge to check point M5.1 and M5.2, using long pressure gauge hoses to be able reading the pressure inside the operators cab. Connect the electronic service tool (BB-3) to the data link adapter X13, with key switch (1S1) in OFF position. Turn key switch (1S1) in ON position: After switching on the power for the Control panel BB-3 the following functions are carried out and shown on the display: 4.1 Self-test and baud rate recognition: The BB-3 automatically recognizes the rate of data transmission from the MC electronics. 4.2 Identification: On recognition of the MC electronics the relevant software in the BB-3 will be started up. 4.3 Main menu: Initialization of remote control unit BB-3 is complete. One of the four main menu items can be selected using the given keys.

First screen (main menu) after connection and Key switch turned ON in German.

F1 F2 PROC TE ACH Language selection To change the language press simultaneously the buttons ALT + Clear

ALT

+

CLEAR

Config/Cal. Diagnostic Status Storage

The language selection menu appears

F1 F2 PROC TE ACH

Config/Cal. Diagnostic Status Storage continued

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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22357d) Method B Cont'd: Language selection Press button 2

2

The language will change to English and the display show the main menu

1. 2. 3. 4.

Deutsch English - - - - -

One of the four main menu items can be selected using the given keys.

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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22357d) Method B Adjustment mode SET 1 and SET 2 There are two adjustment modes (SET 1 and SET 2) integrated. SET 1 is for the main settings and SET 2 is only for the basic adjustments. SET 2 can only activated with a password. After start up of the MC7 with connected BB3 the adjustment modes SET 1 is active. Main display SET 1 Standard after start up F1 F2 PROC TE ACH

Main display SET 2 Only with password.


F1’ F2 PROC TE ACH


F1 F2 PROC TE ACH


Change from SET 1 to SET 2: SET 1

Press

F1

Config/Cal

Press

ALT

+

in the same time

1 2 3 4

Demand Power Max current PID - Factor Error Lamp

A password will be requested Enter password (number: 570875)

1 Press

...

MENU

9

SET 2 to go back to the main menue

To switch back to SET 1 repeat this procedure or switch off and on the MC7.

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?: _

1 2 3 4

Configuration PID Control Low Voltage –––



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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22357d) Method B Number of motor selection: Activate adjustment mode SET 2 as described on page 33 Press

F1

Config/Cal

Press

1

Configuration

Press

2

No of motors



1 2 3 4

Configuration PID Control Low Voltage –––

1 2 3 4

No of valves No of motors –– ––

Select desired number of motors

2

No of motors

use

1

motor

2

No of motors

2

motors

1 2 3 4

No valves No motors –– ––

Press

or

ENTER Acceptation

Press. 2 x MENU Return to sub menu.



Save setting to the EEPROM of the MC7 as described at page 38.

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7.2.3 Checks and adjustments Micro-controller MC7, illustration (Z 22357d) Method B X1-Pressure (maximum current) Adjustment:

F1

Press

Config/Cal

If sub menu SET 2 is displayed change to sub menu SET 2 as described on page 33.

2

Press

Max current

F1 F2 PROC TE ACH


1 2 3 4

Demand Power Max current PID - Factor Error Lamp

1 2 3 4

Valve Valve Valve Valve

Select desired valve Press or Press

1

Valve 1, Motor1

3

Valve 1, Motor2

Example Motor 1, Valve1

Start the respective motor. Do not load the motor. Check the X1-pressure with a pressure gauge and set it to the desired value by: pressing

Press

or

ENTER

Press. 2 x

Acceptation

MENU

Return to main menu

1 2 1 2

Mot. Mot. Mot. Mot.

1 1 2 2

1 Valve 1 Mot. 1 0 – 100±1 71

1 Valve 1 E1 0 – 100±1 78

1 2 3 4

Valve Valve Valve Valve

F1 F2 PROC TE ACH

1 2 1 2

Mot. Mot. Mot. Mot.

1 1 2 2



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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22357d) Method B Demanded power adjustment: Press

F1

Config/Cal

If sub menu SET 2 is displayed change to sub menu SET 2 as described on page 33.

Press

1

Configuration

1 2 3 4

Demand Power Max current PID-Factor Error Lamp

1 2 3 4

Set demand m. Set demand m. Demand power Demand power

Select desired demand power adjustment Press or Press

SET 1

1

demand power Motor1

2

demand power Motor2

1 2 1 2

1 Set demand m. 1 0–0±1 0

Example Motor 1

and Load respective Motor with max power Press ENTER

Selection

Start? ––> Cancel? ––>

Press ENTER

Starting

Function ended Saved Press

Press ENTER Confirm

Press. 2 x

MENU

Return to main menu

F1 F2 PROC TE ACH



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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22636a) Method B PID-Factor adjustment: Jerky movements while lifting with full bucket and swinging at the same time: Reduce jerking ⇒ Reduce the PID-Factor in short steps. To obtain the most efficient pump regulation characteristic adjust to the PID-Factor until the system jerks as close as possible to the boarder line.

Press

F1

F1 F2 PROC TE ACH

Config/Cal

If sub menu SET 2 is displayed change to sub menu SET 1 as described on page 33. SET 1 Press

3

PID-Factor.

Press

1

PID-Factor.

Adjust the PID-Factor by pressing . or

Press

ENTER

Acceptation

and check the machine movement again if necessary repeat PID-Factor adjustment

Press. 2 x

MENU

Return to main menu.


1 2 3 4

Demand Power Max current PID-Factor Error Lamp

1 2 3 4

PID-Factor ––– ––– –––

1 PID-Factor 80–120±1% 100

1 2 3 4

PID-Factor ––– ––– –––

F1 F2 PROC TEACH



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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22357d) Method B Storage all new settings to the MC7: This menu item permits storage of all edited parameters to the EEPROM of the MC electronics

Activate storage menu

F1 F2 PROC TE ACH

Save Params

1 2 3 4

Press ENTER

Store parameters

Teach? ––> Cancel? ––>

Press. MENU

Return to main menu.

1 2 3 4

Press TEACH

Press

1


Save Params Default Rarams Get EEPROM Send EEPROM

Save Params Default Rarams Get EEPROM Send EEPROM

If all adjustments are correct and stored in the MC7, proceed as follow: • Stop the motors and turn key switch (S1) in OFF position • Disconnect the electronic service tool (BB-3) and the pressure gauges.

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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22358d) Method C -

With a laptop computer and BODEM software connected to the serial interface X13 (located in the operators cab) Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. Starting the program 1. Connect the laptop computer to the data link adapter X13, with key switch (1S1) in OFF position. 2. Make sure that the dongle is connected to the laptop computer. If not

3. Turn key switch (1S1) in ON position. 4. Start the computer. 5. Click on the Bodem - icon to start the program.

continued

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Section 7.0 Page 40


7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22358d) Method C Cont'd: Starting the program 6. The program starts (only) the first time with the Demo Version.

7. Open menu FILE → INTERFACE , select the required interface connection (Standard COM1), confirm with OK and leave the program.

8. Start the program again. Now the computer is connected to the Microcontroller. During uploading of the MC7 data to the PC a window opened and shows some hardware and software information.

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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22358d) Method C Language selection Open menu FILE → Language , select the required language and confirm with OK .

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Section 7.0 Page 42


7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22358d) Method C Entering of the password:

)

• The password is only required to adjust the number of valves or engines and for fine tuning of special regulation parameters. All other adjustments are possible without the password.

Open menu Parameters and select Enter password. Write the correct password (570875) and confirm with OK.

)

• After entering a correct password and confirming with OK the BODEM software start a new upload from the MC7 memory to the PC.

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Section 7.0 Page 43


7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22358d) Method C Number of Motor selection: Pre condition: The correct password was entered as described on page 42. Open Parameters and select Display / Edit Parameters. Then select in the left window Configuration. Now on the right side there are two pull down menus. Example: select for PC 8000 1 valve per motor and 2 Motors. Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.

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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22358d) Method C X1-Pressure (maximum current) Adjustment: Make sure the change over valve is in position “Electronic Pump Regulation” Connect a pressure gauge to the respective check point (M5.1 or M5.2), using a long pressure gauge hose to be able reading the pressure inside the operators cab. Open menu Parameters select Display/Edit parameters and Max current, start respective motor without load and wait 30 sec. The X1-pressure will raise to the max. adjusted value. If necessary adjust the required pressure (according to the final test report or hydraulic diagram) with the respective slide bar. (Valve 1 Mot. 1 is the X1-1 pressure and Valve 1 Mot. 2 the X1-2 pressure). Write new setting permanent to the MC7 EEPROM with Apply and confirm with OK.

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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22358d) Method C Demand power adjustment:

)


Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. Open menu Parameters and in the pull down window the menu point Display / Edit Parameters. Now the window with the demand power adjustment will be on screen.

Screen with password Screen without password. The demand power adjustment is possible in both modes. continued

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7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22639d) Method C Cont'd: DEMAND POWER ADJUSTMENT:

)


Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. 1. 2. 3. 4. 5. 6. 7. 8.

Connect pressure gauges to check points M11.1, M11.2, M11.3 and M11.4 at the high pressure filters. Connect pressure gauges to the X1 pressure check points M5.1 and M5.2. Unplug solenoid valves Y6a-1, Y6b-1 and Y6a-2, Y6b-2 to ensure that the hydraulic oil cooler fans are running with maximum speed. Shift the three way cock valves (253.1 and 254.1) to position “Hydraulic (constant) Regulation Mode”. Start one motor. Set the MRV’s of main valve block I, II, III and IV individually to approx. 120 bar *, to prevent the motor from overloading during the test. Set the X1-pressure at pressure reducing valve (253.2) > 34 bar **, to ensure that the pumps remain in Q-max. flow position during the adjustment. Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position until the hydraulic system stalls), and increase the pressure at all 4 MRV’s * equally to the demand power pressure written in the final test report e.g. PC8000, S/N 12037 = 172 bar. Check the current drawn of the respective motor at this stage (reading of text display) Expected: approx. ~ 128 Ampere. Record this values for other tests. continued *Altering the MRV-Setting: − Remove dust cap (a). − Loosen lock nut (b). − Turning the set screw (c) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. **Altering the X1-Setting: − Loosen the lock nut (e). − Turning the set screw (f) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease.

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7.2 Electronic Pump Regulation System 7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22639d) Method C Cont'd: Demand power adjustment: 9.

Select Execute of menu point Set demand m. 1 for motor 1 or Set demand m. 2 for motor 2. Select Start to set the actual power as demand power. Confirm with OK. The new actual demand power will be only shown after a new upload of the MC7 settings. Exit the BODEM software and start again. 10. Stop motor and repeat from item 5 for the second motor.

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Electronic Pump Regulation System 7.2.3 Checks and adjustments Microcontroller MC7, illustration (Z 22636b) Method C PID Factor adjustment: This adjustment is required to obtain the most efficient pump regulation characteristic. Pre-conditions: Normal operating temperature, correct pilot pressure setting and the system must be free of air. • With the PID-Factor adjustment (proportional, integral and differential factors) it is possible to influence the regulation dynamics. • This factor is multiplied with all PID parameters. • Only one factor / adjustment for both motors

)

Open Parameters and select Display / Edit Parameters. Select in the left window PID control. Adjust now the PID-Factor with the slide bar or write direct the requested value to the window with the % value. Write new adjustment permanent to the MC7 EEPROM with Apply and confirm with OK. •

Jerky movements while lifting and swinging at the same time: Reduce the PID-Factor in short steps until the system works smoothly. (As close as possible to the boarder line) • No Jerky movements: 1. Increase the PID-Factor in short steps until the system jerks. (As close as possible to the boarder line) 2. Now reduce the PID-Factor in short steps until the system works smoothly again.

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Hydraulic Constant Regulation System 7.3.1. General The pilot pressure pumps (9.1 and 9.3) deliver the oil through the pressure filters (68.1 and 68.7) to port A of the pressure relief valve (252.2) for limiting the pump support pressure X4 to 60 bar. By the function of pressure reducing valve (252.1), the X4 pressure of 60 bar is reduced to the pilot pressure X2 of 45 bar. The common X2 pressure will be reduced by the function of pressure reducing valves (253.2 – motor 1 and 254.2 – motor 2) to the necessary constant X1 pressure, to prevent the motors from overloading.

)

• For testing purposes the pump regulation system can be changed to the hydraulic operation mode. In case of a failure in the electronic regulation system the hydraulic operation mode can also be used for emergency operation. • The standard operation mode of the pump regulation system is the Electronic Operation Mode.

Legend for illustration (Z 22637): (1 - 4) Main hydraulic pumps (driven by Motor 1) (5 - 8) Main hydraulic pumps (driven by Motor 2) (9.1) Pilot pressure pump (driven by Motor 1) (9.3) Pilot pressure pump (driven by Motor 2) (68.1 +68.7) Pilot pressure filter unit (252.2) Pressure relief valve 60 bar (X4) (252.1) Pressure reducing valve 45 bar (X2) (252.3 + 252.4) Check valve (253.2) Pressure reducing valve: "Pump regulation pressure X1 at hydraulic constant regulation mode " (Motor 1) (254.2) Pressure reducing valve: "Pump regulation pressure X1 at hydraulic constant regulation mode " (Motor 2) (Y61-1) Proportional solenoid valve: "Pump regulation pressure X1 at electronic operation mode" (Standard mode Motor 1) (Y61-2) Proportional solenoid valve: "Pump regulation pressure X1 at electronic operation mode" (Standard mode Motor 2) (253.1) Change over valve: "Electr. or Hydr. pump regulation" Motor 1 (254.1) Change over valve: "Electr. or Hydr. pump regulation" Motor 2

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Hydraulic Constant Regulation System 7.3.2. X1-pressure adjustment (constant-pressure), illustration (Z 22639d) 1. 2. 3. 4. 5. 6. 7. 8.

9. 10. 11.

12. 13.

)

Connect pressure gauges to check points M11.1, M11.2, M11.3 and M11.4 at the high pressure filters. Connect pressure gauges to the X1 pressure check points M5.1 and M5.2. Unplug solenoid valves Y6a-1, Y6b-1 and Y6a-2, Y6b-2 to ensure that the hydraulic oil cooler fans are running with maximum speed. Shift the three way cock valves (253.1 and 254.1) to position “Hydraulic (constant) Regulation Mode”. Start motor 1. Set the MRV’s of main valve block I, II, III and IV individually to approx. 120 bar *, to prevent the motor from overloading during the test. Set the X1-pressure at pressure reducing valve (253.2) to approx. 11 bar ** Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position until the hydraulic system stalls), and increase the pressure at all 4 MRV’s * equally to 260 bar. Check the current drawn of motor 1 at this stage (reading of text display) Expected approx. 120 Ampere. Record this values for other tests. Stop motor 1 and start motor 2 . Set the X1-pressure at pressure reducing valve (254.2) to approx. 11 bar ** Apply max. load to all pumps (e.g. extend the bucket cylinders to the stop position until the hydraulic system stalls), and increase the pressure at all 4 MRV’s * equally to 260 bar. Check the current drawn of motor 2 at this stage (reading of text display) Expected approx. 120 Ampere. Record this values for other tests. Shift the three way cock valves (253.1 and 254.1) to position “Electronic regulation“. Reset the MRV’s * to 310 bar+5bar , and remove the gauges. •

The adjustment has to be carried out separately for each motor

*Altering the MRV-Setting: − Remove dust cap (a). − Loosen lock nut (b). − Turning the set screw (c) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease. **Altering the X1-Setting: − Remove dust cap (d). − Loosen the lock nut (e). − Turning the set screw (f) cw the pressure will increase. − Turning the set screw ccw the pressure will decrease.

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Energy efficiency Legend for illustration (25960a) (1-8) Main pumps (E6) PLC (programmable logic controller) (“I”) Inputs (analogue and digital) (“O”) Outputs (digital) C Controls (lever, pedal) signal S Solenoid valve control M19 Test port, flow control pressure M55 Test port, output of Y146 M56 Test port, output of Y147 (Y17) „Idle time“ control, (Pump control system) (Y17a) ½ Q-max (reduced oil flow at too cold oil) (Y146) Flow control valve (pump No 1, 2, 3, 5, 6, 7) (Y147) Flow control valve (pump No 4 and 8) (265) Pressure reducing valve – reduced pump flow 7.6.1. General Energy, which is not used to do active movement, can be considered in loss energy. Although energy cannot be destroyed it can be converted into heat which is useless for performing work through hydraulics. The not used energy cause increasing power consumption. With the following measures an optimizing of the energy efficiency in our machines optimized oil delivery of specified pumps in relation to definite movements of the excavator. The PLC controls the solenoid valves. Generally logic is during single function we have full pump flow and in combined function it reduces the oil flow. Except the pumps for the swing system, this are back in maximum flow during swing function. The remote control pressure X3 on pump port Pst controls the maximum permissible pump flow. With decreasing pressure the pump volume decreases as well. A pre-set pressure reducing valve (265) is responsible to limit the X3 pressure for the reduced pump flow Qred.

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Energy efficiency Legend for illustration (25961a) (c) Lock nut (d)Set screw (M19) Test point (Pst-pressure, flow reduction) (Y146) Flow reduction solenoid valve (pump No 1, 2, 3, 5, 6, 7) (Y147) Flow reduction solenoid valve (pump No 4,and 8) (265) Pressure reducing valve – reduced pump flow - Qred (255.4) Pressure reducing valve – ½ Qmax (X3 = Pst= 15 bar)

ã

• Values are based for machine working from see level up to 3600m. Machines working on higher altitude require a reduced Qmax setup which influences the test values.

)

• X3 or Pst: both are the same pressure. It is the pressure to control the maximum permissible pump output flow. Pst is the port name of the main pump

7.6.2. Checks and adjustments, flow control (Qred) To check or adjust the function of the Energy efficiency system it is necessary to follow the instructions below. 1. Connect a test gauge (0-60 bar) to port M19. It is located at the pilot control plate at the right bottom corner close to the pressure reducing valve (265). 2. Let both engines / motors run. Diesel engine shift to high idle. 3. Turn superstructure 90° right to the travel direction. 4. Apply the swing parking brake. 5. Move bucket close to the side frame and raise one track off the ground just to get the track free. 6. Activate the travel pedal of the lifted track fully in one direction. Make sure that there is no other function activated. 7. Test of max. pump volume. Y146 and Y147 must be de-energized. Check the time of fife (5) sprocket revolutions. See table Pump Flow control test values next page for the required time.

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8. Test of reduced pump flow (flow reduction). Y146 must be energized. Activate carefully the swing function in one direction against the parking brake. The lever must be fully activated. In the same time activate the travel function of the lifted track also fully in one direction. Check the time of fife (5) sprocket revolutions. See table Pump flow control test values for the required time. 9. To verify the result repeat test from item 4 but now with the left track site. 10. If the value is within the tolerance check resulting Pst pressure at the gauge of test port M19 and record value for future tests as a reference. If adjustment is required a. Loosen lock nut (c) of the pressure reducing valve. b. Turn clockwise set screw (d) of the pressure reducing valve 265 to reduce or counter clockwise to increase the sprocket speed. Adjust the sprocket speed to 69 ±1 sec at 5 revolutions. c. Look set screw with the lock nut. Pump flow control test values No. Function

Y146 [Volt]

Y147 Sprocket right [Volt] time / 5 rev

Sprocket left time / 5 rev

1

Only travel right

0

0

54 ±1 sec

54 ±1 sec

2

Travel right and swing

24

24

69 ±1 sec

69 ±1 sec

3

Only travel left

0

0

54 ±1 sec

54 ±1 sec

4

Travel left and swing

24

24

69 ±1 sec

69 ±1 sec

)

• Additionally of the flow control valves Y146 and Y147 the valve Y17 and Y17a controls the pump angel (pump volume). See table below.

It means there are also influences of the pause time function (no activated controls), hydraulic oil temperature and service switch S155. Pst = 0 bar = Qmin (pause time) Pst = 15 bar = ½ Qmax (pause time or low oil temperature) Pst = 18±1 = Q reduced (flow control) (determined via above procedure). Pst = 45 bar = Qmax

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Operating Hydraulic

Section 8.0 Page 1


Page Operating Hydraulic General 8.1

Hydraulic for the attachment cylinder FSA and BHA

8.2

Hydraulic for the swing circuit

8.3

Hydraulic for the travel circuit

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Operating Hydraulic

8.0

Section 8.0 Page 2

General Overall view of the Hydraulic system, illustration (Z 22676b): (1 – 8) (9) (10) (11) (12) (13) (14) (15)

Main pumps High pressure filters Main control blocks Distributor manifold Attachment cylinders Swing motors Rotary joint Travel motors

General information The control blocks, the piping to the distributor manifold and the connecting hoses to the attachment are different between the Backhoe Attachment (BHA) and the Front Shovel Attachment (FSA). If a conversion is required, contact the service department for further information. Function:

)

• •

Study together with the circuit diagram. The following numbering refers to the hydraulic circuit diagram.

Each main pump (1 to 8) delivers oil trough the high pressure filter (18.1 to 18.4) to port P of the main control blocks (14 to 17). This results in four main circuits. If all spools of the control blocks (14 to 17) are in neutral position, the oil leaves the block at port T and returns via return oil pipes (L23 to L26), return oil collector tube, back pressure valve (26) and the return oil filters (51.1 - 51.7) into the tank. The function of back pressure valve (26) ensures: - sufficient oil supply for all anticavitation valves - and that sufficient oil is forced through the oil coolers. If a control lever or pedal is actuated, pilot pressure oil moves the spools of the control blocks, directing the oil flow from the main pumps to one side of the user (either cylinders or motors). From the opposite side of the user the oil returns to the control block and from there via the return oil circuit back into the tank. Each circuit is provided with one MRV (also called primary valve, at least one SRV (also called secondary valve) and at least one flow restrictor. continued

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Operating Hydraulic

8.0

Section 8.0 Page 3

General Cont'd: Floating function of boom and stick cylinders FSA: illustration (Z 22677c): The Excavator operates automatically with the float position for boom and stick activated. That means the lowering movement of boom and stick is always done in the float position. For deactivation of the float position, two push buttons are installed: a) S95 in the right joy stick (E19) for the Boom function b) S98 in the left joy stick (E20) for the Stick function Press the respective button and keep it depressed as long as the float position shall be deactivated. When releasing the button the float position is activated again. Function: There are different spools in the main control blocks (I, II, III and IV) for boom and stick installed. Spools without a symbol (standard) are connecting the rod side of the cylinders with the pump supply line and the piston side with the tank. Spools with #-symbol (lowering with free pump circulation) are connecting the piston side of the cylinders with the tank only. Spools with $-symbol (floating) are connecting the piston side of the cylinders with the rod side and also with the tank. Only by lowering the boom or retracting the stick is the floating function active if the button on the joy stick is not pushed. The piston and rod side of the respective cylinders are in floating position direct connect to the return line (tank). By external force the cylinder can move up or down with negligible hydraulically resistance. To push down the boom or retract the stick by hydraulically force, the function of the “floating spools” must be interrupted, by activating the respective button on the joy sticks. Boom: S95 ON ⇒ K160 ON ⇒ Float position deactivated S95 OFF ⇒ K160 OFF ⇒ Float position activated S98 ON ⇒ K170 ON S98 OFF ⇒ K170 OFF

Stick:

)

•

⇒ ⇒

Float position deactivated Float position activated

Special spool with (#$)-symbol in control block II for bucket dump

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Hydraulic for the Attachment Cylinders

Section 8.1 Page 1


Page Hydraulic for the attachment cylinder FSA 8.1.1 Electric / Hydraulic Flowchart Boom raising 8.1.2 Electric / Hydraulic Flowchart Boom lowering 8.1.3 Electric / Hydraulic Flowchart Stick extending 8.1.4 Electric / Hydraulic Flowchart Stick retracting 8.1.5 Electric / Hydraulic Flowchart Bucket filling (curl) 8.1.6 Electric / Hydraulic Flowchart Bucket emptying 8.1.7 Electric / Hydraulic Flowchart Clam opening 8.1.8 Electric / Hydraulic Flowchart Clam closing 8.1.9 Checks and adjustments of the Main Relief Valves- MRV’s (Primary valves) 8.1.10 Checks and adjustments of the Service Line Relief Valves - SRV’s (Secondary valves) Boom cylinder piston side FSA Boom cylinder piston rod side FSA Stick cylinder piston side FSA Stick cylinder piston rod side FSA Bucket cylinder piston side FSA Bucket cylinder piston rod side FSA Clam cylinder piston rod side FSA Clam cylinder piston side FSA 8.1.11 Checks and adjustments for the lowering speed. Flow Restrictors Boom cylinder FSA Stick cylinder FSA Bucket cylinder FSA Clam cylinder

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15 + 16 17 + 18 19 + 20 21 + 22 23 + 24 25 + 26 27 28

29 30 31 32

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Section 8.1 Page 2

8.1.1 Electric / Hydraulic flowchart “ Boom raising ” FSA Legend for illustration (Z 22678e): (E19) Control lever (Joy stick) (-Y) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A3) Service module, adjustable –10...0...+10 Volt adjusted to +10 Volt (A10) Amplifier module – Boom (A10a) Amplifier module – Boom (A10b) Amplifier module – Boom (A10c) Amplifier module – Boom (K58) Relay – pilot control: Contacts 8 / 12 and 5 / 9 only closed while lifting the boom. (K160) Relay – pilot control: Contacts 2/ 10 and 1 / 9 closed in normal operating mode. Contacts 6/ 10 and 5 / 9 closed while disable auto-float boom. (K72) Relay – pilot control: Contacts 6 / 10 only closed while extending the stick. (K80) Relay – pilot control: Contacts 6 / 10 only closed while filling the bucket. (K205) Relay – hydraulic flow heating: Contacts 8 / 12 only closed while heating system is switched on. (102.1 – 102.4) Remote control valves (Y23 + Y25) Proportional solenoid valve (Y29 + Y35) Proportional solenoid valve (Y23A) Directional solenoid valve (Y29A + Y35A) Directional solenoid valve (I + III + IV) Main control blocks (73) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E19) arrives via ramp time module (E49) at terminal 5 of the amplifier modules (A10 to A10c) and further to the proportional and directional solenoid valves of the remote control blocks (102.1, 102.2, 102.3, and 102.4). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks (I , III and IV). Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I , III and IV) and arrives via distributor manifold (73) at the hydraulic cylinders.

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8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA Single movement in normal operating mode (Auto Float ON ) Legend for illustration (Z 22679e): (E19) Control lever (Joy stick) (+Y) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A3) Service module, adjustable –10...0...+10 Volt adjusted to +10 Volt (A10) Amplifier module – Boom (A10a) Amplifier module – Boom (A10b) Amplifier module – Boom (A10c) Amplifier module – Boom (K58) Relay – Contacts 8 / 12 and 5 / 9 only closed while lifting the boom. (K160) Relay – Contacts 2 / 10 and 1 / 9 closed in normal operating mode. Contacts 6 / 10 and 5 / 9 closed while disable auto-float. (K72) Relay – Contacts 6 / 10 only closed while extending the stick. (K80) Relay – Contacts 6 / 10 only closed while filling the bucket. (K205) Relay – hydraulic flow heating: Contacts 8 / 12 only closed while heating system is switched on. (102.1 – 102.4) Remote control valves (Y23 + Y25) Proportional solenoid valve (Y29 + Y35) Proportional solenoid valve (Y23B + Y25B) Directional solenoid valve (Y29B + Y35B) Directional solenoid valve (I – IV) Main control blocks I – IV (73) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E19) arrives via ramp time module (E49) at terminal 5 of the amplifier modules (A10 to A10c) and further to the proportional and directional solenoid valves of the remote control blocks (102.1, 102.2, 102.3, and 102.4). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks (I to IV). Hydraulic oil flow Only oil of main pumps 4+8 flows through the standard spool in control block (II) to the rod side of the boom cylinders. The spool with #-symbol (lowering with free pump circulation) in control block (III) is connecting the piston side with the tank only. The floating spools($) in control blocks (I + IV) are connecting the piston side of the cylinders with the rod side and also with the tank. Now the boom can move down by gravity, since all pressure lines are connected via distributor manifold (73) and the control blocks to one common return line.

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8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA Combined movement with stick out and bucket fill (Auto Float ON ) Legend for illustration (Z 22680d): (E19) Control lever (Joy stick) (+Y) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A3) Service module, adjustable –10...0...+10 Volt adjusted to +10 Volt (A10) Amplifier module – Boom (A10a) Amplifier module – Boom (A10b) Amplifier module – Boom (A10c) Amplifier module – Boom (K58) Relay – Contacts 8 / 12 and 5 / 9 only closed while lifting the boom. (K160) Relay – Contacts 2 / 10 and 1 / 9 closed in normal operating mode. Contacts 6 / 10 and 5 / 9 closed while disable auto-float. (K72) Relay – Contacts 6 / 10 only closed while extending the stick. (K80) Relay – Contacts 6 / 10 only closed while filling the bucket. (K205) Relay – hydraulic flow heating: Contacts 8 / 12 only closed while heating system is switched on. (102.1 – 102.4) Remote control valves (Y23) Proportional solenoid valve (Y29 + Y35) Proportional solenoid valve (Y23B) Directional solenoid valve (Y29B + Y35B) Directional solenoid valve (I – IV) Main control blocks I – IV (73) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E19) arrives via ramp time module (E49) only at terminal 5 of the amplifier modules (A10 + A10b A10c) and further to the proportional and directional solenoid valves of the remote control blocks (102.1, 102.3, and 102.4). Amplifier module (A10a) is not active , because the function of bucket fill or stick extend will in turn open the relay contacts of K80 or K72. Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks (I, III and IV). Hydraulic oil flow No pump delivery to the cylinders, because the standard spool in control block (II) is not involved. The spool with #-symbol (lowering with free pump circulation) in control block (III) is connecting the piston side with the tank only. The floating spools($) in control blocks (I + IV) are connecting the piston side of the cylinders with the rod side and also with the tank. The boom can move up and down by external force (Floating), since all pressure lines are connected via distributor manifold (73) and the control blocks to one common return line.

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8.1.2 Electric / Hydraulic flowchart “ Boom lowering ” FSA Single movement with push button S95 depressed (Auto Float OFF) Legend for illustration (Z 22681d): (E19) Control lever (Joy stick) (S95) Push button – Auto Float OFF (+Y) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E49) Ramp time module (A3) Service module, adjustable –10...0...+10 Volt adjusted to +10 Volt (A10) Amplifier module – Boom (A10a) Amplifier module – Boom (A10b) Amplifier module – Boom (A10c) Amplifier module – Boom (K58) Relay – Contacts 8 / 12 and 5 / 9 only closed while lifting the boom. (K160) Relay – Contacts 2 / 10 and 1 / 9 closed in normal operating mode. Contacts 6 / 10 and 5 / 9 closed while disable auto-float. (K72) Relay – Contacts 6 / 10 only closed while extending the stick. (K80) Relay – Contacts 6 / 10 only closed while filling the bucket. (K205) Relay – hydraulic flow heating: Contacts 8 / 12 only closed while heating system is switched on. (102.1 – 102.4) Remote control valves (Y25) Proportional solenoid valve (Y29 ) Proportional solenoid valve (Y25B) Directional solenoid valve (Y29B) Directional solenoid valve (I – IV) Main control blocks I – IV (73) Distributor manifold Electrical signal flow The auto float button in joy stick (E19) is depressed, with the result that relay K160 is energized. Signal voltage of joy stick (E19) arrives via ramp time module (E49) only at terminal 5 of the amplifier modules (A10a and A10b) and further to the proportional and directional solenoid valve of the remote control blocks (102.2 and 102.3). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks (II and III). Hydraulic oil flow The oil of main pumps 4+8 flows through the standard spool in control block (II) and arrives via distributor manifold (73) at the rod side of the boom cylinders. The spool with #-symbol (lowering with free pump circulation) in control block (III) has a closed pressure port and is connecting the piston side with the tank only. The floating spools ($) in control blocks (I + IV) are not involved. Now a pressurized lowering of the boom is possible.

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8.1.3 Electric / Hydraulic flowchart “ Stick extending ” FSA Legend for illustration (Z 22682e): (E20) Control lever (Joy stick) (+Y) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A3) Service module, adjustable –10...0...+10 Volt adjusted to +10 Volt (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A8b) Amplifier module – Stick (A8c) Amplifier module – Stick (K58) Relay – Contacts 6/10 only closed when lifting the boom. (K71) Relay – Contacts 6 / 10 only closed when boom up or down. (K72) Relay – Contacts 5 / 9; 7 / 11 and 8 / 12 closed when stick out. (K73) Relay – Contacts 5 / 9; only closed when traveling or swinging. (K78) Relay – Contacts 6 / 10; only closed when bucket dump. (K80) Relay – Contacts 7 / 11 and 8 / 12; only closed when bucket fill. (K170) Relay – Contacts 2 / 10; 3 / 11 and 4 / 12 closed in normal operating mode. Contacts 6 / 10; 7 / 11 and 8 / 12 closed when auto-float OFF. (K205a) Relay – hydraulic flow heating: Contacts 5 / 9 and 6 / 10 only closed while heating system is switched on. (K207b) Relay – hydraulic flow heating: Contacts 5 / 9 only closed while heating system is switched on. (102.1 – 102.4) Remote control valves (Y21 + Y26) Proportional solenoid valve (Y31 + Y34) Proportional solenoid valve (Y21A + Y26A) Directional solenoid valve (Y31A + Y34A) Directional solenoid valve (I – IV) Main control blocks I – IV (73) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8 to A8c) and further to the proportional and directional solenoid valves of the remote control blocks (102.1, 102.2, 102.3, and 102.4). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks (I to IV). Hydraulic oil flow Now the oil of the main pumps flows through the main control blocks (I to IV) and arrives via distributor manifold (73) at the hydraulic cylinders.

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8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA Single movement in normal operating mode (Auto Float ON ) Legend for illustration (Z 22683e): (E20) Control lever (Joy stick) (-Y) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A3) Service module, adjustable –10...0...+10 Volt adjusted to +10 Volt (A8) Amplifier module – Stick (A8a) Amplifier module – Stick (A8b) Amplifier module – Stick (A8c) Amplifier module – Stick (K58) Relay – Contacts 6/10 only closed when lifting the boom. (K71) Relay – Contacts 6 / 10 only closed when boom up or down. (K72) Relay – Contacts 5 / 9; 7 / 11 and 8 / 12 only closed when stick out. (K73) Relay – Contacts 5 / 9; only closed when traveling or swinging. (K78) Relay – Contacts 6 / 10; only closed when bucket dump. (K80) Relay – Contacts 7 / 11 and 8 / 12; only closed when bucket fill. (K170) Relay – Contacts 2 / 10; 3 / 11 and 4 / 12 closed in normal operating mode. Contacts 6 / 10; 7 / 11 and 8 / 12 closed when auto-float OFF. (K205a) Relay – hydraulic flow heating: Contacts 5 / 9 and 6 / 10 only closed while heating system is switched on. (K207b) Relay – hydraulic flow heating: Contacts 5 / 9 only closed while heating system is switched on. (102.1 – 102.4) Remote control valves (Y21 + Y26) Proportional solenoid valve (Y31 + Y34) Proportional solenoid valve (Y21B + Y26B) Directional solenoid valve (Y31B + Y34B) Directional solenoid valve (I – IV) Main control blocks I – IV (73) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E20) arrives via ramp time module (E48) at terminal 5 of the amplifier modules (A8 to A8c) and further to the proportional and directional solenoid valves of the remote control blocks (102.1, 102.2, 102.3, and 102.4). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks (I to IV). Hydraulic oil flow Oil of main pumps 4+8 (control block II) and main pumps 1+5 (control block IV) flows through their standard spools to the rod side of the stick cylinders. The spool with #-symbol (lowering with free pump circulation) in control block (I) is connecting the piston side with the tank only. The floating spool($) in control blocks (III) is connecting the piston side of the cylinders with the rod side and also with the tank. Now the stick can move down by gravity, since all pressure lines are connected via distributor manifold (73) and the control blocks to one common return line.

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8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA Combined movement with boom up and bucket fill (Auto Float ON ) Legend for illustration (Z 22684d): (E20) Control lever (Joy stick) (-Y) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A3) Service module, adjustable –10...0...+10 Volt adjusted to +10 Volt (A8 – A8c) Amplifier modules – Stick (K58) Relay – Contacts 6/10 only closed when lifting the boom. (K71) Relay – Contacts 6 / 10 only closed when boom up or down. (K72) Relay – Contacts 5 / 9; 7 / 11 and 8 / 12 only closed when stick out. (K73) Relay – Contacts 5 / 9; only closed when traveling or swinging. (K78) Relay – Contacts 6 / 10; only closed when bucket dump. (K80) Relay – Contacts 7 / 11 and 8 / 12; only closed when bucket fill. (K170) Relay – Contacts 2 / 10; 3 / 11 and 4 / 12 closed in normal operating mode. Contacts 6 / 10; 7 / 11 and 8 / 12 closed when auto-float OFF. (K205a) Relay – hydraulic flow heating: Contacts 5 / 9 and 6 / 10 only closed while heating system is switched on. (K207b) Relay – hydraulic flow heating: Contacts 5 / 9 only closed while heating system is switched on. (102.1 + 102.3) Remote control valves (Y21) Proportional solenoid valve (Y31) Proportional solenoid valve (Y21B) Directional solenoid valve (Y31B) Directional solenoid valve (I + III) Main control blocks I + III (73) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E20) arrives via ramp time module (E48) only at terminal 5 of the amplifier modules (A8 + A8b) and further to the proportional and directional solenoid valves of the remote control blocks (102.1 + 102.3). Amplifier modules (A8a+ A8c) are not active, because the function of bucket fill or boom up will in turn open the relay contacts of K80 or K58. Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks (I and III). Hydraulic oil flow No pump delivery to the cylinders, because the standard spools in control block (II +IV) are not involved. The spool with #-symbol (lowering with free pump circulation) in control block (I) is connecting the piston side with the tank only. The floating spool ($) in control blocks (III) is connecting the piston side of the cylinders with the rod side and also with the tank. The stick can move up and down by external force (Floating), since all pressure lines are connected via distributor manifold (73) and the control blocks to one common return line

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8.1.4 Electric / Hydraulic flowchart “ Stick retracting ” FSA Single movement with push button S98 depressed (Auto Float OFF) Legend for illustration (Z 22685d): (E20) Control lever (Joy stick) (S98) Push button – Auto Float OFF (-Y) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (E48) Ramp time module (A3) Service module, adjustable –10...0...+10 Volt adjusted to +10 Volt (A8 – A8c) Amplifier modules – Stick (K58) Relay – Contacts 6/10 only closed when lifting the boom. (K71) Relay – Contacts 6 / 10 only closed when boom up or down. (K72) Relay – Contacts 5 / 9; 7 / 11 and 8 / 12 only closed when stick out. (K73) Relay – Contacts 5 / 9; only closed when traveling or swinging. (K78) Relay – Contacts 6 / 10; only closed when bucket dump. (K80) Relay – Contacts 7 / 11 and 8 / 12; only closed when bucket fill. (K170) Relay – Contacts 2 / 10; 3 / 11 and 4 / 12 closed in normal operating mode. Contacts 6 / 10; 7 / 11 and 8 / 12 closed when auto-float OFF. (K205a) Relay – hydraulic flow heating: Contacts 5 / 9 and 6 / 10 only closed while heating system is switched on. (K207b) Relay – hydraulic flow heating: Contacts 5 / 9 only closed while heating system is switched on. (102.1 – 102.4) Remote control valves (Y21 + Y26) Proportional solenoid valve (Y34) Proportional solenoid valve (Y21B+ Y26B) Directional solenoid valve (Y34B) Directional solenoid valve (I + II + IV) Main control blocks I + II + IV (73) Distributor manifold Electrical signal flow. The auto float button in joy stick (E20) is depressed, with the result that relay K170 is energized. Signal voltage of joy stick (E20) arrives via ramp time module (E48) only at terminal 5 of the amplifier modules (A8, A8a and A10c) and further to the proportional and directional solenoid valve of the remote control blocks (102.1, 102.2 and 102.4). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks (I and III). Hydraulic oil flow Oil of main pumps 4+8 (control block II) and main pumps 1+5 (control block IV) flows through their standard spools and arrives via distributor manifold (73) at the rod side of the stick cylinders. The spool with #-symbol (lowering with free pump circulation) in control block (I) has a closed pressure port and is connecting the piston side with the tank only. The floating spool ($) in control block (III) is not involved. Now a pressurized lowering of the stick is possible.

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8.1.5 Electric / Hydraulic flowchart “ Bucket filling ” FSA Legend for illustration (Z 22686e): (E19) Control lever (Joy stick) (-X) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (ws / gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A9 – A9c) Amplifier modules – Bucket (A3) Service module, adjustable –10...0...+10 Volt adjusted to +10 Volt (E17) EBL – module (Electronic Bucket Leveling) (K50) Relay – Contacts 6 / 10 closed under normal operating conditions i.e. hydraulic oil temperature and grease lube systems are o.k. (K58) Relay – Contacts 7 / 11 only closed when lifting the boom. (K71) Relay – Contacts 5 / 9 only closed when boom up or down. (K73) Relay – Contacts 6 / 10; only closed when traveling or swinging. (K74) Relay – Contacts 5 / 9; only closed when stick in or out. (K80) Relay – Contacts 5 / 9; only closed when bucket fill. (K205) Relay – hydraulic flow heating: Contacts 7 / 11 only closed while heating system is switched on. (102.1 – 102.4) Remote control valves (Y22 + Y27) Proportional solenoid valve (Y30 + Y33) Proportional solenoid valve (Y22A+ Y27A) Directional solenoid valve (Y30A+ Y33A) Directional solenoid valve (I – IV) Main control blocks I – IV (73) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E19) arrives via relay contacts 10/6 of K50 at terminal 19 of the EBL module (E17). From (E17) the signal voltage arrives via several relay contacts at terminal 5 of the amplifier modules (A9 to A9c) and further to the proportional and directional solenoid valves of the remote control blocks (102.1, 102.2, 102.3 and 102.4). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks (I to IV). Hydraulic oil flow Now the oil of all main pumps flows through the main control blocks (I, II, III, IV) and arrives via distributor manifold (73) at the piston side of the bucket cylinders.

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8.1.6 Electric / Hydraulic flowchart “ Bucket emptying ” FSA Legend for illustration (Z 22687e): (E19) Control lever (Joy stick) (+X) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (ws / gn) Colour code of signal voltage cable ( Joy stick) (X2...) Terminal rail with number (A9 – A9c) Amplifier modules – Bucket (A3) Service module, adjustable –10...0...+10 Volt adjusted to +10 Volt (E17) EBL – module (Electronic Bucket Leveling) (K50) Relay – Contacts 6 / 10 closed under normal operating conditions i.e. hydraulic oil temperature and grease lube systems are o.k. (K58) Relay – Contacts 7 / 11 only closed when lifting the boom. (K71) Relay – Contacts 5 / 9 only closed when boom up or down. (K73) Relay – Contacts 6 / 10; only closed when traveling or swinging. (K74) Relay – Contacts 5 / 9; only closed when stick in or out. (K80) Relay – Contacts 5 / 9; only closed when bucket fill. (K205) Relay – hydraulic flow heating: Contacts 7 / 11 only closed while heating system is switched on. (102.1 – 102.4) Remote control valves (Y22 + Y27) Proportional solenoid valve (Y30 + Y33) Proportional solenoid valve (Y22B+ Y27B) Directional solenoid valve (Y30B+ Y33B) Directional solenoid valve (I – IV) Main control blocks I – IV (73) Distributor manifold Electrical signal flow. Signal voltage of joy stick (E19) arrives via relay contacts 10/6 of K50 at terminal 19 of the EBL module (E17). From (E17) the signal voltage arrives via several relay contacts at terminal 5 of the amplifier modules (A9 to A9c) and further to the proportional and directional solenoid valves of the remote control blocks (102.1, 102.2, 102.3 and 102.4). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control blocks (I to IV). Hydraulic oil flow Oil of main pumps 2+6 (control block I) and main pumps 3+7 (control block III) flows through their standard spools and arrives via distributor manifold (73) at the rod side of the bucket cylinders. The spools with #-symbol (lowering with free pump circulation) in control blocks (II +IV) are connecting the piston side with the tank only.

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Section 8.1 Page 12

8.1.7 Electric / Hydraulic flowchart “ Clam opening ” FSA Legend for illustration (Z 22688b): (E24) Control pedal (-10V) Signal voltage (Maximum) (rs) Colour code of signal voltage cable (control pedal) (X2...) Terminal rail with number (A11) Amplifier modules – Clam (102.4) Remote control valves (Y32) Proportional solenoid valve (Y32A) Directional solenoid valve (IV) Main control block IV (73) Distributor manifold Electrical signal flow. Signal voltage of control pedal (E24) arrives at terminal 5 of the amplifier module (A11) and further to the proportional and directional solenoid valves of the remote control block (102.4). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control block (IV). Hydraulic oil flow Oil of main pumps 1+5 (control block IV) flows through their standard spools and arrives via distributor manifold (73) at the rod side of the clam cylinders.

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Section 8.1 Page 13

8.1.8 Electric / Hydraulic flowchart “ Clam closing ” FSA Legend for illustration (Z 22689b): (E23) Control pedal (+10V) Signal voltage (Maximum) (rs) Colour code of signal voltage cable (control pedal) (X2...) Terminal rail with number (A11) Amplifier modules – Clam (102.4) Remote control valves (Y32) Proportional solenoid valve (Y32B) Directional solenoid valve (IV) Main control block IV (73) Distributor manifold Electrical signal flow. Signal voltage of control pedal (E23) arrives at terminal 5 of the amplifier module (A11) and further to the proportional and directional solenoid valves of the remote control block (102.4). Hydraulic signal flow. (pilot pressure) When the proportional and directional solenoid valves are energized pilot pressure oil flows to the pilot pressure ports of the main control block (IV). Hydraulic oil flow Oil of main pumps 1+5 (control block IV) flows through their standard spools and arrives via distributor manifold (73) at the piston side of the clam cylinders.

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Section 8.1 Page 14

Hydraulic for the Attachment Cylinders 8.1.9 Checks and adjustments of the Main Relief Valves (MRV), illustration (Z 22690b):

There are four main relief valves (primary valves) installed, one in each main control block, to limit the maximum pump supply line pressure (operating pressure). Control block circuit Circuit I Circuit II Circuit III Circuit IV

MRV in control block I II III IV

Check point M11.2 M11.1 M11.3 M11.4

Functions FSA Travel L. Swing Travel R. Clam

Stick Boom Boom Bucket

Bucket Stick Bucket Stick

Boom Bucket Stick Boom

Each MRV can be checked and adjusted individually by selecting one function of the control block circuits. Checking: 1. Connect the gauge to the required check point M11.1 to M11.4. 2. Start the motors. 3. Lower the attachment to the ground and apply the swing parking brake 3. Extend the bucket cylinder to the stop position until the hydraulic system stalls. 4. Read the pressure. Required: 310 + 5 bar for valve blocks I – IV If the pressure is not correct, carry out a comparative measurement with an other function, in order to avoid wrong measuring results caused by wrongly adjusted SRV or other defects in the system. Adjusting: 1. Remove protection cap (a). 2. Loosen lock nut (b). 3. Turn set screw (c) -clockwise to increase pressure, Counter-clock wise to decrease pressure. 4. Tighten lock nut (b) and install cap (a).

)

• Make sure that the complete MRV-valve and SRV-valve is firmly tightened with 300 Nm. Otherwise, internal leaks could occur which result in: problems of correct adjustment, loud flow noises and high temperatures.

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Hydraulic for the Attachment Cylinders 8.1.10

Section 8.1 Page 15

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22691c): Boom cylinder “Piston side” FSA There are four service line relief valves (secondary valves) installed at the distributor manifold (73), to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 132.1 SRV 132.2 SRV 132.3 SRV 132.4 MRV circuit I MRV circuit II MRV circuit III MRV circuit IV

Press. check point M16.1 M16.2 M16.3 M16.4 M11.2 M11.1 M11.3 M11.4

Location Manifold (73) section B Manifold (73) section B Manifold (73) section P Manifold (73) section P Double high pressure filter Double high pressure filter Double high pressure filter Double high pressure filter

1. 2. 3. 4. 5. 6.

Connect gauges to all above listed check points. Start the motors. Extend the boom cylinder to the stop position until the hydraulic system stalls. Remove protection cap (1) of MRV. Loosen lock nut (2). Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV’s, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar.

)

7. 8.

• Since the piston side of the boom cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s. Turn set screw (3) of the MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #6 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 16

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22691c): Cont'd: Boom cylinder “Piston side” FSA 9. Adjust all four SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn, set screw (3) in the following sequence: 132.1 Ì 132.2 Ì 132.3 Ì 132.4 Remove protection cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 132.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

)

•

Now all gauges will show the same value of 350 bar, but only SRV-132.1 has the correct setting.

11. Proceed with the other valves in the same manner in the following sequence: 132.2 Ì 132.3 Ì 132.4 • Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all four service line relief valves. 12. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protection cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1).

)


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Section 8.1 Page 17

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22692d): Boom cylinder “Piston rod side” FSA There are two service line relief valves (secondary valves) installed, in main control blocks III and IV, to limit the maximum possible pressure peaks in the service line. On machines with hydraulic oil heating system the standard SRV is replaced by a pressure increasing valve (PIV) with two different pressure settings (remote controlled). Since the opening pressure of the SRV and PIV is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 33.8 PIV 262 MRV circuit II 1. 2. 3. 4. 5. 6. 7. 8.

)

Press. check point M11.1 M11.1 M11.1

Location Double high pressure filter Double high pressure filter Double high pressure filter

Connect gauges to the above listed check points. Disconnect the pilot pressure line L47 at port X of the pressure increasing valve and close the line with a suitable plug.. Loosen lock nut (4) of the pressure increasing valves (PIV) and turn in set screw (5) until piston (8) comes to stop. Start one engine and let it run with max. speed. Retract the boom cylinder to the stop position until the hydraulic system stalls. (With button S95 in R.H. joystick E19 activated) Remove protection cap (1) of MRV. Loosen lock nut (2). Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV, while observing the pressure gauge. Stop as soon as the pressure does not raise any further. The gauge pointer should remain at 350 bar + 5 bar. • Since the piston rod side of the boom cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s. continued

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Section 8.1 Page 18

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22692d): Cont'd: Boom cylinder “Piston rod side” FSA 9. Adjust the SRV (PIV), until all gauges show a pressure of 360 bar. SRV a) Remove protective cap (1) of the SRV. b) Loosen lock nut (2). c) Turn set screw (3) -clockwise to increase pressure, Counterclock wise to decrease pressure. d) Tighten lock nut (2). PIV

a) Loosen lock nut (6) b) Turn set screw (7) -clockwise to increase pressure, Counterclock wise to decrease pressure. c) Tighten lock nut (6).

10. Reduce the pressure, at SRV- 33.8 to a value below the required value, and then increase up to the required pressure (350 bar), while observing the gauge.

)

•


11. Reduce the pressure, at PIV 262 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges. 12. Adjust the lower setting of the pressure increasing valve 262. Turn out (ccw) set screw (5) until the gauge show the required lower pressure (100 bar). • Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all service line relief valves. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished Stop engine. Install all protective caps. Reconnect the pilot line L20 to the pressure increasing valve 262 to port X.

13. 14. 15. 16.

)


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Section 8.1 Page 19

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22693c): Stick cylinder “Piston side” FSA There are four service line relief valves (secondary valves) installed at the distributor manifold (73), to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 131.5 SRV 131.6 SRV 131.7 SRV 131.8 MRV circuit I MRV circuit II MRV circuit III MRV circuit IV


Location Manifold (73) section H Manifold (73) section H Manifold (73) section K Manifold (73) section K Double high pressure filter Double high pressure filter Double high pressure filter Single HP filter, L.H.

1. 2. 3. 4. 5. 6.

Connect gauges to all above listed check points. Start the motors. Extend the stick cylinder to the stop position until the hydraulic system stalls. Remove protection cap (1) of MRV. Loosen lock nut (2). Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV’s, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar.

)

7. 8.

• Since the piston side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s. Turn set screw (3) of the MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #6 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 20

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22693c): Cont'd: Stick cylinder “Piston side” FSA 9. Adjust all four SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn, set screw (3) in the following sequence: 131.5 Ì 131.6 Ì 131.7 Ì 131.8 Remove protection cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 131.5 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

)

•



)


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Section 8.1 Page 21

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22694c): Stick cylinder “Piston rod side” FSA There are two service line relief valves (secondary valves) installed, in main control blocks I and IV, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 33.1 SRV 33.7 MRV circuit II MRV circuit IV

Press. check point M11.1 M11.4 M11.1 M11.4

Location Double high pressure filter R.H. Double high pressure filter L.H. Double high pressure filter R.H. Double high pressure filter L.H.

1. 2. 3.

Connect gauges to all above listed check points. Start the motors. Retract the stick cylinder to the stop position until the hydraulic system stalls. (With button S95 in R.H. joystick E19 activated) 4. Remove protection cap (1) of MRV. 5. Loosen lock nut (2). 6. Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV’s, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar.

)

7. 8.

• Since the piston rod side of the stick cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s. Turn set screw (3) of the MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #6 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 22

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22694c): Cont'd: Stick cylinder “Piston rod side” FSA 9. Adjust both SRV’s equally, until the gauges show a pressure of 360 bar. Adjust in steps of ¼ turn, set screw (3) in the following sequence: 33.1 Ì 33.7 Remove protection cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 33.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

)

•


11. Proceed with the other valves in the same manner. • Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all service line relief valves. 12. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protection cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1).

)


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Section 8.1 Page 23

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22695c): Bucket cylinder “Piston side” FSA There are four service line relief valves (secondary valves) installed at the distributor manifold (73), to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 131.1 SRV 131.4 SRV 131.11 SRV 131.12 MRV circuit I MRV circuit II MRV circuit III MRV circuit IV


Location Manifold (73) section C Manifold (73) section E Manifold (73) section N Manifold (73) section N Double high pressure filter Double high pressure filter Double high pressure filter Double high pressure filter

1. 2. 3. 4. 5. 6.

Connect gauges to all above listed check points. Start the motors. Extend the bucket cylinder to the stop position until the hydraulic system stalls. Remove protection cap (1) of MRV. Loosen lock nut (2). Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV’s, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar.

)

7. 8.

• Since the piston side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s. Turn set screw (3) of the MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #6 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 24

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22695c): Cont'd: Bucket cylinder “Piston side” FSA 9. Adjust all four SRV’s equally, until all gauges show a pressure of 360 bar. Adjust in steps of ¼ turn, set screw (3) in the following sequence: 131.1 Ì 131.4 Ì 131.12 Ì 131.11 Remove protection cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 131.1 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

)

•



)


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Section 8.1 Page 25

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22696c): Bucket cylinder “Piston rod side” FSA There are three service line relief valves (secondary valves) installed, in main control blocks I, II and IV, to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV’s is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 33.2 SRV 33.3 SRV 33.6 MRV circuit I MRV circuit III

Press. check point M11.2 + M11.3 M11.2 + M11.3 M11.2 + M11.3 M11.2 M11.3

Location Double high pressure filter Double high pressure filter Double high pressure filter Double high pressure filter Double high pressure filter

1. 2. 3. 4. 5. 6.

Connect gauges to all above listed check points. Start the motors. Retract the bucket cylinder to the stop position until the hydraulic system stalls. Remove protection cap (1) of MRV. Loosen lock nut (2). Increase slowly the pump supply line pressure, by turning in set screws (3) of the MRV’s, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar.

)

7. 8.

• Since the piston side of the bucket cylinders are protected by several SRV’s, the pressure gauges show the pressure of that valve with the lowest setting. Even when the gauges show the required pressure it is possible that one or more valves have a higher setting. • To ensure that only the SRV’s open during checks and adjustments it is necessary to further increase the setting of the MRV’s. Turn set screw (3) of the MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #6 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). continued

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Section 8.1 Page 26

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22696c): Cont'd: Bucket cylinder “Piston rod side” FSA 9. Adjust all SRV’s equally, until the gauges show a pressure of 360 bar. Adjust in steps of ¼ turn, set screw (3) in the following sequence: 33.2 Ì 33.3 Ì 33.6 Remove protection cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). 10. Reduce the pressure, at SRV- 33.2 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges.

)

•


11. Proceed with the other valves in the same manner. • Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all service line relief valves. 12. Reset the MRV’s to 310 bar + 5 bar after the check / adjustment is finished, as follows: Remove protection cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1).

)


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Section 8.1 Page 27

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22697b): Clam cylinder “Piston Rod side” (clam opening) FSA There is one service line relief valve (secondary valve) installed at the distributor manifold (73), to limit the maximum possible pressure peaks in the service line. Since the opening pressure of the SRV is higher than the setting of the Main Relief Valves (MRV’s) it is necessary to increase the main relief pressure for testing and adjusting purposes. Valve SRV 131.9 MRV circuit IV 1. 2. 3. 4. 5. 6.

7. 8. 9. 10.

)

Press. check point M19.5 M11.4

Location Manifold (73) section L Double high pressure filter

Connect gauges to all above listed check points. Start the motors. Retract the clam cylinder (open the bucket) to the stop position until the hydraulic system stalls. Remove protection cap (1) of MRV’s. Loosen lock nut (2). Increase slowly the pump supply line pressure, by turning in set screws (3) of MRV in control block IV, while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 350 bar + 5 bar. If necessary correct the adjustment as follows: Turn set screw (3) of the MRV’s ½ turn further in, the gauge pointers will remain at the value shown at item #6 (350 bar + 5 bar). Tighten lock nut (2) and install cap (1). Reduce the pressure, at SRV 131.9 to a value below the required value, and then increase up to the required pressure (350 bar), while observing all gauges. Reset the MRV to 310 bar + 5 bar after adjustment is finished, as follows: Remove protective cap (1). Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure. Tighten lock nut (2) and install cap (1). • Make sure that the complete MRV-valve and SRV-valve is firmly tightened with 300 Nm. Otherwise, internal leaks could occur which result in: problems of correct adjustment, loud flow noises and high temperatures.

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Section 8.1 Page 28

Checks and adjustments of the Service Line Relief Valves (SRV), illustration (Z 22698b): Clam cylinder “Piston side” (clam closing) FSA There are two service line relief valves (secondary valves) installed in block (92), at distributor manifold (73), to limit the maximum possible pressure in the service line when closing the bucket. To avoid damages at the clam shell, due to improper operation, the SRV’s should be adjusted in a way that the pressure is just sufficient to keep the bucket closed. Valve SRV – block 92

MRV circuit IV 1. 2. 3. 4.

Press. check point M20.1 (operating pressure) M20.2 (dump line pressure) M20.3 dump line pressure) M11.4

Location Manifold (73) section F Manifold (73) section F Manifold (73) section F Double high pressure filter

Connect gauges to all above listed check points. Start one motor. Raise the attachment and bring the back wall of the bucket in a horizontal position (bucket dump). Depress pedal “bucket closing” until the hydraulic system stalls. Release the pedal back to neutral position. The bucket must stay closed. That means the clam-cylinders must not be retracted by the force (weight) of the clam shell. Adjust the SRV’s as follows: Remove protective cap (1) of SRV’s. Loosen lock nut (2). Turn set screw (3) -clockwise to increase pressure, Counter-clock wise to decrease pressure, with depressed pedal “clam closing”. Tighten lock nut (2) and install cap (1). Adjust the SRV’s equally (same dump line pressure at M20.2 and M20.3), until the gauge at check point M20.1 show a pressure of 220 bar. • Strong pulsation of the return line hoses, indicates deviation in opening pressure of SRV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all service line relief valves.

5.

)

Now reduce the pressure at the SRV’s equally in steps of 5 bar until the bucket opens by gravity (check with released pedal). Read the pressure and increase the setting with 10%, to compensate the weight of material stuck at the clam shell. •

For standard buckets the pressure is 150 bar, reinforced or with heavy wear package attached, the pressure maybe raised up to 200 bar.

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Section 8.1 Page 29

Checks and adjustments of the lowering speed, illustration (Z 22699a): Purpose of the Flow Restrictors: • To avoid an interruption of the pump delivery. • To provide an uniform and smooth cylinder travel. • To limit the return oil flow through the control block to the maximum permissible volume. Maximum permissible lowering speed for boom: Function Boom down (FSA)

Cylinder retracting time/meter (s /m) 1,5

Total time(s) 4,7

Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Activate service switch S155 (located in the cab base) during the checks and adjustments, to ensure that the main pumps are in Qmax position. 4. Rapidly move the control lever (E19) to the front end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). • Lower the boom so, that the bucket stops just above the ground. 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 132.1, 132.2, 132.3 and 132.4 at the distributor manifold (73). Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.

6. Check lowering speed again and repeat the adjustment if necessary. 7. If the adjustment is finished tighten lock nut (1) and reset service switch S155.

)

•

If it is impossible to move the cylinder over the whole way, mark a distance of one meter with permanent pen P/N 621 566 40 on the piston rod and measure the time for only one meter movement.

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Section 8.1 Page 30

Checks and adjustments of the lowering speed, illustration (Z 22700a): Purpose of the Flow Restrictors: • To avoid an interruption of the pump delivery. • To provide an uniform and smooth cylinder travel. • To limit the return oil flow through the control block to the maximum permissible volume. Maximum permissible lowering speed for stick: Function Stick in (FSA)


Total time(s) 2,2

Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Activate service switch S155 (located in the cab base) during the checks and adjustments, to ensure that the main pumps are in Qmax position. 4. Rapidly move the control lever (E20) to the rear end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 131.5, 131.6, 131.7 and 131.8 at the distributor manifold (73). Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.


)

•


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Section 8.1 Page 31

Checks and adjustments of the lowering speed, illustration (Z 22701a): Purpose of the Flow Restrictors: • To avoid an interruption of the pump delivery. • To provide an uniform and smooth cylinder travel. • To limit the return oil flow through the control block to the maximum permissible volume. Maximum permissible lowering speed for bucket: Function Bucket empty (FSA)


Total time(s) 3,1

Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Activate service switch S155 (located in the cab base) during the checks and adjustments, to ensure that the main pumps are in Qmax position. 4. Rapidly move the control lever (E19) to the r.h. end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time, the speed must be reduced by altering the throttle valves 131.1, 131.4, 131.11 and 131.12 at the distributor manifold (73). Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw. Since there are several valves throttling the return oil flow the valves must be set synchronously. The adjusting screws have to be turned in by the same amount of revolutions.

O.K.


)

•


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Section 8.1 Page 32

Checks and adjustments of the lowering speed, illustration (Z 22702): Purpose of the Flow Restrictors: • To avoid an interruption of the pump delivery. • To provide an uniform and smooth cylinder travel. • To limit the return oil flow through the control block to the maximum permissible volume. Maximum permissible lowering speed for Clam: Function Clam closing (FSA)

Cylinder retracting time/meter (s /m) -----

Total time(s) 2,8

Adjustments / Checks: 1. Use a stop watch to measure the cylinder running time. 2. Raise the fully extended attachment with empty bucket to the maximum height position (A). 3. Activate service switch S155 (located in the cab base) during the checks and adjustments, to ensure that the main pumps are in Qmax position. 4. Rapidly push the control pedal (E23) to the end position (start the stop watch) and hold it until the final position (B) is reached.(stop the stop watch). 5. If the lowering speed is too high, i.e. the measured time is less than the permissible time or uncomfortable, the speed must be reduced by altering throttle valve 131.9 at the distributor manifold (73). Adjust as follows: To decrease the lowering speed loosen lock nut (1) and turn the bolt (2) cw. To increase the lowering speed loosen lock nut (1) and turn the bolt (2) ccw. 6. Check lowering speed again and repeat the adjustment if necessary. 7. If the adjustment is finished tighten lock nut (1) and reset service switch S155.

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Hydraulic for the Swing Circuit

Section 8.2 Page 1


Page Hydraulic for the swing circuit 8.2.1 Swing Circuit (Brief description)

2+3

8.2.2

Swing Motor

4+5

8.2.3

Swing Gear Box

6

8.2.4

Swing Parking Brake (Gear house Brake)

7

8.2.5

Swing Brake Valve

8+9

8.2.6

Electric / Hydraulic flowchart “Swing Left”

10

8.2.7

Electric / Hydraulic flowchart “Swing Right”

11

8.2.8

Checks and adjustments for the swing circuit

12 + 13

8.2.9

Function check for the hydraulic swing brake

14

8.2.10

Function check for the swing parking brake

15

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Section 8.2 Page 2

8.2.1 Swing Circuit Legend for illustration (Z 22703a): (4 + 8) Main pumps (II) Control block (20.1 + 20.2 + 20.3) Swing motors Brief description (Service circuits) (Study together with the for the machine valid hydraulic and electric circuit diagram). The swing motors (20.1 + 20.2 + 20.3) are driven by the pumps (4 + 8). The oil flows from the pumps through high pressure filters to the control block (II). With the spools in neutral position oil flows via the return oil line (L24) into the collector tube and further to the tank. On its way to tank the oil must flow through the back pressure valve (26) and the return oil filter (51.1 - 51.7). (Back pressure valve function see section 4.) When operating the control lever for "Swinging" the pump line is connected in the control block (II) with the corresponding service line (A1 or B1) to the swing motors (20.1 + 20.2 + 20.3). The oil flows from the control block through each one of the swing brake valves (49.1 + 49.2 + 49.3); description see page 8 and 9) and the swing motors (20.1 + 20.2 + 20.3). Each swing gear includes one spring loaded multi disk brake (House brake) for locking the superstructure. The leak oil (case drain) flows through the line (L42 + L43 + L44) and the leak oil filter (66) back to tank. continued

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Section 8.2 Page 3

Cont'd.: 8.2.1 Swing Circuit: Legend for illustration (Z 22704a): (4 + 8) (II) (49.1 + 49.2 + 49.3) (50.1 + 50.2 + 50.3) Y24 Y24a + Y24b Y127

Main pumps Control block Swing brake valve blocks Swing motors proportional solenoid valve => control block II directional solenoid valves => control block II proportional solenoid valve (hydraulic swing brake)

Brief description (Control circuits) When the lever (E20) is moved out of its neutral position, proportional solenoid valves Y24 and directional solenoid valves Y24a (L.H.-swing) or Y24b (R.H.swing) are energized simultaneously, so that pilot pressure oil is send to one side of the control block (II). At the same time by the function of proportional solenoid valve Y127 pilot pressure is present at port „X“ of each brake valve block thus a maximum pressure built up in the service lines is possible. i.e. Swing speed = Oil flow of pump 4+8

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8.2.2

Section 8.2 Page 4

Swing Motor Axial piston motor A2FLM (with SL-bearing) The axial piston units of product group A2FM with fixed displacement can operate as a hydraulic motor only. The drive speed is proportional to the consumption capacity. The output torque increases with the pressure drop between high and low pressure side. The motor converts hydrostatic energy into mechanical energy. Legend for illustration (Z 21936): (1) (2) (3) (4) (5) (5a) (6a) (6b) (7) (8)

Drive shaft Housing Case drain port Retaining plate Piston Pivot (center) pin Upper dead point Lower dead point Cylinder Control lens

(9) (10) (11) (12) (13) (14) (15) (16) (17) (18)

End plate Centering spring Taper roller bearing Spring Slipper pads Thrust washer Roller bearing Circlip Sealing flange Radial seal ring

Description of the SL-bearing (SL = slipper bearing) The main part of the axial forces is supported by the slipper pads (13) which are installed on the driving circular side of the drive shaft. Each piston is allocated to one slipper pad. These slipper pads are located in the cylinder chamber and get pressurized via piston borings (5). The slipper pads support themselves on the thrust washer (14) and discharge axially the tapered roller bearing (11). Without pressure the slipper pads are kept on the thrust washer by means of spring (12).

continued

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Section 8.2 Page 5

Cont'd.: 8.2.2 Swing Motor Axial piston motor A2FLM (with SL-bearing), illustration (Z 21936): Function: The pressure oil inlet (A or B) and consequent oil outlet (B or A) determine the output drive direction of the drive shaft (1). Direction of rotation: "Clockwise" = Direction of flow A to B "Counter-Clockwise" = Direction of flow B to A with view onto drive shaft! Via the control lens (8) the oil is directed to the cylinder bores. The piston (5) is moved from the lower (6b) to the upper dead point (6a) by means of the force acting on it and causes the drive shaft to rotate. On further rotation of the drive shaft (additional pistons are pressurized) this piston is moved towards the lower dead point again and oil of the cylinder chamber is forced out through the kidney formed openings of the control lens. This oil is fed back to the tank via the return line. If the supply and return line is changed it changes the output drive direction of the drive shaft. By means of the angled arrangement of the cylinder (7) (bent axis design), a certain piston stroke is produced which results in a fixed displacement per revolution of the drive shaft. According to the size of the applied flow this produces a specific output speed. The output torque at the drive shaft is dependent on the size of the motor and the required operating pressure.

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Section 8.2 Page 6

8.2.3 Swing Gear Box Legend for illustration (Z 22438a): (1) Drive housing (2) Drive shaft (3) Sun gear shaft (4) House brake (Multi disk brake) (5) Breather filter Drive shaft housing (6) Oil level gauge (dipstick) Drive shaft housing (7) Disk brake housing (8) Cylindrical roller bearing (9) Internal ring gear (10) Cylindrical roller bearing

(11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Bearing ring Cartridge Spherical roller bearing Oil drain plug, gear box Cylindrical roller bearing Oil level gauge (dipstick) Gear box First planetary stage Drive shaft to second stage Second planetary stage Radial seal ring Drive pinion Grease line port

The swing gear is of compact design with a two stage planetary gear including a multi disk house brake. The gear is bolted to the superstructure and fits firmly due to the machined diameter (A) and the bolt torque. The torque loaded on the hydraulic motor is transmitted by drive shafts (2) and sun gear shaft (3) to the first planetary stage (17). The sun shaft (17) of the first planetary stage transmits the torque into the second planetary stage (19). By the planetary gears the output drive shaft is rotated and transmits the torque to the pinion (21). The drive housing, and the gearbox are filled with gear oil. Aeration is done by breather filters. To lubricate the pinion bearing port (22) is connected to the central lubrication system.

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Section 8.2 Page 7

8.2.4 Swing Parking Brake (Gear house Brake) The Spring Loaded Multi-disk Brake is a safety brake; applied by spring force and released by oil pressure. Legend for illustration (Z 22439a): (1) Disk housing (2) Thrust washer (3) Inner disks (lamellas) (4) Outer disks (lamellas) (5) Sinus (spacing) ring (6) Piston (7) Quad-Rings with back- up rings (8) Quad-Rings with back- up rings (9) (10) (11) (12) (13)

Springs Thrust washer Circlip Drive shaft Oil pressure port

Function: Brake applied: The outer disks (4) engaged to the housing by serration and the inner disks (3) in serrated connection with drive shaft (12) are pressed together by the springs (9). This results in a fixed connection between housing and drive shaft. Brake released: Oil pressure via port (13) reaches the bottom of the piston (6) and forces the piston upwards against the thrust washer (10). This function eliminates the spring force onto the disks so that the sinus (spacing) rings can keep the outer disks (4) apart, thus the brake is released. The releasing pressure is 19 - 20 bar, the maximum permissible pressure 60 bar. This is a so named "Wet Brake" because the brake housing is splash lubricated by gear oil.

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Section 8.2 Page 8

8.2.5 Swing Brake Valve Legend for illustration (Z 21935): (1) Pressure increasing valve (items 6 - 13) (2) Check valve circuit A (3) Check valve circuit B (4) Anti-cavitation valve circuit B (5) Anti-cavitation valve circuit A (6) Jet bore, of main piston plug Ports: (Y) (T) (A) (A1) (B) (B1)

(7) (8) (9) (10) (11) (12) (13)

Spring of main piston Jet bore Valve poppet Spring Intermediate piston Pilot pressure piston Main piston

Leak oil Return oil Service line from control block Service line to the motor Service line from control block Service line to the motor

Pressure check points: (MA) Circuit A (MB) Circuit B Explanation of the function by the symbol: When ever a swing motion is carried out or the foot brake is used, pilot pressure arrives the pressure increasing valve (1) at port "X". The pilot pressure pre-loads these valves. The oil for the hydraulic motor from the control block arrives the service line port A or B, depending if a R.H. or a L.H. swing motion is carried out. The ports A and B are internally connected to the ports A1 and B1 and these ports in turn with the hydraulic motor. The operating pressure, at either port A or B closes the anti-cavitation valves (4 or 5) and opens the check valves (2 or 3). That means by the check valves (2 or 3) the service lines are connected to the pressure increasing valve. When ever the pressure is higher than the setting of the pressure increasing valve, this valves opens and dumps the oil into the return line (T) to tank. The pressure can be checked at the check points MA or MB. continued

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Section 8.2 Page 9

Cont'd.: 8.2.5

Swing Brake Valve, illustration (Z 21935) If after a swing motion the joy stick is put into neutral position without using the foot brake, the superstructure is turned by inertial force and the hydraulic motor acts as a pump because it is driven by the swing gear. In this period the pressure in the service line is lower than the pressure in the return line, because there is a back pressure valve at the tank, and oil is forced through the anti-cavitation valves into the service line. Function of the pressure increasing valve. When ever a swing motion is carried out or the foot brake is used, pilot pressure arrives the pressure increasing valve (1) at port "X". The pilot pressure pre-loads these valves. By applying pilot pressure via the external port X to piston (12), the pretensioning of the pressure spring (10) is increased by the amount of the piston stroke "S", which results in the actual valve setting. The system pressure is in front of the main piston (13) and via the jet bore (6) also in the chamber of the spring (7) and via the jet bore (8) at the pressure relief valve poppet (9). Due to the force balance the piston (13) is kept in its position supported by the spring (7). Overcomes the system pressure the setting of the valve (9), this valve opens a channel to the dump line port (Y). Due to the drop of force the piston (13) is moved to the right. The pressure line gets connected with the return line (T). Damped opening and closing are obtained by the throttled volumetric change that is caused by the jet bores.

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Section 8.2 Page 10

8.2.6 Electric / Hydraulic flowchart “Swing Left” Legend for illustration (Z 22705a): (E20) Control lever (Joy stick) (E22) Control pedal swing brake (-X) Direction (axis) of joy stick (-10V) Signal voltage (Maximum) (ws/gn) Colour code of signal voltage cable ( Joy stick) – white/green (br – gn) Colour code of voltage cable ( brake pedal) – brown – green (X2...) Terminal rail with number (E50 + E50b) Ramp time modules (A7) Amplifier module – Swing (Y24 + Y24a/b – Block II) (A16) Amplifier module – Swing brake (Y127) Proportional solenoid valve– Swing brake (K190) Relay – Swing brake without ramp time (102.2) Remote control valve block (Y24) Proportional solenoid valve (Y24A) Directional solenoid valve (II) Main control block II (24) Distributor manifold (49.1 – 49.3) Swing brake valve blocks (PIV) Pressure increasing valve (20.1 – 20.3) Swing motors The electrical signal flow. [ ] Start of swing with control block II: (E20) => (E50) =>

=> (A7 terminal 3) => (A7 terminal 7-8)

Simultaniously (E20) => (K190 contacts 1 / 4) => (E50b) => (K190 contacts 5 / 6) => =>=> => =>=> => (A16 terminal 7-8)

=> (Y24a) => (Y24) => (Y127)

The hydraulic signal. (pilot pressure) [ ] When the proportional and directional solenoid valves are energized pilot pressure oil flows to the caps at the main control blocks. Proportional valve Y127 will increase the pilot pressure at the pressure increasing valves (PIV) in relation to the lever deflection. The hydraulic oil flow [ ] Maximum swing speed is obtained when the oil volume of main pumps (4, 8) via block II is directed to swing motors (20.1 – 20.3).

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Section 8.2 Page 11

8.2.7 Electric / Hydraulic flowchart “Swing Right” Legend for illustration (Z 22706a): (E20) Control lever (Joy stick) (E22) Control pedal swing brake (+X) Direction (axis) of joy stick (+10V) Signal voltage (Maximum) (ws/gn) Colour code of signal voltage cable ( Joy stick) – white/green (br – gn) Colour code of voltage cable ( brake pedal) – brown – green (X2...) Terminal rail with number (E50 + E50b) Ramp time modules (A7) Amplifier module – Swing (Y24 + Y24a/b – Block II) (A16) Amplifier module – Swing brake (Y127) Proportional solenoid valve– Swing brake (K190) Relay – Swing brake without ramp time (102.2) Remote control valve block (Y24) Proportional solenoid valve (Y24b) Directional solenoid valve (II) Main control blocks II (24) Distributor manifold (49.1 – 49.3) Swing brake valve blocks (PIV) Pressure increasing valve (20.1 – 20.3) Swing motors The electrical signal flow. [ ] Start of swing with control block II: (E20) => (E50) =>

=> (A7 terminal 9) => (A7 terminal 7-8)

Simultaniously (E20) => (K190 contacts 1 / 4) => (E50b) => (K190 contacts 5 / 6) => =>=> => =>=> => (A16 terminal 7-8)

=> (Y24b) => (Y24) => (Y127)

The hydraulic signal. (pilot pressure) [ ] When the proportional and directional solenoid valves are energized pilot pressure oil flows to the caps at the main control blocks. Proportional valve Y127 will increase the pilot pressure at the pressure increasing valves (PIV) in relation to the lever deflection. The hydraulic oil flow [ ] Maximum swing speed is obtained when the oil volume of main pumps (4, 8) via block II is directed to swing motors (20.1 – 20.3).

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8.2.8

Section 8.2 Page 12

Checks and adjustments for the swing circuit

)

• It is important that the complete MRV-valve and the Pressure Increasing Valve is firmly (with 300 Nm) tightened. Otherwise, internal leaks could occur which result in problems of correct adjustment, loud flow noises and high temperatures. • Whenever pressure checks are carried out, they must be carried out for all swing motors, to make sure the control lines and the check valves in the brake valve blocks are in good condition. • Because the Swing motors are working hydraulically in combined operation, the pressure gauge shows the pressure of the pressure increasing valve with the lowest setting. Even when the gauge shows the required pressure it is possible that one valve has a higher setting. Therefore lower the pressure on one valve below the required pressure and then increase up to required pressure. Proceed with next valves in the same manner.

High pressure check / adjustment 1. Connect a pressure gauge to check point M11.1 at the high pressure filter units. 2. Disconnect the pilot pressure lines from the T-unions and close the lines with a suitable plug (P). 3. Loosen lock nut (3) of all pressure increasing valves (PIV) and screw in set screw (4) until piston (5) comes to stop. 4. Start one motor. 5. Lower attachment to ground and apply house brake with switch S29. 6. Adjust the MRV-pressure to ~350 bar. 7. Actuate either L.H. or R.H. rotation until the hydraulic system stalls. Read the pressure, required = 330 ±5 bar. 8. If the gauge shows a smaller or greater value the pressure increasing valves must be adjusted: a) Loosen lock nut (1) of the first pressure increasing valve PIV (49.1). b) Adjust pressure with set screw (2) of PIV (49.1) to ~340 bar. If the pressure won’t increase, turn set crew (2) of the other PIV’s (49.2 + 49.3) a ¼ turn further in (c.w.). c) Secure by tightening lock nut (1). d) Loosen lock nut (1) of the second PIV (49.2). e) Reduce the pressure with set screw (2) of PIV (49.2) to a value of about 320 bar, and then increase up to the required pressure of 330 bar. f) Secure adjusted set screw (2) by tightening lock nut (1) g) Loosen lock nut (1) of the third PIV (49.3). h) Reduce the pressure with set screw (2) of PIV (49.3) to a value of about 320 bar, and then increase up to the required pressure of 330 bar. i) Secure adjusted set screw (2) by tightening lock nut (1) continued

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8.2.8

Section 8.2 Page 13

Checks and adjustments for the swing circuit Cont'd.: j) Loosen lock nut (1) of the first PIV (49.1). k) Reduce the pressure with set screw (2) of PIV (49.1) to a value of about 320 bar, and then increase up to the required pressure of 330 bar. l) Secure adjusted set screw (2) by tightening lock nut (1) Low pressure check / adjustment 9.

[Swinging down path (drifting) with still disconnected pilot pressure line]

Actuate either L.H. or R.H. rotation until the hydraulic system stalls. a) Loosen lock nut (3) of all (PIV’s) and reduce the pressure equally with set screws (4) to a value of about 130 bar, secure setting with lock nut (3) b) Loosen lock nut (3) of the first PIV (49.1). c) Reduce the pressure with set screw (4) of PIV (49.1) to a value of about 110 bar, and then increase up to the required pressure of 120 bar. d) Secure adjusted set screw (4) by tightening lock nut (3) e) Loosen lock nut (3) of the second PIV (49.2). f) Reduce the pressure with set screw (4) of PIV (49.2) to a value of about 110 bar, and then increase up to the required pressure of 120 bar. g) Secure adjusted set screw (4) by tightening lock nut (3) h) Loosen lock nut (3) of the third PIV (49.3). i) Reduce the pressure with set screw (4) of PIV (49.3) to a value of about 110 bar, and then increase up to the required pressure of 120 bar. j) Secure adjusted set screw (4) by tightening lock nut (3)

10. Re-connect the pilot pressure line. 11. Re-set MRV-pressure and remove the gauges after the check / adjustment is finished • Strong pulsation of the return line hoses, indicates deviation in opening pressure of PIV’s and must be avoided. Repeat the adjusting procedure until the oil returns well-balanced via all three pressure increasing valves. Brake pilot pressure - check / adjustment 1. Connect the gauge to the check point M4. 2. Start motors. 3. Depress fully the foot brake pedal (E22) and read the pressure. The pressure must be 24 +1 bar. If adjustment is required: Alter the position of the potentiometer R2 of the amplifier A16 until the pressure is 24 +1 bar. Basic adjustment for A16 see section 5

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Section 8.2 Page 14

8.2.9 Function check for hydraulic swing brake Legend for illustration (Z 22713): (M39) Pressure check point – (Pressure to pressure increasing valve) (S22) Switch – Position of access ladder (S28) Switch – Operators seat (Y120) Solenoid valve – hydraulic swing brake ON - OFF (Y127) Proportional solenoid valve – hydraulic swing brake Safety circuit (automatic actuation) The hydraulic swing brake will be applied automatically when the access ladder and/or the service arm of the central refilling system is not in its completely lifted position and/or if the operators seat is not occupied. Brake apply pressure 1. Connect gauge to check point (M39). 2. Start the motors. 3. Lift the access ladder to the end position. 4. Check the pressure at check point(M39) under the following conditons: a) Seat is occupied and access ladder complete up. 0 bar=> released. No message should appear on the text display b) Seat is occupied and access ladder down. The message “ Pilot control cut out “ should appear

45 bar=> applied.

c) Seat is not occupied and access ladder complete up. The message “ Pilot control cut out“ should appear

45 bar=> applied.

Operation circuit (manual actuation through joystick or brake pedal) To shorten the braking angle of the superstructure either the brake pedal must be actuated or the a counter action of the joystick is required. As a result, proportional valve Y127 will vary the pilot pressure at the pressure increasing valves (PIV) in relation to the lever deflection. Brake apply pressure 5. Apply the parking brake. Therefore move toggle switch (S29) in position “1” 6. Actuate either the joystick (L.H. or R.H.) or the swing brake pedal and read the pressure. Required: 0 <=> 24 bar. (variable i.e. proportional to the lever deflection) 7. Disconnect the pressure gauge.

)

• In case of malfunction check the electrical control system and the function of solenoid valve Y120 and/or Y127.

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Section 8.2 Page 15

8.2.10 Function check for the swing parking brake Legend for illustration (Z 22714): (M1.2) Pressure check point – (X2 - pilot pressure) (M10) Pressure check point – (Pressure to swing parking brake) (B16) Pressure switch (Y5) Solenoid valve –swing parking brake ON - OFF (252.1) Pressure reducing valve Parking Brake Release Pressure. (House Brake Pressure) 1. Connect gauge to check point (M1.2). 2. Start both motors and read the pressure. Required = 45 ±3 bar. If not, correct the pilot pressure adjustment. (refer to Section 5). 3. Apply the parking brake. Therefore move toggle switch (S29) in position “1”, now the following message should appear:

Swing gear house brake ON

4. Actuate either L.H. or R.H. rotation, the machine should not turn. • If the machine turns the parking brake must be repaired. 5. Release the parking brake. Therefore move toggle switch (S29) in position “0”, now the swing function must be possible again and the monitor returns to standard display.

)

• In case of malfunction check the electrical control system and the function of solenoid valve Y5.

Function Check of pressure switch B16 1. Connect pressure gauge to check point (M10). 2. Start the motors. Gauge must show normal pilot pressure X2 = 45 ±3 bar. 3. Move toggle switch (S29) in position “0” 4. Set pilot pressure reducing valve (252.1) to 22 bar. 5. Unplug and reconnect solenoid valve Y5 to allow pressure relieve from pilot pressure line to house brake. The text display must show “Swing gear house brake ON” 6. Increase the pilot pressure up to 26 bar. “Swing gear house brake ON” must disappear. 7. Reset pilot pressure X2 to 45 ±3 bar.

)

• Pressure at B16 <24 bar => Brake applied (ON) • Pressure at B16 >24 bar => Brake released (OFF)

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Hydraulic for the Travel Circuit

Section 8.3 Page 1


Page Hydraulic for the travel circuit 8.3.1 Travel Circuit (Brief description)

2+3

8.3.2 Travel Motor

4

8.3.3 Rotary distributor

5

8.3.4 Travel Gear Box

6

8.3.5 Travel Parking Brake (Gear house Brake)

7

8.3.6 Travel Brake Valve

8

8.3.7 Electric / Hydraulic flowchart “Travel forward”

9

8.3.8 Electric / Hydraulic flowchart “Travel backward”

10

8.3.9 Checks and adjustments for the travel circuit

11

8.3.10 Function check for the travel parking brake

12

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Section 8.3 Page 2

8.3.1 Travel Circuit Legend for illustration (Z 22717): (2 + 3 + 6 + 7) (I + II + III + IV) (22.1 – 22.4) (39.1+ 39.2) (77.1 – 77.4) (59) (96) (147) (Y16) (Y20 + Y20a/b) (Y28 + Y28a/b) (L36) (L38) (L39)

Main pumps Control blocks Travel motors Travel brake valves Travel parking (house) brakes Rotary distributor Main oil reservoir Pressure reducing valve (35 bar) Solenoid valve for travel parking brake Remote control valves (control block I => L.H. crawler) Remote control valves (control block III => R.H. crawler) Return oil line Case drain (leak oil) line Pilot pressure line to the travel parking brake

Brief description (Control circuits) (Study together with the hydraulic and electric circuit diagram). When the pedals E21a and E21b are moved out of there neutral position, proportional solenoid valves Y20 and Y28 and simultaneously the directional solenoid valves Y20a or Y20b (L.H.-crawler) and Y28a or Y28b (R.H.- crawler) are energized. (E21a) Control pedal A – forward => Y20 +Y20b Left track B – reverse => Y20 +Y20a

(E21b) Control pedal A – forward => Y28 +Y28b Right track B – reverse => Y28 +Y28a

continued

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Section 8.3 Page 3

8.3.1 Travel Circuit Cont'd.: Illustration (Z 22717): Brief description (Service circuits) (Study together with the hydraulic and electric circuit diagram). The L.H. travel motors (21.1 + 21.2) are driven by the pumps (2 + 6) and the R.H. travel motors (21.3 + 21.4) are driven by the pumps (3 + 7). The oil flows from the pumps through the high pressure filters to the control blocks (I + III). In neutral position of the spools the oil flows via the return oil lines (L23 + L25) into the collector tube and further to the tank. On its way to tank the oil must flow through the back pressure valve (26) and the return oil filter (51.1 - 51.7). (Back pressure valve function see section 4.) When operating the foot pedal for "Travelling" the pump line of each control block is connected with the corresponding service line (A1 or B1) via the rotary distributor (59) and travel brake valves (39.1 + 39.2) to the travel motors (22.1 – 22.4). The travel brake valve acts as a flow control valve in order to avoid the travel motors picking up speed when travelling downhill. Each travel gear includes a spring loaded multi disk brakes (House brakes 77.1 – 77.4). They are used as parking brakes, automatically applied by the function of Y16 whenever the prime mover is switched OFF. The brake release pressure (X2 pressure reduced to 35 bar by valve 147) is monitored by the pressure switch (B48). The leak oil (case drain) flows through the line (L38) and the leak oil filter (66) back to tank. Anti cavitation circuit Due to terminal leakage and in order to avoid a vacuum in the system, e.g. due travelling downhill, additional oil must be fed into the circuit. This is done by the anti cavitation valves (32.1 + 32.2 respectively 32.9 + 32.10). Function: The line from port T of the control blocks is connected to the return oil pipe at the tank. Due to the adjustment of the back pressure valve (26) there is under any circumstance enough oil under pressure available at the anti cavitation valves. Any time the pressure in the service line to the motors is less than the back pressure additional oil is forced through the anti cavitation valves into the circuit.

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Section 8.3 Page 4

8.3.2 Travel Motor Axial piston motor A2FLM The axial piston units of product group A2FM with fixed displacement can operate as a hydraulic motor only. The drive speed is proportional to the consumption capacity. The output torque increases with the pressure drop between high and low pressure side. The motor converts hydrostatic energy into mechanical energy. Legend for illustration (Z 22505): (1) (2) (3) (4) (5) (5a) (6a) (6b) (7)

Drive shaft Housing Case drain port Retaining plate Piston Pivot (center) pin Upper dead point Lower dead point Cylinder

(8) (9) (10) (11) (12) (13) (14) (15) (16)

Control lens End plate Taper roller bearing Roller bearing Thrust washer Circlip Circlip Sealing flange Radial seal ring

Function: The pressure oil inlet (A or B) and consequent oil outlet (B or A) determine the output drive direction of the drive shaft (1). Direction of rotation: "Clockwise" = Direction of flow A to B "Counter-Clockwise" = Direction of flow B to A with view onto drive shaft! Via the control lens (8) the oil is directed to the cylinder bores. The piston (5) is moved from the lower (6b) to the upper dead point (6a) by means of the force acting on it and causes the drive shaft to rotate. On further rotation of the drive shaft (additional pistons are pressurized) this piston is moved towards the lower dead point again and oil of the cylinder chamber is forced out through the kidney formed openings of the control lens. This oil is fed back to the tank via the return line. If the supply and return line is changed it changes the output drive direction of the drive shaft. By means of the angled arrangement of the cylinder (7) (bent axis design), a certain piston stroke is produced which results in a fixed displacement per revolution of the drive shaft. According to the size of the applied flow this produces a specific output speed. The output torque at the drive shaft is dependent on the size of the motor and the required operating pressure.

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Section 8.3 Page 5

8.3.3 Rotary Distributor Task: The rotary distributor (joint) permits a hydraulic connection between the superstructure and the undercarriage, that means between the rotating and the stationary part. Legend for illustration (Z 22723): (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Rotary distributor housing Rotor Mover Clam ring Cover Sealing element O-ring Rotor guide rings Splitted maze disk Centering disk

Ports: A-D F L ST K1/K2

(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)

O-ring Race Support flange Ring Seal-ring O-ring with back-up ring Seal-ring O-ring Plug screws Grease nipple

Service lines Grease Leak (case drain) oil Control oil Return oil to tank

Function: During operation superstructure and under carriage constantly rotate towards each other. Nevertheless, the travel oil motors must be supplied with hydraulic oil in every position in which the superstructure is moved in regard to the undercarriage. Oil is directed by the control blocks to the ports (A-D) of the housing (1). The oil flows to the outlet ports (A-D), of the rotor (2), via ring grooves as well as longitudinal and cross holes. The rotor is bolted to the under carriage. The sealing of the ring grooves among one another is done by sealing elements (6/7). The hydraulic connection for return, case drain, house brake and the track tensioning cylinders is done via the ports (K1/K2), (L), (St) and (St). The entering of dirt gets blocked by the half disks (9) and the collar of mover (3) (Principe of labyrinth sealing). Both areas are connected via grease nipple (20) to the central lubrication system which causes an additional sealing. The rotor (2) is at the top and bottom section guided in the housing by the guide rings (8).

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Section 8.3 Page 6

8.3.4 Travel gear The travel gear consists of one spur gear set and two planetary stages. The travel gearbox is fitted to the side frame with bolts. Legend for illustration (Z 21388): (22) ** Motor drive housing with house brake (9 / 10) Spur gear stage (15) Drive shaft to 1. planetary gear (7) 1. Planetary gear (8) Internal geared double wheel for the first planetary gear (12) Drive shaft to 2. planetary gear (4) Bearing ring (6) Bearing ring (2) 2. Planetary gear (3) Internal geared double wheel for the second planetary gear ** For more information see picture on next page Function: The spur gear (9/10) is driven by two hydraulic motors via the input drive shafts (11, see illustration Z21389 on the following page). The 1. planetary gear (7) is driven by the shaft (15) which is connected to the spur gear. The planetary gear supports themselves in the internal geared wheel (8) which causes that the 2. planetary gear (2) is driven by the shaft (12). The sprocket drive shaft is driven via the splines of the planetary carrier (2).

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Section 8.3 Page 7

8.3.5 Travel parking brake (Gear house brake) The Spring Loaded Multi-disk Brake is a safety brake; applied by spring force and released by oil pressure. Legend for illustration (Z 21389) (1) Drive shaft (90) Springs (18) Disk carrier (91) Piston (27) Intermediate ring (92) Quad-Rings (29) Inspection cover (93) Oil pressure port (39) Ball bearing (94) Oil level plug (43) Radial seal ring (95) Oil drain plug (44, 47,+58) O-Ring (96) Housing (50) Cover bolts (97) Oil filler plug * (57) Brake fitting bolts (98) Thrust washer (53+74) Seeger clip ring (99) Inner and outer disks (83 + 82) Bolt and lock washer (100) Retainer * The brake must be released for oil change! Function: Brake applied: The outer disks (99) engaged to the housing (96) by serration and the inner disks (99) in serration connection with the drive shaft (11) are pressed together by the springs (90). This results in a fixed connection between housing (96) and shaft (11). Brake released: Oil pressure via port (93) reaches the bottom of the piston (91) and forces the piston against the retainer (100). This function eliminates the spring force onto the disks thus the brake is released. The releasing pressure is 21 - 23 bar, the maximum permissible pressure 50 bar. This is a so named "Wet Brake" because the brake housing is filled with gear oil. The oil must be filled in after removing the filler plug (97) up to the edge of the level control plug (94) thread.

)

• For more information refer to the OPERATION AND MAINTENANCE MANUAL, PARTS BOOK and REPAIR MANUAL of the corresponding machine.

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Section 8.3 Page 8

8.3.6 Travel Brake Valve Illustration Z 21695 Task: Travel brake valves control the oil flow from the hydraulic motor to the tank depending on operating pressure. This braking action prevents the motors from over speeding. Function: Spring force keeps the spool in the lowest flow position. with increasing operating pressure the opening for the return oil flow becomes larger. On its way to the hydraulic motor the oil flows from A to A1 respectively from B to B1 depending on the selected travel motion. Example: Operating pressure at port A moves spool (1) against the force of the spring (2) and opens the way for the return oil (B1 to B). Check valve (3) prevents a direct oil flow from B1 to B. If the operating pressure decreases to such an extend that the spring force overcomes the pressure, the flow to the tank becomes restricted, resulting in braking of the machine.

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Section 8.3 Page 9

8.3.7 Electric / Hydraulic flowchart “ Traveling forward ” Legend for illustration (Z 22715a): (E21a) Foot pedal left crawler (E21b) Foot pedal right crawler (+10V) Signal voltage (Maximum) (rs) Colour code of signal voltage cable ( footpedal) (X2...) Terminal rail with number (E51) Ramp time module (E52) Ramp time module (A12) Amplifier module – left crawler (A13) Amplifier module – right crawler (K177) Relay – Controlled by cable drum switches 5S6 and 5S7. Contacts 5/9 and 6/10 closed in normal operating condition. (102.1 + 102.3) Remote control valves (Y20 + Y28) Proportional solenoid valve (Y20B + Y28B) Directional solenoid valve (I + III) Main control blocks (59) Rotary distributor (22.1 – 22.4) Hydraulic motors (29.2 + 29.3) Manifold (39.1 – 39.2) Travel brake valves Electrical signal flow. [ ] Signal voltage of foot pedals (E21a + E21b) arrives via ramp time module (E51 + E52) at terminal 5 of the amplifier modules (A12 and A13) and further to the proportional and directional solenoid valves of the remote control blocks (102.1 and 102.3). The directional solenoid valves Y20B and Y28B are only deactivated with open contacts of relay K177 i.e. the power supply cable is to tight (5S6) or the safety winding is used (5S7), which results in interruption of forward traveling. Hydraulic signal flow. (pilot pressure) [ ] When the proportional and directional solenoid valves are energized pilot pressure oil flows to the caps at the main control blocks. (I + III) Hydraulic oil flow. [ ] Now the oil of the main pumps flows through the main control blocks (I + III) and arrives via Rotary distributor (59) and travel brake valves (39.1 – 39.2) at the hydraulic travel motors.

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Section 8.3 Page 10

8.3.8 Electric / Hydraulic flowchart “ Traveling backward ” Legend for illustration (Z 22716a): (E21a) Foot pedal left crawler (E21b) Foot pedal right crawler (-10V) Signal voltage (Maximum) (rs) Colour code of signal voltage cable ( footpedal) (X2...) Terminal rail with number (E51) Ramp time module (E52) Ramp time module (A12) Amplifier module – left crawler (A13) Amplifier module – right crawler (K178) Relay – Controlled by cable drum switches 5S6 and 5S4. Contacts 5/9 and 6/10 closed in normal operating condition. (K179) Relay – Controlled by cable drum switches 5S8. Contacts 5/9 closed in normal operating condition. (K180) Relay – Controlled by cable drum switches 5S9. Contacts 6/10 closed in normal operating condition. (102.1 + 102.3) Remote control valves (Y20 + Y28) Proportional solenoid valve (Y20A + Y28A) Directional solenoid valve (I + III) Main control blocks (59) Rotary distributor (22.1 – 22.4) Hydraulic motors (29.2 + 29.3) Manifold (39.1 – 39.2) Travel brake valves Electrical signal flow. [ ] Signal voltage of foot pedals (E21a + E21b) arrives via ramp time module (E51 + E52) at terminal 5 of the amplifier modules (A12 and A13) and further to the proportional and directional solenoid valves of the remote control blocks (102.1 and 102.3). The directional solenoid valves Y20A and Y28A are deactivated with open contacts of relay K178 i.e. the power supply cable is to slack (5S6) or the cable drum is full (5S4), which results in interruption of backward traveling. Y20A is also deactivated with open contacts of relay K179 i.e. to strong deflection to the left (5S8), => interruption of backward traveling the L.H. crawler only. Y28A is also deactivated with open contacts of relay K180 i.e. to strong deflection to the right (5S9), => interruption of backward traveling the R.H. crawler only. Hydraulic signal flow. (pilot pressure) [ ] When the proportional and directional solenoid valves are energized pilot pressure oil flows to the caps at the main control blocks. (I + III) Hydraulic oil flow. [ ] Now the oil of the main pumps flows through the main control blocks (I + III) and arrives via Rotary distributor (59) and travel brake valves (39.1 – 39.2) at the hydraulic travel motors. PC8000-6-E_Sec_8-3_#12048_rev0.doc

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Section 8.3 Page 11

8.3.9 Checks and adjustments for the travel circuit Legend for illustration (Z 22752a): (1) Protective cap (59) Rotary distributor (2) Locknut (32.1 + 32.2) Anti cavitation valves L.H. (3) Set screw (32.9 + 32.10) Anti cavitation valves R.H (127) Main control block I (39.1 + 39.2) Travel brake valves (129) Main control block III (M11.. – M31..) Pressure check points Pressure check of the Service Line Relief Valves (SRV) 1. Connect pressure gauge to the required check points : L.H. track M11.2 = Operating pressure for the L.H.-motors M31.1 = SRV- pressure L.H.-travel forward M31.2 = SRV- pressure L.H.-travel backward

R.H. track M11.3 = Operating pressure for the R.H.-motors M31.3 = SRV- pressure R.H.-travel forward M31.4 = SRV- pressure R.H.-travel backward

2. Unplug solenoid valve Y16 (located at the central control and filter panel) to keep the parking brake applied. 3. Start both motors. 4. Engage carefully the desired travel motion and keep the pedal in final position to built up max. pressure. 5. Increase slowly the MRV-pressure while observing the pressure gauge. Gauge value must remain at 310bar + 5bar. If the gauge shows a smaller or greater value the SRV must be adjusted

)

• A faulty Anti-cavitation Valve (32.1 + 32.2, 32.9 + 32.10) or a leaking seal of the rotary joint (59) can influence the SRV pressure reading / setting. Repair or replace faulty parts if necessary

Adjusting the SRV’s : + 1. Set MRV’s to 320 bar 10 bar (using an attachment cylinder function) 2. Engage carefully the desired travel motion and keep the pedal in final position to built up max. pressure. 3. Lower the pressure at the required SRV to 290 bar and then increase up to the required pressure of 310bar. Proceed with next valves in the same manner. + 4. Re-set MRV’s to 310 bar 5 bar (using an attachment cylinder function) and re-plug the solenoid valve Y16. How to adjust MRV’s and SRV’s: a) Remove protective cap (1) and loosen lock nut (2). b) Adjust pressure with set screw (3). c) Secure adjustment by tightening lock nut (2) and replace cap (1). d) Re-check pressure setting.

)

• It is important that the complete MRV-valve and SRV-valve is firmly (with 300 Nm) tightened. Otherwise, internal leaks could occur which result in: problems of correct adjustment, loud flow noises and high temperatures.

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Section 8.3 Page 12

8.3.10 Function check for the travel parking brake Legend for illustration (Z 22755): (252.1) Pressure reducing valve (B48) Pressure switch (E35) Text display

(M1.2) Pressure check point (M9) Pressure check point (Y16) Solenoid valve

Parking Brake Release Pressure. (House Brake Pressure) 1. Connect gauge to check point (M1.2). 2. Start both motors and read the pressure. Required = 45 ±3 bar. If not, the X-2 pilot pressure adjustment must be corrected. (refer to Section 5). 3. Disconnect plug connection from solenoid valve Y16, now the following message should appear: Travel gear house brake ON

4. Operate the travel pedals, the machine should not travel. • If the machine moves the parking brake must be repaired. 5. Reconnect plug connection to solenoid valve Y16, now the travel function must be possible again and the monitor returns to standard display.

)

• In case of malfunction check the electrical control system and the function of solenoid valve Y16.

Function Check of pressure switch B48 1. Connect pressure gauge to check point (M9). 2. Start the motors. Gauge must show normal pilot pressure X2 = 45 ±3 bar. 3. Set pilot pressure relief valve (252.1) to 22 bar. 4. Unplug and reconnect solenoid valve Y16 to allow pressure relieve from pilot pressure line to house brake. The text display must show “Travel gear house brake ON” 5. Increase the pilot pressure up to 26 bar. “ Travel gear house brake ON” must disappear. 6. Reset pilot pressure X2 to 45 ±3 bar.

)

• Pressure at B48 <24 bar => Brake applied (ON) • Pressure at B48 >24 bar => Brake released (OFF)

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Hydraulic Track Tensioning System Section 9.0 Page 1


Page Hydraulic Track Tensioning System General

2

9.1

Functional description

3+4

9.2


5

9.3

Tensioning Cylinder

6

9.4

Adjustments / Checks

7 + 8 + 9 + 10

9.5

Functional test

10

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9.0

General: Legend for illustration (Z 21398b): (21) Rotary distributor (joint). (ST) Supply line, pilot pressure from travel parking brake circuit (118.1) Supply line shut-off cock. "O" = open (118.2 + 118.3) Service shut-off cocks. "C" = closed (118.4) Main shut-off cocks. (119.1 + 119.2) Membrane accumulator, 1,3 liter (pre-charge pressure 31bar) (120.1 – 120.4) Bladder accumulator, 5 liter (pre-charge pressure 150bar) (121.1 + 121.2) Check valves (prevents feedback pressure to pilot pressure) (124.1 – 124.4) Track tensioning cylinders (125.1 + 125.2) Check valves (prevents a cross-over flow) (141) Pressure increasing valve.

*

The hydraulic track tensioning system ensures automatically the correct track tension. The pilot pressure pumps (9.1 and 9.3) will supply oil to all four tensioning cylinders (124.1 – 124.4). The maximum pressure is limited by pressure increasing valves (141). The pressure in the tensioning cylinders transmits the required force to move the guide wheels to the front, until the correct track tension is obtained. External forces acting at the guide wheels will be absorbed through the pressure accumulators (119.1 + 119.2, first stage) and (120.1 – 120.4, second stage).

)

• For information about the preventative track inspection, refer to the Operation and Maintenance Manual.

Functional description on next page

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9.1

Functional description: Illustration Z 22756a and Z 22757a (on next page):

)

• Under normal operating condition shut-off cock (118.4) located on the valve block (140) in the car body is closed. The shut-off cock (118.1) located on the valve block (140) in the car body and (118.2 and 118.3) located inside the side frames are open.

The oil flow of the pilot pressure pumps (9.1 + 9.3), filtered by pressure filters (68.1 + 68.7) enters port "P" of solenoid valve Y16, via the common pilot pressure supply line (45 bar) of the central control and filter panel (36). If solenoid valve Y16 is actuated (i.e. pressure at sensor B48), the oil for the travel parking brake (reduced to 35 bar by the function of valve 147), flows via rotary joint (21), shut-off cock (118.1), the orifice, the two check valves (121.1 + 121.2) and the shut-off cocks (118.2 + 118.3) the into the tensioning cylinders (124.1 – 124.4). The resulting force moves the guide wheels toward the front, until the correct track tension is obtained. Simultaneously the system is via check valves (125.1 + 125.2) connected to the pressure increasing valve (141). External forces acting at the guide wheels will be absorbed through the pressure accumulators (119.1 + 119.2, first stage) and (120.1 – 120.4, second stage). Purpose of the pressure increasing valve The two system pressures • 35 bar with engine stopped • 310 bar with engine running are controlled by the pressure increasing valve as follows. With stopped motor and switched off ignition there is no pilot pressure (L39) at pressure increasing valve (141) and only the lowest adjusted pressure of 35 bar remains in the system. As soon as the motor has been started, the pilot pressure acts on the pressure increasing valve. As a result the system pressure can rise to the adjusted pressure of 310 bar. continued

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9.1

Functional description: Cont'd.: Illustration (Z 22757a): Cushioning Function When the tensioning cylinders (124.1 – 124.4) are moved in by external forces, the none return valves (121.1 + 121.2) will be closed. A certain amount from the displaced oil of the tensioning cylinders is taken up by the pressure accumulators. First stage:

at a pressure higher than 31 bar, oil is taken up by the side frame accumulators (119.1 + 119.2).

Second stage: at a pressure higher than 150 bar, oil is taken up by the center section accumulators (120.1 – 120.4). The system pressure can rise up to 310 bar pressure increasing valve (141) setting. With reduction of external forces, the oil is pushed back by the accumulator pressure into the tensioning cylinders. If the displaced oil volume was higher than the accumulators could take up, oil is added from the pilot pressure circuit, as soon as the pressure in the lines to the tensioning cylinder is lower than 35 bar. To avoid serious damages to the pilot pressure system in case of a faulty check valve, pressure relief valve (257.1) with a 55 bar setting is installed.

)

• For information about the preventative track inspection, refer to the Operation and Maintenance Manual. • To check the accumulator charging pressure refer to PARTS & SERVICE NEWS “AH01531a” latest edition.

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9.2


)

• The pressure increasing valve is a remote controlled pressure relief valve.

Legend for illustration (Z 21846): (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11+12) (13+14)

Pilot valve with valve seat Valve poppet Compression spring Main valve with sleeve Main piston Closing spring Set screw - low pressure 35 bar Set screw - high pressure 310bar Piston Pin Jet bore Lock nut

Function: The valve poppet (2) is connected via the jet bores (11) and (12) with the P port. If static pressure increases above the set pressure value, the valve poppet (2) opens and allows oil to flow freely to tank (T1). This oil generates a pressure drop in the spring chamber of the main spool, the closing force of the spring (6) is cancelled, and the main piston (5) opens to allow the pump flow to flow to tank (T2). Damped opening and closing is obtained by the throttled volumetric change. By applying external pressure of Pst max = 60 bar to the main spool (9) via port X, the pre-tensioning of the pressure spring (3) is increased by the amount of the piston stroke "S" and system pressure is increased correspondingly. The setting is fixed by means of the setting screw (7) and lock nut (13); 1 turn of the screw ~ 150 bar.

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9.3

Tensioning cylinder: Legend for illustration (Z 21929a): (1)

Cylinder tube

(2)

Piston

(3)

Piston guide ring

(4)

Piston guide strap

(5)

Seal ring (light)

(6)

O-ring

(7)

Scraper

(8)

Retracting device

(9)

Seal ring (dark)

(M) Bleeder port (P)

ã

Oil supply

• Maximum permissible piston stroke 360mm! During bench test an external stroke limitation must be used!

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9.4

Adjustments / Checks Legend for illustration (Z 22758a): (1+3+5) Lock nut (2+4+6) Set screw (147) Pressure reducing valve – Track tensioning system (35 bar) (252.1) Pressure reducing valve for pilot pressure X2 (45bar) (252.2) Pressure relief valve for pump support pressure X4 (60bar) (257.1) Pressure relief valve – Safety valve for Travel brake / Track tensioning system (55 bar) (M1.1) Check point – X4 pressure (60 bar) (M1.2) Check point – X2 pressure (45 bar) (M9.1) Check point – Travel parking brake / Track tensioning safety pressure (55 bar) (M9.2) Check point – Track tensioning operating pressure (35 bar) (Y16) Solenoid valve travel parking brake Checking / Setting the 55 bar pressure relief valve (257.1) – safety valve 1. Connect pressure gauges to check point M1.1 + M1.2 + M9.1 2. Start the both motors. 3. Check the X4-pressure at M1.1, required 60 bar. If necessary correct the setting by the function of valve 252.1 as follow: a) Loosen lock nut (1). b) Set pressure with set screw (2). c) Tighten lock nut (1). 4. Unplug solenoid valve Y16. 5. Increase the pilot pressure X2 by the function of valve 252.2 to ~ 60 bar. a) Loosen lock nut (3). b) Set pressure with set screw (4). c) Tighten lock nut (3). 6. Check the Safety-pressure at M9.1, required 55bar. If necessary correct the setting by the function of valve 257.1 as follow: a) Loosen lock nut (5). b) Set pressure with set screw (6). c) Tighten lock nut (5). 7. Re-connect solenoid valve Y16. 8. Re-set the X2-pressure to 45 bar by the function of valve 252.2 Checking / Setting the 35 bar pressure reducing valve (147) – supply pressure 1. Connect a pressure gauge to check point M9.2. 2. Start the both motors. 3. Read pressure, required = 35+2 bar If readjustment is required proceed as follow a) remove dust cap (a) and loosen lock nut (b). b) Set pressure with set screw (c). c) Tighten lock nut (b) and re-install cap (a). continued

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9.4

Adjustments / Checks Cont'd.: Legend for illustration (Z 22759a): (1) Piston (2) Lock nut (3) Set screw - high pressure 310bar (4) Lock nut (5) Set screw - low pressure 35 bar (P) Plug (X) Pilot pressure port (141) (118.1) (118.3) (118.4) (119.2) (120.3 / .4) (124.3 / .4) (M11.5) (M29.2) (M29.4) (MRV)

Pressure increasing valve Service shut-off cock – supply line Service shut-off cock in the side frame (or the L.H.-side) Main shut-off cock Membrane accumulator 31 bar Bladder accumulators 150 bar Track tensioning cylinders Pressure check point (Main control block IV) pump 5 Pressure check point at the track tensioning cylinders L.H.-side Pressure check point at the bladder accumulators L.H.-side Main relief valve – Operating pressure of main control block IV

Checking / Setting the pressure increasing valve Pre-conditions: Correct MRV, SRV and pilot pressure setting and the system must be free of air. The description is only for the R.H. track. The same procedure applies also for the L.H. side. Basic Adjustment: 1. Connect a pressure gauge to check point M11.5 2. Start the motors. 3. Increase the MRV-setting (Block IV), to ~ 330 to 340 bar. 4. Switch OFF the motors, open cock valve (118.4) to allow pressure relieve of track cylinders, and close it again.

continued

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9.4

Adjustments / Checks Cont'd.: 5. 6. 7. 8.

9. 10.

W

Move the pressure gauge from M11.5 to M29.4 Connect pressure check point M11.5 with pressure check point M29.2, using a long pressure gauge hose. (required for the oil supply) Disconnect the pilot pressure line at port X of the pressure increasing valve (141) and close the hose with a plug (P). Loosen lock nut (4) of the pressure increasing valve and screw in set sleeve (5) until piston (1) comes to stop. (substitution of 35bar pilot pressure) Start the motors Stall the hydraulic with the clam opening function (clam cylinders completely retracted) and observe pressure at check point M29.4. A pressure of 310 + 5 bar must reached within a time period of 10 – 15 minutes and must remain at this value. The maximum pressure will be shown only after the accumulators are completely filled with oil. When the pressure reaches the pre-charge gas pressure ( 31 bar and 150 bar) the gauge pointer moves slower depending on the gas compression.

If the gauge shows a lower or higher value the pressure increasing valve must be adjusted. Setting procedure, high pressure stage (Valve 141) a) Loosen lock nut (2). b) Adjust pressure with set screw (3). c) Secure adjustment by tightening lock nut (2). d) Re-check pressure setting. 11.

The low pressure setting of the pressure increasing valve must now be reset (with the pilot pressure line at port X still disconnected): Setting procedure, low pressure stage (Valve 141) a) Stall the hydraulic with the clam opening function (clam cylinders completely retracted) and observe pressure at check point M29.4. b) loosen lock nut (4) and turn set screw (5) ccw until gauge at check-point M29.8 shows 35 bar. c) Tighten lock nut (4). d) Re-check pressure setting. continued

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9.4

Adjustments / Checks Cont'd.: 12. 13.

Switch OFF the motors and open cock (118.4) to allow pressure relieve. Re-connect the pilot pressure line to port X of the pressure increasing valve (141). Remove the pressure gauge hose between pressure check point M11.5 and pressure check point M29.2. Close the cock (118.4). Re-set MRV (Block IV)to 310 + 5 bar after the check / adjustment is finished.

13. 15. 16.

9.5

Functional Test After all adjustments are finished, do the following: a) Bleed all air from the system b) Place shutoff and pressure relief cocks into correct operating position. c) Connect pressure gauge to check point (M29.4). d) Start motors. e) Travel approx. 10 m with the shovel. f) Stop the motors. g) The pressure must drop to 35 bar. If the pressure remains the at a higher or lower pressure*, re-adjust the low pressure setting at the pressure increasing valve (141).

)

*

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The pressure may drop below 35 bar after a longer time, this is o.k. because of internal leakage.

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Access ladder hydraulically operated

Section 10.0 Page 1


Page Access ladder hydraulically operated 10.0 General

2

10.1

Function of hydraulically operated access ladder

3+4

10.2

Adjustments / Checks

5

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Section 10.0 Page 2

10.0 Access ladder hydraulically operated General Legend for illustration Z22813a (A) Access ladder in lowered position (B) Access ladder in upper position (Working position) (C) Stop bar (D) Inner pivot bracket of the access ladder (E) Pull chain for emergency lowering of the access ladder (Z) Hydraulic cylinder (36) Central control and filter panel (S84) Ladder control switch for lowering the Ladder (S84B) Ladder control switch for lifting the Ladder (S84A) Safety switch for emergency lowering of the access ladder. When the chain (E) is being pulled down with the motor running the pilot control system is made inoperative preventing further movement of the shovel. (S22) Safety sensor, located on ladder pivot bracket Function of sensor (S22): Cut out of the pilot control system and actuation of the hydraulic swing brake with the ladder in lowered position. (S91) Monitor and control sensor Function of sensor (S91): This sensor monitors the ladder position and controls the moving speed of the ladder. In case the sensor (S22) fails to function properly, the sensor (S91) prevents unintended movement of the ladder.

The access ladder is hydraulically operated by the hydraulic cylinder (Z) with the pilot pressure X4 of 60 bar. The movement of the ladder is controlled by the function of switch: S84: => Lowering the ladder S84B => Lifting the ladder Lifting the ladder is only possible with the motor running. The lowering movement is possible by hydraulic force with the motor running or by the force of gravity with the motor at stand sill.

)

If the ladder is not in the final upper position the pilot control is switched off and solenoid valve Y120 activates the hydraulic swing brake. The display in the operators cab shows a message.

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Section 10 Page 3

10.1 Function of hydraulically operated access ladder Legend for illustration Z22814 (2 + 6) Main pumps (9.1 + 9.3) Pilot pumps (36) Central control and filter panel (68.1 + 68.7) Filter with filter monitoring switch B22-1 / B22-2 (157) Solenoid valve Y123a/b (252.1) Pressure relieve valve (45 bar) – X2-pressure (252.2) Pressure reducing valve (60 bar) – X4-pressure (252.3 + 252.4) Check valves (258.1) Solenoid valve Y125 (258.3) Pressure relieve valve (safety valve 70 bar) (258.4) Shuttle valve (258.5 + 258.6) Check valves (258.7) Orifice Y125 Solenoid valve: lowering speed control (OFF => reduced speed) Y123A Solenoid valve: ON => ladder up Y123B Solenoid valve: ON => ladder down Prime drive is running Study together with illustration Z22814 and the electric diagram on the next page. The pumps (9.1 + 9.3) are delivering the oil through the filters (68.1 + 68.7) and via check valves (252.3 + 252.4) to port A of pressure relief valve (252.2). The pressure relief valve (252.2) maintains the adjusted pressure of 60 bar, called „X4“-pressure. The „X4“-pressure passes check valve 258.6 and is present at port P of solenoid valve Y123A/B. If solenoid valve Y123 A or B is energized the oil flows to the cylinder and the ladder will move up or down. By the function of shuttle valve (258.4) both service lines are connected to safety valve (258.3), which limits the pressure to 70 bar. Return oil from cylinder (137) flows back via solenoid valve Y123A/B to solenoid valve Y125. Y125 = ON => Maximum cylinder speed, return oil flow not restricted when both proximity switches S22 and S91 are not activated (ladder between top and bottom end position) Y125 = OFF => Reduced cylinder speed, return oil flow is restricted by orifice (258.7) when one of the proximity switches S22 (ladder up) or S91 (ladder down) is activated i.e. cushioning function just before the final upper or lower end position is reached. If the ladder is in the “top – position” the activated sensor S22 de-energizes Y125 and energizes Y123A, with the result that the cylinder of the ladder is always charged with pressure in this position. If switch S84 is in neutral position and the ladder in “ bottom – position” sensor S91 de-energise all solenoids (Y125; Y123 A+B) and the ladder is “blocked”. continued PC8000-6-E_Sec_10-0_#12048_rev0.doc

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Section 10.0 Page 4

10.1 Function of hydraulically operated access ladder Cont'd: Prime drive is not running and the ladder is in the “final upper position” With switch S84 activated in position 2 (ladder down) solenoid valve Y123B and relay K132 are active. Y123B connects the piston side of the cylinder to the return line and K132 activates Y125, so that the oil can return without resistance to the tank. Now the ladder can move down only by its own mass (due to the force of gravity). The operator has to push the ladder slightly until it starts moving down by its own weight. The rod site of the cylinder receives oil via anti-cavitation valve (258.5). It is not necessary to activate the key switch, because the involved components are directly battery supplied via fuse F17. There is an additional pull switch S84A below the ladder support. With this switch activated the ladder can moved down from the ground. • Make sure that there are no obstacles in the moving range of the ladder. Stop raising the ladder by releasing the control switch (S84) if there are any obstacles in the moving range. • Mount the ladder only in completely lowered position. • Do not lift persons or objects (tools) with the hydraulic access ladder. Serious injury or death could occur.

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9

Section 10.0 Page 5

10.2 Adjustments / Checks Legend for illustration Z22815a (1 + 3) Lock nut (2 + 4) Set screw (252.2) Pressure relieve valve (60 bar) – X4-pressure (258.3) Pressure relieve valve (safety valve 70 bar) (A) Access ladder in lowered position (B) Access ladder in upper position (Working position) (C) Stop bar (D) Inner pivot bracket of the access ladder (E) Pull chain for emergency lowering of the access ladder (36) Central control and filter panel (S84) Ladder control switch for lowering the Ladder (S84B) Ladder control switch for lifting the Ladder (S84A) Safety switch for emergency lowering of the access ladder. When the chain (E) is being pulled down with the motor running the pilot control system is made inoperative preventing further movement of the shovel. (S22) Safety sensor, located on ladder pivot bracket, Function of sensor (S22): Cut out of the pilot control system and actuation of the hydraulic swing brake with the ladder in lowered position. (S91) Monitor and control sensor, Function of sensor (S91): This sensor monitors the ladder position and controls the moving speed of the ladder. In case the sensor (S22) fails to function properly, the sensor (S91) prevents unintended movement of the ladder. Checking / Setting the 70 bar pressure relief valve (258.3) – safety valve 1. Connect pressure gauges to check point M1.1 and M37.1. 2. Start both motors. 3. Lift the ladder to the final upper (working) position, using switch (S84B) 4. Check the X4-pressure at M1.1 and M37.1, required 60 bar. 5. Increase slowly the X4-pressure, by turning in set screws (2) of pressure relieve valve (252.2), while observing the pressure gauges. Stop as soon the pressure does not raise any further. The gauge pointers should remain at 70 bar ± 2 bar. 6. If necessary correct the setting as follow: a) Turn set screw (2) of valve (252.2) a ½ turn further in, the gauge pointers will remain at the value shown under item #5 b) Set the pressure of 70 bar ± 2 bar with set screw (4) at valve (258.3). c) Tighten lock nut (3). 7. Reset valve (252.2) to 60 bar and tighten lock nut (1), adjustment is finished.

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Cable drum

Section 11.0 Page 1

Table of contents section 11.0 Section 11.0 Cable drum

Page

11.0

General

2

11.1

Components

3

11.2

Function 11.2.1 Controlling of the drive motor

4

11.2.2 Travel motion control

5

11.3

Checks and Adjustments

6

11.4

Description and operating instruction for cam switch 5S4 and 5S6

7

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Cable drum

Section 11.0 Page 2

11.0 Cable drum General Legend for Illustration Z 22831a (5M6) Brake motor (5S3) Rotation direction indicator (switch) (5R1) Resistor for brake motor torque adjustment (5S4) Gear type cam switch for resistor controlling and for monitoring of the two last cable windings. (5S6) Pendulum control cam switch, to detect slack or tight cable (5S8, 5S9) Proximity switch to detect cable deflection to right or left (5S10, 5S11) Proximity switch for ground contact protection.

)

Task: The cable drum, driven by a brake motor with slip ring rotor, is installed to wind up or unwind the power supply cable automatically. 1. To considerably improve the mobility of the excavator. 2. To make the operation safer (Material and personnel) i.e. less risk to damage the cable when travelling backwards and less danger of injury because the cable must not manual moved. 3. To increase the lifetime of the cable, because the cable is not dragging on the ground. For the optimal use of the cable drum it is necessary that the operator understands the system very well. Regular maintenance is essential

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Cable drum

Section 11.0 Page 3

11.1 Components Legend for Illustration Z 22832a (5M6) Brake motor (5S1) Service switch for manual actuation of cable drum. (5S3) Rotation direction indicator (switch) (5R1) Resistor for brake motor torque adjustment (5S4) Gear type cam switch for resistor controlling and for monitoring of the two last cable. (5S6) Pendulum control cam switch, to detect slack or tight cable. (5S8, 5S9) Proximity switch to detect cable deflection to right or left (5S10, 5S11) Proximity switch to detect ground contact (5K7, 5K8, 5K12, 5K13) Relay for brake motor direction controlling (5K10, 5K11) Relay for brake motor torque controlling (5F13) Circuit breakers (5B79) Brake motor temperature probe (F79) Motor temperature control unit (X8) Terminal box The resistor 5R1 serves as a series resistor for a three- phase motor with a slip ring rotor (stand still, sliding rotor-brake motor) It is a resistor with one or more taps (as a function of drum design), to make a selection of different star bridges possible. The taps serve to regulate the motor and brake torque during winding up and unwinding. With service switch 5S1 is it possible to control the cable drum manually in both directions (windup, unwind, stop and automatic) The terminal box X8 contains the terminal rails , the relays 5K7, 5K8, 5K10, 5K11, circuit breakers 5F13 + 5F14 and motor temperature control unit F79. Direction of rotation monitoring switch 5S3 opens its contact and de-energizes 5K10 and 5K11 while unwinding (traveling forward) and eliminates the resistor which controls the star bridge. (Lowest tensioning force) Gear type cam switch 5S4* reduces the tensioning as soon as half of the cable is unwinded (contact 21/22 opens and de-energizes 5K11) or stops reverse travelling as soon as the max. length of the cable is winded up (contact 31/32 opens and de-energizes K178). The proximity switch 5S8 stops L.H. crawler reverse travelling at too much deflection of the power supply cable to the left (contact br/sw opens and de-energizes K179). The proximity switch 5S9 stops R.H. crawler reverse travelling at too much deflection of the power supply cable to the right (contact br/sw opens and de-energizes K180). Pendulum control cam switch 5S6* stops forward travelling at too tight power supply cable (contact 11/12 opens and de-energizes K177) or reverse travelling at too much slack of power supply cable (contact 21/22 opens and de-energizes K178). The limit switch 5S7* stops forward travelling by de-energizing K177 as soon as the safety cable length on the drum gets unwinded. The motor temperature control unit F79 interrupts all travel motions as soon as drive motor 5M6 reaches a critical temperature (monitored by sensor 5B79).

*Refer to page 7 for adjustment procedure

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Cable drum

Section 11.0 Page 4

11.2 Function Legend for Illustration Z 22834a (5M6) Brake motor (5S3) Rotation direction indicator (switch) (5R1) Resistor for brake motor torque adjustment (5S4) Gear type cam switch for resistor controlling (5K7, 5K8) Relay for brake motor direction controlling (5K10, 5K11) Relay for brake motor torque controlling (5F13) Circuit breakers (F79) Motor temperature control unit (X2 + X8) Terminal board D53 Time relay at the X2 board 11.2.1 Controlling of the drive motor General: In the automatic mode of control switch 5S1, the power supply to drive motor 5M6 is controlled by the function of the travel control system, which controls relay 5K7, i.e. while traveling the contacts of 5K7 are closed and kept closed for further 10 seconds after stopping the travelling motion (controlled by time relay D53), before the power supply will be interrupted and the motor brake is active. The torque of drive motor 5M6 is controlled by the function of the relay 5K10 and 5K11; which changes the resistance at the star bridge (5R1). Both relay are simultaneously controlled by switch 5S3 (Direction of rotation monitoring switch), to ensure the lowest tensioning force while unwinding (i.e. traveling forward) Winding up (automatic mode of control switch 5S1): While winding up the NC-contact of switch 5S3 remains closed which allows voltage to the relay 5K10 and (if the contact 21/22 of switch 5S4 is closed) also to 5K11. Example travelling reverse: Cable length on drum: ½Max. – Max. => 5K10 ON + 5K11 ON => max. torque Cable length on drum: Min. – ½Max. => 5K10 ON + 5K11 OFF => reduced torque Unwinding (automatic mode of control switch 5S1): The NC-contact of switch 5S3 opens while traveling forward and de-energizes simultaneously 5K10 and 5K11, with the result that there is just enough torque to hold the cable tight.

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Section 11.0 Page 5

Cable drum

11.2 Function 11.2.2 Travel motion control, illustration Z 22835 General: The cable drum is equipped with safety switches for the protection of the power supply cable during travelling and turning operations. Movements which could damage the power cable are automatically switched off.

Cable condition

Monitored by

Travel shut off relay

Directional Solenoid valves

Travel response

K177

Y20b + Y28b

crawler left + crawler right

Switch / contacts 1. Too tight

5S6 / 11–12

forward motion stopped 2. Too slack

5S6 / 21–22

K178

Y20a + Y28a

crawler left + crawler right reverse motion stopped

3. Too strong deflection to the left

5S8 / br–sw

K179

Y20a

crawler left reverse motion stopped

4. Too strong deflection to the right

5S9 / br–sw

K180

Y28a

crawler right reverse motion stopped

5. Maximum permissible cable length on the drum

5S4 / 31–32

6. Safety cable winding unwinded

5S4 / 11–12

K178

Y20a + Y28a


K177

Y20b + Y28b

crawler left + crawler right forward motion stopped

7. Ground contact

5S10 and/or 5S11

K178

Y20a + Y28a


) )

If the reverse motion stopped because of a activated ground contact switch 5S10 or 5S11 it is possible to activate the reverse motion manually via activation of horn switch at the left control lever in the cab.

Refer to section 8.3 in this Manual for further information.

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Cable drum

Section 11.0 Page 6

11.3 Checks and Adjustments Legend for Illustration Z 22836a (5S3) Rotation direction indicator (switch) No adjustment required. Check the function of contact 2/P. The built-in switch must open while unwinding. (5S4)

Gear type cam switch for resistor controlling and safety switch to detect full cable drum and the last two safety cable windings. The contact 31/32 must open as soon as the maximum permissible cable length is on the drum, travel reverse will stop by deactivated relay K178. As soon as the last second winding comes up contact 11/12 opens and travel forward will stop by deactivated relay K177. Adjusting procedure see section 11.4 on next page and check the function under operating conditions.

(5S6)

Pendulum control cam switch, to detect slack or tight cable. Adjust the switch in such a way that contact 11/12 opens at too tight cable and contact 21/22 opens at too slack cable. Check the function under operating conditions. Make sure that the shock absorber at the pendulum will work in its permissible range. Adjusting procedure see section 11.4 on next page. (5S7)

(5S8, 5S9)

Proximity switch to detect cable deflection to right or left. Adjust the distance between switch and metal bar to 7mm. Check the function under operating conditions.

(F79)

Motor temperature control unit with monitoring LED’s. (R) – red LED on => motor temperature to high. (G) – green LED on => permissible temperature range. Hysteresis: Rcold ≤ 1kΩ, Rswitch point ≥ 3kΩ (Sensor between P1 and P2) Check the function with potentiometer.

(D53)

Time relay for power cut off after 10 seconds without travelling. Check adjustment, refer to service Bulletin 21-584 for more information.

(X2 + X8)

Terminal board

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11.0 7

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Cable drum

Section 11.0 Page 7

11.4 Description and operating instruction for cam switch 5S4 Legend for Illustration Z 22837 (1) Micro switch housing (2) Actuator (Roller lever) (3) Cam disc (4) Adjusting spanner (5) Cup spring (6) Tension nut The cam discs (3), arranged in pairs on the centering discs, can be adjusted individually and continuously by means of a adjusting spanner (4) The centering discs can be reversed and are fixed to the square shaft without clearance. Adjustment can be performed in any position without having to turn the control shaft. The cam discs, separated from each other by the guard plate, slide past each other without touching during adjustment. The cam ring next to the cam ring to be adjusted will not shift and remains in the set position. Hollow-type rivets prevent accidental shifting of the cam discs. By selecting the appropriate contact - either make or brake - any angle between 0° and 350° can be set without changing the cam rings. When the cam hits the actuator (2), the latter will operate the micro switch (1). Adjustment of the switch mechanism. 1. Loosen the tensioning nut (6) with the handle of the adjusting spanner (4). 2. Bring the adjusting spanner (4) in the position shown on illustration Z22837. 3. Set the cam discs (3) to the required position. 4. Adjust all other cam discs, following this procedure. 5. When all cam discs have been adjusted, tighten the tensioning nut.

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Hints for reading the Hydraulic Circuit Diagram

Section 12.0 Page 1


Page Hints for reading the hydraulic circuit diagram General 12.1

28.11.05

Symbols 12.1.1 Lines, unions 12.1.2 Components, valves 12.1.3 Sensors 12.1.4 Valves, valve components 12.1.5 Pumps, motors, cylinders 12.1.6 Assemblies and main components

2 5 5-6 7 8 9-12 13-14 15-16

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Section 12.0 Page 3

12.0 General: Legend for Illustration Z22987

) Item

• • • • • • • •

• • 28.11.05

• • •

The illustrations are used for exemplary explanations only. Use original circuit diagram for detailed reading There are more symbols on the following pages shown as in the diagrams drawn. Some symbols of the diagrams not shown in the following pages. Description

Number / Code

Explanation

A

Diagram No. and Type of the 897 895 40 a respective machine PC8000-E

Diagram No. only for the respective machine

B

Respective Serial No.

C

Sheet-No. / Quantity of sheets 01 / 04

1st of four sheets

D

Co-ordinates to describe the location of a component

Page 1 on co-ordinate C vertical and 10 horizontal Remote control valve 102.1

E

Component-No. 127

F

Line-No. with cross hint,

12041 1 C 10

127 L37/3B9

Main control block I Case drain line (Line No.37) comes from / goes to sheet 2 coordinate E7

All the components drawn in neutral and pressure less position. Full wide continues black line shows a main component or assembly. (Ex.: Valve and Filter panel, Main pump, Hydraulic tank, ...) Continues black line shows a main hydraulic line. This lines are temporary or continues load with high or pilot pressure. Broken line shows a return, drain or control oil line. Black dot shows a connection point. The position of this connection is not definitely fixed. White dot shows a connection or port of a component with a fix definitely position or port number. Page 1 shows the high pressure main hydraulic circuits with all pilot control valves, control blocks, distributor manifold and cylinders or motors. Page 2 shows all main pumps and pilot pressure pumps with the main pump control system and the other auxiliary pilot pressure circuits as lubrication system and ladder. Page 3 shows the main pump control arrangement, the auxiliary circuits with oil cooling system and the hydraulic tank. Page 4 shows the car body hydraulic with travel brakes, travel motors and track PC8000-6-E_Sec_12-0_#12048_rev0.doc

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Hints for reading the Hydraulic Circuit Diagram 12.1

Section 12.0 Page 5

Symbols Illustration Z 22988 12.1.1 Lines, unions Symbol

Description

Used as / at / on

1

Oil supply line, can be a hose or a pipe.

2

Return oil line, can be a hose or a pipe.

3

Case drain (leak) oil line, can be a hose or a pipe.

4

Control oil line, can be a hose or a pipe.

5

Crossed lines

Pipes or hoses not connected

6

Connection point, is a connection of hydraulic lines without definite position Component connection point, is a connection with a definite position at a component Plugged connection point, can be plugged with any kind of plugs.

Connection between several lines

Plugged line inside of a manifold, can be plugged with different kind of plugs.

Not used connection points.

7

8

9

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Suction line or pressurized line of main hydraulic circuit or pilot pressure circuit or auxiliary circuits (e.g. fan drive). Return lines, connected to the return oil filter chamber of the main oil reservoir. Return lines, connected to the case drain (leak) oil filter chamber of the main oil reservoir. Pilot control line, pump regulation line and parking brake control lines.

Connection to components like, valve blocks, tanks, pumps, ... Not used connection points.

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12.0 6 12.1

Symbols 12.1.1 Line, union Symbol

10

Description

Used as / at / on

Compensator, Compensate line length differences depend on vibration and temperature. Quick coupling, is a special union with integrated check valve

Oil tank outlet to the pumps

12

Blind, Orifice, not adjustable with orifice diameter in mm

e.g. Oil cooler inlet,

13

Pressure check point With a special quick coupling.

HP Filter, Fan valve block....at all important circuits

14

Distributor block

Connection of lines with the same destination e.g. return lines to tank

11

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Tank drain couplings, often removed lines (e.g. at grease systems with removable barrels).

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Section 12.0 Page 7

Symbols 12.1.2 Components, valves Symbol

Description

Used as / at / on

Accumulator, is filled with nitrogen gas with for the respective accumulator specified pressure Screen filter, the screen size is 1.0 mm

Input line to the remote control valves, return oil collecting tube, track tensioning system

17

Oil cooler,

Hydraulic oil cooler, PTO oil cooler

18

Breather filter,

On top of PTO or hydraulic tank

19

Spray nozzles, inside of a case for cooling and lubricating

Gearbox (PTO) cooling and lubricating system

15

16

Installed in suction lines to the pumps, oil tank outlet, return oil collecting tube

continued

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12.0 8 12.1

Symbols 12.1.3 Sensors Symbol

Description

Used as / at / on

20

Pressure switch / sensor Input = pressure Output = electrical signal analogue or digital

e.g. return / leak oil chamber (digital), high pressure filter (analogue)

21

Pressure switch Input = pressure Output = digital electrical The switch point is 24 bar

e.g. swing or travel detection PC3000,

22

Temperature sensor, Input = temperature Output = electric signal proportional to the temperature

e.g. hydraulic tank

23

Level sensor, Input = fluid level Output = electrical signal analogue or digital

Hydraulic tank, fuel tank

24

Chip sensor, Input = contaminate oil Output = electrical digital signal

Main pumps

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Section 12.0 Page 9

Symbols 12.1.4 Valves, valve components Symbol

Description

Used as / at / on

25

Manuel operated unit Lever

Valve in track tensioning system,

26

Electric / magnetic operated unit Solenoid

Solenoid valve

27

Pilot pressure controlled unit

Pressure relief valve, disc brake, ...

28

Spring, with fixed force

Solenoid valves,

29

Spring adjustable spring force is adjustable

Pressure relieve valves,....

30

Check valve In drawn pos.: from right to left free flow, from left to right blocked flow.

31

Check valve spring loaded Opened in flow direction only against spring force = pressure Double check valve, in drawn pos.: opened only from the left to the bottom or from the right to bottom

e.g. main pump outlet, swing brake valve block, anti cavitation valves at main control blocks or distribution manifold By pass of the return oil filter, by pass of secondary filter

32

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Swing brake control,

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12.0 10 12.1

Symbols

Symbol

33

12.1.4 Valves, valve components Description Used as / at / on Shut-off Valve with Gate valve between main oil monitoring switch, reservoir and suction tank the adjustable switch monitors the valve position

34

2/2 control valve manual operated, 2/2 cock valve

Track tensioning system

35

3/2 control valve manual operated, 3/2 cock valve

Change over valve from electronically pump regulation to emergency mode (hydraulically pump regulation)

36

4/2 directional control valve as solenoid valve 4/2 way solenoid valve, electrically controlled. Neutral position: P-A and B-T connected. Variable throttle valve hydraulically controlled pilot control port pressure less = maximum restriction 3/2 directional control solenoid valve, seat design = leak oil free 3/2 way solenoid valve, neutral = port P-A open 4/3 directional control solenoid valve 4/2 way solenoid valve, in neutral all ports closed External pilot controlled proportional floating valve

e.g. swing parking brake, travel parking brake, ladder controlling,,

37

38

39

40

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Travel brake valve, located in the car body

Service arm controlling

Ladder controlling, service arm controlling

PC 3000 and PC4000 with floating system

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Section 12.0 Page 11

Symbols 12.1.4 Valves and valve components Symbol

Description

Used as / at / on

41

Main control valve Standard control valve for “standard function” two directions of cylinder or In neutral position: motor. open pump flow (P-PU) and control port flushing (T – a, T – b), in position a or b closed circulation port (P- PU)

42

Main control valve “pressure less lowering” Neutral position: open pump flow (P-PU), control port flushing (T– a, T– b) Position b: closed circulation port (P-PU), normal function P – B and B - T, Position a: open circulation port P – PU, only port B – T connected Main control valve “floating function” Neutral position: open pump flow (P-PU), control port flushing (T– a, T– b), Position b: closed circulation port (P-PU), normal function P – B and B - T, Position a: open circulation port (P – PU) = A, B, T, P connected together via tank Pressure reducing valve, assembly Variable inlet pressure at port B and constant lower output pressure at port A, output pressure is adjustable.

43

44

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Control valve for pressure less lowering. Used to assist the floating function of boom and stick,

Control valve with floating function in position a, e.g. floating valve for boom or stick, .

Emergency mode pressure (X3-pressure), pilot oil pressure

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12.0 12 12.1

Symbols 12.1.4 Valves and valve components Symbol

Description

Used as / at / on

45

Pressure relief valve, direct controlled and adjustable

e.g. ladder controlling, service arm controlling ..

46

Pressure relief valve with anti cavitation valve (check valve) Assembly, external drain at port Y

Secondary relieve valve at main control blocks

47

Pressure increasing valve pressure relieve valve with variable setting, pilot pressure controlled via port X. Low pilot pressure = low relieve pressure

Swing brake block, track tensioning system.

48

Proportional pressure valve, reduce the pressure in port A proportional to the solenoid current. 4 port proportional pressure relief valve, direct operated by a proportional solenoids.

Remote control valves to control the main control blocks,

50

Pressure relief valve, mechanical and hydraulically via pilot port X adjustable, oil drain port Y

Radiator and oil cooler fan drive

51

Throttle check valve with secondary relieve valve, throttle and secondary valve mechanical adjustable, external drain at port Y.

Distribution manifold normally in the line to the cylinder piston side.

49

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Pump regulation, only output port A is used for our systems

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Symbols 12.1.5 Pump, motor, cylinder Symbol

Description

Used as / at / on

52

Single acting Cylinder, pressurised moving only in one direction, return by external force

Track tensioning system

53

Double acting Cylinder, Cylinder in which the fluid pressure operates alternately in both directions (forward and backward strokes) A = Piston side B = Rod side

Attachment i.e. boom, stick, bucket or clam cylinder

54

Drive shaft of a motor or pump with one direction

Main pumps, swing motor, fan drive, travel drive

55

Hydraulic pump with fix volume per revolution suction port S and pressure outlet P

Fan pump, circulation pump, pilot pump, PTO lubrication pump

56

Hydraulic pump with variable output volume per revolution with external case drain

Main pumps

57

Hydraulic pump assembly with pump bearing lubrication, one direction and external case drain

Main pumps

A

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B

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12.0 14 12.1

Symbols 12.1.5 Pump, motor, cylinder Symbol

Description

Used as / at / on

58

Variable hydraulic pump with charge pump and external drive shaft bearing lubrication

Main pump

59

Hydraulic motor can be used in both direction, with external case drain L

Fan motor

60

Motor with disc brake disc brake is spring loaded it means: pressure less pilot line = maximal brake torque

Travel motor

61

Variable swing motor with integrated control valves and flushing valves

Swing motor PC5500

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Symbols 12.1.6 Assembly and main components Symbol

Description

Used as / at / on

62

Lubricant pump drive differential cylinder with integrated control valves to propel the grease pump

Lubricant pump station for central lubrication system and swing ring lubrication system

63

Swing brake valve assembly, act as a hydraulical back pressure system parallel to a motor with variable pressure setting and independent pressure side. Input port A or B and outlet on the opposite connection to the motor..

Swing brake system.

64

Rotary joint Upper part with connections drawn to the top, lower part with connections drawn to the bottom

Hydraulical connection between superstructure and car body

65

Travel brake valve block with secondary pressure relieve valve is connected in the line to the travel motors. The return oil flow is restricted according to the pressure inlet.

mounted in the supply line to the travel motors, is located in the car body

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12.0 16 12.1

Symbols 12.1.6 Assembly and main components Symbol

Description

Used as / at / on

66

Remote control lever to control the main control blocks

Control lever in the operators cabin

67

Remote control pedal to control the main control blocks

Control lever in the operators cabin

68

Hydraulic oil tank with leak and return oil filter, back pressure valve and sensors

Main hydraulic tank

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Hints for reading the Electric Circuit Diagram

Section 13.0 Page 1


Page Hints for reading the electric circuit diagram 13.1

Designation of electrical devices

2

13.2

Symbols

3+4

13.3

General information

5+6

13.4

Reading a circuit diagram

7+8


Section 13.0 Page 2

13.1 Designation of electrical devices Indicating letter A B

C D E F G H K L M N P Q R S T U V W X Y Z

Kind of component System, subassembly, parts group, trigger boxes, control units Transducer for conversion of non-electrical variables to electrical variables, and vice versa. Speed sensors, pressure sensors, pressure switches, oil-pressure switches, temperature sensors Condenser, capacitor, Condensers and capacitors, general Elements with time lag, memory elements, binary elements Various devices and equipment Protection device Fuses, current protection circuits Power supply, generator Batteries, generators, alternators Monitor, alarm, signaling device Indicator lights, signal lights, headlights, warning buzzers, horn Relay, contactors Inductor Coils, windings Motor Regulators, amplifiers Measuring instrument High voltage switching units Resistors, heating devices Switches, selectors Transformer Modulator, converter from one electrical in an other electrical value Semiconductor, electron tubes, diodes, rectifiers, zener diodes Transmission path, conductor, antenna Terminal, Plug, Plug and socket connection Electrically actuated mechanical device Solenoid-operated valves Compensating units, filters, limiters cable connection

13.0 3


Section 13.0 Page 3

13.2 Symbols Legend for illustration (Z 21816): Our common used symbols in accordance to VDE/IEC (Association of German Electrical Engineers DIN 40710 - 40716 and the International Electrical Commission) differ for the most part from the symbols in accordance to JIC/ASA (Joint Industrial Concil and American Standard Association) USA and Canada JIC EMP-1-1967 and ASA 2 32-3). For this reason the following comparative chart. 1) Normally open contact

2) Maintained contact

4) Normally closed contact

5)

7) Manual operated switch isolator, disconnect switch 10) NO contact with time lag

8) Foot-operated push-button switch 11) Multi-position switch selector

13) Contacts with time lag

14) Resistor general

16) Battery

17) Tapped resistor

18) Voltmeter

19) Inductive resistance

20) Continuously adjustable, general

21) Recording instrument

22) With iron core

23) Adjustable in steps

24) Signal lamps pilot lights

25) Continuously adjustable

26) Potentiometer rhesostat

27) Operating coil solenoid

28) Transformer

29) Capacitor general, continuously adjustable

30) Rectifier, semi conductor

Push-button switch

3) Single pole two way contact break before make 6) Limit switch NO contact NC contact 9) Pressure operated switch 12) Indicating instrument (general) symbol 15) Ammeter

13.0 4


Section 13.0 Page 4

13.2 Symbols Legend for illustration (Z 21817): 31) Rectifier bridge

32) Thermal over load limit

33) Phase, 4-wire system

34) Current transformer

35) Undervoltage relay

36) Junction of conductors

37) Voltage transformer

38) Temperature relay

39) Junction

40) Circuit interrupter

41) Contactor

42) Terminal

43) Circuit breaker, three phase

44) Generator (G)Motor (M)

45) Terminal

46) Thermal over- ground, load protection

47) 3-phase-motor

48) Earthing, general

49) Magnetic over- socket current protection

50) 3-phase squirrel cage

51) Plug and

52) Slipring motor

53) Fuse with bolted contacts 54) 3-phase squirrel cage induction motor in Star-delta starting 55) Thermal overload relay 55) Two speed motor (tapped windings) (for ex. 8 to 4 poles)

13.0 5


Section 13.0 Page 5

13.3 General information Legend for illustration (Z 21823): Komatsu circuit diagrams Each sheet has the following information in the bottom right hand corner: Diagram Number example: 897 844 40 Machine Type example: PC4000-6 Sheet Number and Total Number of sheets 01/63 - 02/ . etc. Each sheet is numbered from 8 (at the left corner) to 1 (at the right corner) along the top and bottom lines, and lettered down from F (at the top) to A (at the bottom) along the left and right side lines. This coordinate system enables you to find components easily. On the table of contents, page one, the individual circuits are listed up with the respective page number. Example: The circuit for the superstructure lighting is shown on page 39. Pages number two, three and four are cross reference lists of component codes related to page numbers. Example: The relay with the component code “K1-1” is shown on page 8. On page five is a list of answers to frequently asked questions (FAQ) concerning abbreviations, function of components (e.g. time relays) mathematical symbols etc. used in the diagram. All electrical components are connected via cable harnesses to the main switch board “X2”. There is only one Plug connector in between, which is always located close to the respective component like sensors, solenoids etc. All 24 volt wires are blue and have a printed code (every 10 cm) at each end of the wire. (see illustration) The first part of the code shows the required connection and the second part gives the information what is connected at the other side of the wire. Example: going to coming from coming from going to

X2S 45

= X2-Board, terminal group “S” = Terminal No 45

Y136 = Plug connector to solenoid .1 = Terminal 1 of connector

All circuits are shown currentless and all relays and switches are in neutral position.

13.0 6


Section 13.0 Page 6

13.3 General information Legend for illustration (Z 21824): Explanation of the Drawing Concept (1) (2) (3) (4) (5) (6) (7) (8)

Drawing number Sheet number / quantity of sheets Designation of drawing Designation of component or assembly Column (vertical sections) Lines (horizontal sections) Component symbol Neutral wire / machine ground

(9) (10) (11) (12) (13) (14) (15) (16)

Designation of phase Phase strip Terminal strip and terminal Cable plug and pin number Relay coil Relay contacts, partially with detailed information Cross reference for the continuation, Page / Column Indication where the relay contact opens or closes

Location of the Main Terminal Boxes (X1) Dashboard inside the cabin (X2) Main switch board inside the cab base (3E14-1) Electronic control module (ECM- Quantum) left bank of the engine (3E54-1) Electronic control module (ECM- Cense) flywheel end of the engine

13.0 7


Section 13.0 Page 7

13.4 Reading a Circuit Diagram. Legend for illustration (Z 21825): • Examples are shown by sectional drawings out of the electric circuit diagram 897 844 40 page 08.

) (1)

Section F8 / sheet 08 The hint F11/06.1 indicates that the wire from F11 is continued on sheet 06 column 1.

(2)

Section C4 / sheet 08 Shown is the relay coil K51-1 only and not its contacts. The contacts are shown somewhere else in the diagram. Switching and contact positions are shown below at the foot of that particular circuit in row C-C as shown below.

Example for K51-1: 08.5 : : :

1 5 2 6 3 7 4 8

9 10 11 12

opens on sheet 8 section 5 when relay is energized Not used Not used Not used

When diodes are fitted to a relay, they are fitted to allow a current flow in one direction only. An LED* (Light Emitting Diode) indicates a current flow if it lights up. When diodes ** are fitted anti-parallel to a relay coil, they absorb the high induced voltage caused by making and breaking the current flow through the coil. This occurs each time we operate a switch supplying current to the coil. The diode effect allows the induced current to circulate within the coil windings and decay when the energy to the coil is cut. * **

LED between A1 and coil Diode between A1 and A2.

(3)

Section F7 / sheet 08 Connectors and Terminals are identified by a letter and number code. X2 o 23-28 = Terminal box X2 Terminals 23 to 28 are linked with a metal bridge. continued

13.0 8


Section 13.0 Page 8

Cont.: 13.4 Reading a Circuit Diagram. Legend for illustration (Z 21826): (4)

Section E 1 sheet 08 The components have a letter and a number prefix, and these are explained below in rows A and B. Components are depicted in a system unique to VDE/IEC (Association of German Electrical Engineers DIN 40710-40716 and the International Electrical Commission) or to KMG standard. S27 = Toggle switch (with non-automatic return)

a.

F11

b.

F11 / 10.5 =

Power line F11, comes from circuit breaker F11, sheet 08 section 8 and continues on sheet 10 section 5.

c.

S27 / 20.7 =

Line S27, comes from switch S27, sheet 08 section 1 and continues on sheet 20 section 7.

=

Circuit breaker (24V power supply)

Function: If switch S27 is actuated, terminal A and B are connected and 24VDC will energize the coils of K121 and K121a on page 08 and simultaneously via line S27 a digital input to the PLC on sheet 20 section 7. Now the machine can be operated in emergency mode and a warning text appears on the display.

Electronic Control System ECS

Section 14.0 Page 1


Page Electronic Control System ECS 14.1

14.2

14.3

14.4

14.5

14.6

General Design of the ECS-T System

2

14.1.1 14.1.2 14.1.3 14.1.4

3 3 4 5 + 6 +7

Input and outputs of the PLC Task PLC DIGSY plus ® Definitions; Symbols and Abbreviations

How to Proceed due Maintenance and Installation

8+9

14.2.1 14.2.2 14.2.3

10 + 11 12 13

Meaning of the Status LED’s Short Circuit Marker -LED “MK” Diagnostic for Temperature-Module “ANM”

Front Connector Arrangement

14

14.3.1 14.3.2 14.3.3 14.3.4

14 + 15 16 + 17 18 19

Front Connector Arrangement BIM-Module Front Connector Arrangement, ANM-Module Ground connection of the Control Unit Interface-Connection COM SP /SK

Power supply

20

14.4.1 14.4.2 14.4.3 14.4.4 14.4.5

20 21 22 22 22

Operation Voltages +24 V Safety Precautions for Faultfinding CPU Voltage Range Electric Classification Fuse

Function explanations with electrical diagram

23

14.5.1 14.5.2 14.5.3 14.5.4

23 24 25 + 26 27

General Pressure Measuring Temperature Measuring Temperature – Resistance Chart PT100

Hints for reading the functional flow charts

28

14.6.1 14.6.2

28 29

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General Example

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Section 14.0 Page 2

14.1 General Design of the ECS System ECS

Electronic Control System

Legend: (1) (2) (3) (4) (5) (6) (7) (8) I/ O

)

•

Illust. Z 21407a

PLC Programmable Logic Control (DIGSY plus ®) Text display Keys for function control and pre-adjustments Outlet “X27” for data transfer Field computer system (like MODULAR MINING) Printer Memory card unit Laptop Input / Output data transfer Items 5 to 8 are optional equipment

Meaning of the PLC front cover codes • BIM Binary Module • ANM Analog Module • MK Short Circuit Memory • A Digital Output • E Digital Input • DIAG Diagnostic More in detail see page 4

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Electronic Control System ECS 14.1.1

Section 14.0 Page 3

Input and Output of the PLC, Illust. Z 21408 PLC = Programmable Logic Control (Programmable Logic Control = Control system with a write-readingmemory, whose content can be altered (via an serial interface) by a PC and the resp. Software. No mechanical action necessary.)

14.1.2

Task The PLC receives from the monitored excavator components the actual values and does an evaluation. The evaluation results in a control and display function. See I / O connection table (chapter 10) and electric circuit diagram for I / O levels and ports.

)

•

The picture shows as an example the application for a two motor version.

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Section 14.0 Page 4

PLC DIGSY plus ® (circuit diagram code E6) Legend for illustration Z 21409b 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Central Processing Unit (CPU) board. Binary Module (BIM) board. Analogues Module (ANM) board. MK Output short circuit marker LED red Input state-LED green, Inputs E1.1 - E1.8 up to E14.1-E14.8 Input or Output State-LED red (A2/ E9, Af/E10, A6/E11, A8/E12, A14/E21) Can be used as Inputs or Outputs Output state-LED red, Output A1.1 - A1.8 up to A13.1-E13.8 Diagnostic-LED (DIAG), (green flashing = OK.) 5Volt Voltage-LED (+5V), (green = OK.) Diagnostic LED for ANM COM SP Interface (COM SP) (Text display connection) COM SK Interface (COM SK) (PC-Connection) Binary Module BIM-plug-in location (slots) (X1-X5) Analog Module ANM-plug-in location (slots) (X6-X8) Ground Connection (GND)

)

• The quantity and configuration of the BIM and ANM Module can be vary, depend on the excavator type and additional options.

MK-LED, The short circuit marker are used to indicate an external short to GND • MK1, MK3, MK5, MK7 & MK9- LED for outputs A1.1 - A1.8 A3.1 - A3.8, A5.1 - A5.8, A7.1 - A7.8 & A13.1 – A13.8 • MK2, MK4 , MK6, MK8 and MK10 if there groups as outputs used • A MK-marker is placed, if an output (e.g. A1.1) gets from the program an output signal and at the same output happens an external short. The red MK 1-LED lights ON

)

• If there is a short all outputs of the resp. Output group i.e.. A1.1 - A1.8) are switched Off • The short circuit marker remains until the control system gets switched Off/ON (after eliminating the short).

State-LED Input lights up with a present 24 Volt signal. State-LED Output lights up with a switched On output. 5V-LED, indicate specified operation states by different colors and duration of lightning (Continuos On or flashing). DIAG-LED, indicate specified operation states by different colors and duration of lightning (Continuos On or flashing).

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Section 14.0 Page 5

Definitions; Symbols and Abbreviations

≡ ≠ Bit

Sign used for “corresponds to” Sign used for “not equal to” A bit is the smallest unit for information. It can assume only two conditions: logical 0 or logical 1 ( also referred to as logical L-Level and logical H-Level).

Boolean algebra Mathematical rules for binary variables and conditions. For Boolean equations the following signs are used: Logical AND operation (AND or &) ∧ Logical OR operation (OR or >=1) ∨ Logical Negation (NOT or 0) ¬ Byte

Unit for Information unit comprised of 8 bits. A byte can assume a value between 0 and 255.

Word

Memory unit comprised of 2 byte or 16 bit. A word covers the numeric range from –32767 to +32767.

Clock

Signal pulse

VWP

VerWaltungProgramm: (management program) A control program created by the user.

AWP

AnWender Program: (Application program, user program) A control program created by the user.

AWL

AnWeisungsListe: (instruction sequence) Representation of a program using alphanumeric signs and symbols as defined in DIN 19239. Programming in AWL (selection logic) is the at present widely applied method of programming.

CMOS

Complementary Metal-Oxide Semiconductor: Complementary metaloxide semiconductor technology with very low-level closed circuit current. These semiconductors are used above all for accumulator and battery buffering.

RAM

Random Access Memory: Read-write memory in which each memory cell can be addressed in order to read, write or delete at any time. RAM losses all of its information when the computer is turned off which is why it is often buffered by accumulators or batteries.

EPROM

Erasable Programmable Read Only Memory: Read-only memory erasable by ultraviolet light and electrically programmable. With this memory type, the contents remain intact in the event of a power failure. In the case of DIGSY plus ® this memory contains the management program (firmware). continued

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Section 14.0 Page 6


Cont'd: EEPROM

Electrically Erasable Programmable Read-Only Memory (also called E2PROM):Electrically erasable and programmable memory. In the event of a power failure, the contents of this type of memory remain intact. The DIGSY plus ® application program (AWP) is loaded into this type of memory.

COMPILER A program that translates the instructions of a programming language (e.g. instruction sequence [AWL]) into machine code (processor instructions). EDITOR

Utility program for the creation and changing of programs.

Loop

Program loop.

Off-Line

Operational method of a programming device without attached automation device.

On-Line

Operational method of a programming device (PC) is connected to the automation device thereby enabling data and programs to be read or changed.

PC

Personal Computer: Programmable unit for the DIGSY plus ®.

Watch-Dog: Internal supervisory unit in computers and automation devices used to recognize system and memory errors. CPU

Central Processing Unit: Control and central unit in an automation device usually based on a microprocessor. It can read the application program code and run the instructions contained therein.

Cycle Time

Time required for the application program to run through once. continued

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Section 14.0 Page 7


Cont'd: Coding Types and Number Systems ASCII

American Standard Code for Information Interchange: A standardized information processing code developed in the USA based on 7 bits = 0 – 127 (7-bit code), (extended ASCII-code of 8-bit = 0 - 255)

Digital

(Eng. Digit) is the representation of a continuos value or a physical quantity (e.g. voltage) in several levels as a numeric value. With regard to automation devices one also refers to “word processing” in which case a “word” is a number (e.g. 573).

Analogue

is the representation of a continuos physical quantity (e.g. current or voltage) which corresponds to the value of a proportional condition (e.g. rotational speed, routing, temperature, etc.) For an automation device this physical value converted into 1024 levels, for example (10-bit analogues-digital conversion). The digitalized value thus acts within a defined range (e.g. 0 ≡ 0 volts to 1024 ≡ 10 volts) in proportion to a certain input quantity (e.g. voltage). Conversely, by using a digital-analog conversion, a digitalized value can be converted into a continuous output signal (current, voltage).

Numeral

A value expressed in one digit: from 0 to 9 in the decimal system and 0-F in the hexadecimal system.

Number

Value consisting of one or more numeric characters.

Baud

Unit used in serial transmission of data: bits per second (bit/s).

Baud Rate

Modulation rate or transmission speed of serial transmission of binary numbers. The DIGSY plus uses a baud rate of 2400 baud for communication and down-loading.

Binary

Numbers, data and information which are exclusively expressed using the two values 0 and 1 are bivalent = binary dates and information, exclusive with the use of digits 0 and 1 (e.g. 1 = current 0 = no current).

Dual(Binary) Number (Dual = 2) is the simplest binary numeric expression. Each position is arranged according to increasing powers of 2. Example: 13463dec. = 0011 0100 1001 0111dual

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Electronic Control System ECS 14.2

Section 14.0 Page 8


Keep in mind • - BE CAREFUL • - BE ALERT • - THINK ABOUT WHAT YOU ARE DOING Any PERSON doing any work in or around the machine must be familiar with the local SAFETY INSTRUCTIONS and with the specific SAFETY INSTRUCTIONS REGARDING TO HIS OCCUPATION. • Serious damage may happen at unqualified actions at the System or Unit or when not paying attention to the hints given in this manual or on labels at the units Qualified persons in sense of the safety relevant hints in this manual or on the product, are persons which are • either as project engaged person familiar with the safety concept for automatic control systems; • or as operating personal for the use of an automatic control system being instructed; • or having the authorization and occupation to put such systems into operation or doing repair work as well as having the authorization and occupation to put such systems/units into operation regarding the power circuits and there safety standards and, to earth and to mark it. continued

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Electronic Control System ECS 14.2

Section 14.0 Page 9


Cont’d.: • Serious damage may happen at irrelevant opening and improper repair. Open always the resp. circuit breaker before opening a unit. I/O – cables may only be connect or disconnect in a powerless state. A BIM module will be damaged while supplying an external power of 24VDC to the inputs and/ or outputs. If it is necessary for faultfinding or external unit checks the connection to the PLC has to be interrupted. • Without power interruption the interface cable are only allowed to be disconnect or connect when following preconditions are given: 1. The cable must be shielded and the shield must be connected to the cover of the plug-in connector. 2. A potential balance must be made by connecting the GND potential parts of the plug connector parts before connecting the cables. • Replace the fuses only by fuses which matches the values given in the technical dates

ã

• Do not through batteries into open flame and do not solder at their cell body, explosion can occur (max. Temperature 100° C). Do not open and do not recharge batteries that contain lithium or mercury. Replace them by same type only! • Dispose batteries and accumulators as special waste.

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Meaning of the Status LED’s, Illust. Z 21431b The DIGSY plus performs by the function of the Status LED’s (5V and DIAG) and the so named Diagnostic Words* (DW1 up to DW256) many data and statuses. With a PC and the Program- and Diagnostic Software the. Diagnostic Words are visible on a monitor. The following sections explain the diagnostic possibilities more in detail. * Can be called-up by PC assistance only. Table: Statuses of the +5 V-LED and their meaning LED Effect Cause 5 V-LED Voltage green o.k. 5 V-LED CPU not working Supply red (RESET) < 4,65V DIAG-LED red 5 V-LED CPU not working Supply OFF (except the is missing LED is defect) Fuse S1 defect

Remedy Check the +24 V Supply if not o.k. *) Check the +24 Volt Replace the ** Fuse F1

LED defect (if DIAG LED is ON)

*)

others

*)

Watchdog in operation

*)

5 V-LED flashing red/green

cyclically new starts

red/ orange Continuos Reset Component fault *) ** Replacement only after co-ordination with Komatsu Mining Germany, Dept. 8124.1 *) = Return PLC to manufacturer continued

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14.2.1 Meaning of the Status LED’s, Illust. Z 21431b Cont’d.: Table: State of the DIAG-LED and their meaning LED Effect Cause DIAG-LED Program Communication via green in operation Interface COM-SP not active (interrupted) COM-SP<╪> Text display DIAG-LED ProgramTemperature orange state inside housing unchanged too high +24 VCPU < 14 V

Increase the voltage

Accumulator voltage too low

Replace the accumulator module

Fixed operands deleted

Check the accumulator connections

SPS in start loop after voltage ON

wait

programming in operation EEPROM not Initialized

Stop the programming *1) Initialize EEPROM *1)

EEPROM- or RAM- fault

Initialize EEPROM *1) if the fault is still present *2) Start program *1)

DIAG-LED RED

DIAG-LED OFF

Program not running (stopped)

Program not running (except LED defect)

Program stopped

No Program otherwise LED defect DIAG ProgramCommunication via flashing state Interface COM-SP or COM-SK active unchanged Color State COM-SP⇔ Text depending Display COM-SK⇔ (PC) *1) Function of the Programming Software PROSYD *2) = Return PLC to manufacturer

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Remedy Check the cable connection and the Interface port

External cooling

Load program *1) *2)

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Short Circuit Marker -LED “MK” The short circuit markers are used to indicate a short of the outputs at an external short to GND. A “MK” marker will be initialized if by the user-program an output signal is given and at the same output is an external short present. The “MK” marker remains until (after short elimination) the control system is switched OFF and ON. See also Section 14.1.3 page 4

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Diagnostic for Temperature-Module “ANM” For the function control a two-color LED is used, visible at the front cover. The diagnostic - LED indicates following states: - LED red: System in reset mode or range overflow of one or more analog outputs. - LED green:

Ordinary operation, no range overflow.

- LED red/green flashing (2Hz) Watch-dog timer response or cyclically overflow of one ore more analog outputs.

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14.3 Front Connector Arrangement 14.3.1

Front Connector Arrangement, BIM Module (Digital Input / Output)

)

• .This is an example for the first Slot. Additional BIM Modules can be vary depend on configuration of the variable input/output port A2/E9/ A4E10, A6/E11, A8/E12 or A14/E21. • The configuration for the respective excavator is written in the EA-Configuration chart (EA-Belegungsliste) see Appendix.

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Symbol Input 1.1 Input 1.2 Input 1.3 Input 1.4 Input 1.5 Input 1.6 Input 1.7 Input 1.8 Input 9.1 Input 9.2 Input 9.3 Input 9.4 Input 9.5 Input 9.6 Input 9.7 Input 9.8 0 V (GND) Input 2.2 Input 2.4 Input 2.6 Input 2.8

Operand E 1.1 E 1.2 E 1.3 E 1.4 E 1.5 E 1.6 E 1.7 E 1.8 E 9.1 E 9.2 E 9.3 E 9.4 E 9.5 E 9.6 E 9.7 E 9.8 E2.2 E2.4 E2.6 E2.8

Definition Input 1 of the input group. 1 Input 2 of the input group. 1 Input 3 of the input group 1 Input 4 of the input group 1 Input 5 of the input group 1 Input 6 of the input group 1 Input 7 of the input group 1 Input 8 of the input group 1 Input 1 of the output group 2 Input 2 of the output group 2 Input 3 of the output group 2 Input 4 of the output group 2 Input 5 of the output group 2 Input 6 of the output group 2 Input 7 of the output group 2 Input 8 of the output group 2 Ground Input 2 of the input group 2 Input 4 of the input group 2 Input 6 of the input group 2 Input 8 of the input group 2

continued

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Front Connector Arrangement, BIM Module (Digital Input / Output)

Cont’d.: Pin 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Symbol Output 1.1 Output 1.2 Output 1.3 Output 1.4 Output 1.5 Output 1.6 Output 1.7 Output 1.8 UE/A UE/A UE/A UCPU Input 2.1 Input 2.3 Input 2.5 Input 2.7 Output 1.1 Output 1.2 Output 1.3 Output1.4 Output1.5 Output 1.6 Output 1.7 Output 1.8 UE/A UE/A UE/A UCPU 0 V (GND)

Operand A 1.1 A 1.2 A 1.3 A 1.4 A 1.5 A 1.6 A 1.7 A1.8

E 2.1 E 2.3 E 2.5 E 2.7 A 1.1 A 1.2 A 1.3 A 1.4 A 1.5 A 1.6 A 1.7 A1.8

Definition Output 1 of the output group 1 Output 2 of the output group 1 Output 3 of the output group 1 Output 4 of the output group 1 Output 5 of the output group 1 Output 6 of the output group 1 Output 7 of the output group 1 Output 8 of the output group 1 Under Load Voltage Under Load Voltage Under Load Voltage DIGSY (plus)- Operation Voltage Input 1 of the input group 2 Input 3 of the input group 2 Input 5 of the input group 2 Input 7 of the input group 2 Output 1 of the output group 1 Output 2 of the output group 1 Output 3 of the output group 1 Output 4 of the output group 1 Output 5 of the output group 1 Output 6 of the output group 1 Output 7 of the output group 1 Output 8 of the output group 1 Under Load Voltage Under Load Voltage Under Load Voltage DIGSY (plus)- Operation Voltage. Ground / GND

UE/A = Voltage. Input / Output

There are two pins (two channels) parallel connected only for output A1.1 – A1.8 (the same for additional boards A3, A5, A7, A13). • • •

E1, E2,...E7, E13 and E14 input port fix configured. A2/E9, A4/E10, A6/E11, A8/E12 and A14/E21 variable input or output ports depend on software programming. A1/A9, A3/A10, A5/A11, A7/A12 and A13/A21 output ports fix configured.

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)

PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 •

Front Connector Arrangement, ANM-Module (Analogues Input) • .This is an example for the first ANM slot. Additional ANM modules configuration can be vary depend on configuration (temperature or pressure). • The configuration for the respective excavator is written in the EAConfiguration chart (EA-Belegungsliste) see Appendix and the respective electric diagram.

PIN-NAME KR KG KA GND/ANA GND/ANA GND/ANA GND/ANA A1I A1U A2I A2U A3I A3U A4I A4U A4G A3G A2G GND/ANA GND/ANA GND/ANA E8G E7G E6G E5G

OPERAND

AW Z.1 AW Z.1 AW Z.2 AW Z.2 AW Z.3 AW Z.3 AW Z.4 AW Z.4

COMMENTARY Relay contact Relay contact Relay contact Analog GND Analog GND Analog GND Analog GND Current output 1 Tension output 1 Current output 2 Tension output 2 Current output 3 Tension output 3 Current output 4 Tension output 4 GND – Output 4 GND – Output 3 GND – Output 2 Analogues - GND Analogues - GND Analogues - GND GND – input 8 GND – input 7 GND – input 6 GND – input 5

All pins are internal connected continued

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Front Connector Arrangement, ANM-Module (Analogues Input)

Cont’d.: PIN 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

PIN-NAME A1G 4U+E4G A2G E3G A3G E2G A4G E1G GND/ANA E8 GND/ANA E7 GND/ANA E6 GND/ANA E5 A1G E4 E4 E3 E3 E2 E2 E1 E1

OPERAND

EW Z+1.4 EW Z +1.3 EW Z +1.3 EW Z +1.3 EW Z.4 EW Z.4 EW Z.3 EW Z.3 EW Z.2 EW Z.2 EW Z.1 EW Z.1

COMMENTARY GND - Output 1 GND - Input 4 GND - Output 2 GND - Input 3 GND - Output 3 GND - Input 2 GND - Output 4 GND - Input 1 Analogues – GND Input (U/I) 8 Analogues – GND Input (U/I) 7 Analogues – GND Input (U/I) 6 Analogues – GND Input (U/I) 5 GND – Output 1 Input (U/I) 4 Input (U/I) 4 Input (U/I) 3 Input (U/I) 3 Input (U/I) 2 Input (U/I) 2 Input (U/I) 1 Input (U/I) 1

• All pins are internal connected

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Ground connection of the Control Unit Attention: The complete shield of the analog cable must be connected to the ground (GND) bolt of the PLC housing. This bolt must be connected to the X2 frame / machine ground by a cable (as short as possible) with 2,5 mm2 cross section. When using plug connectors with metal boxes and connected shield the additional complete shielding of the analog cable with the ground bolt is not necessary. But attention must be played that the metal box is connected by screws with the PLC housing. The twisted signal lines are pair wise shielded and already via the 50-pol female part of the connector connected to ground. The single shielding at the free end of the cable must not be connected with earth.

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Interface-connection COM SK / SP

Legend for illustration Z 21425a (Exemplary picture about what possible) (1) Text display (2) PLC (3) Plug socket “X27” (4) Laptop computer (5) Memory card system (6) Portable printer (7) Field dispatch system Cables: VL3 VL4 VL5 VL6 VL7 VL8

X27 to Laptop X27 to Memory Card System 24V Power supply to Memory Card System X27 to Portable Printer 24V Power supply to Portable Printer X27 to Field Computer System

Communication interface: COM-SK => Programming interface (Baud rate 19200) COM-SP => Communication with text display (Baud rate 9600)

)

• Data cables and/or communication systems are optional equipment. • For more detailed information see OPERATION MANUAL of the shovel and the Software Program for the individual Communication System

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14.4 Power supply 14.4.1 Operation Voltages +24 V, Illust. Z 21426 Study together with the relevant circuit diagram 50-pin SUB Connector: + 24 V CPU-Supply: GND: + 24 V I/O-Supply:

Pin 33 and 49 Pin 17 and 50 Pin 30 - 32, 46 – 48

This supply voltage is the operating voltage for the module outputs. It must be strong enough to carry the load current of all outputs. It is provided with a LOAD-DUMP protection to protect (for short times) wrong polarity and over voltage peaks. • Wrong polarity causes destroying of the module! • External 24 V supply to the outputs causes destroying of the module!

See next page for more information

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14.4 Power supply 14.4.2

Safety Precautions for Faultfinding, Illust. Z21427

• As already mentioned no external 24 V supply is allowed to the outputs of the BIM modules of the PLC. • If it is necessary while tracing faults, the cable to the PLC must be disconnected subsequent to a component check, thus as relays, solenoids or others by the PLC controlled components. Procedure: Study together with the relevant circuit diagram 1. Find the terminal between the component and the PLC. 2. Example terminal 8X2-280 for the solenoid valve 8Y6.1. 3. Disconnect the wire on one side of the terminal. 4. 5.

Now supply 24 V to the solenoid and check function of it. Finally re-connect the wire to the terminal

Binary Outputs A 2A-Short circuit proof Each single Output of the Output group can withstand a load of 2A, but the total load must not exceed 10 A. The Output group will be switched OFF if one of the Output becomes overloaded (> 2 A), the short circuit marker will be set and the “MK”- LED comes ON. (A1¿ MK1, A3¿ MK3, A5¿ MK5)

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14.4 Power supply 14.4.3 CPU Voltage Range • Electrical requirements +24 supply volt • 14 V up to 36 V without any restrictions regarding the max. current consumption of 4 amps out of the +5 V logic voltage. • At voltage drops below 18 V the 2amps-outputs switched OFF due to safety reasons. The short circuit markers initiated. • The +24 V CPU is monitored on the CPU plus DB16.1 After the diagnostic bit “Under-voltage UCPU “ DB16.1 has been set, all access to the EEPROM memory of the CPU plus is blocked • A drop below 9V results in a reset. • During and after voltage drops according to DIN 40839 part 2 operates the CPU plus normally.

14.4.4 Electric classification The voltage supply meets the requirements according to: • ISO 7637-2 Automotive Technique 24V • DIN 0871-B • IEC 801-4 step 4, VDE 0843-4. • DIN/VDE 0470 part1 (old DIN 40050)

14.4.5 Fuse TR5 / 2.5AT IEC 127-3 Manufacturer Wickmann,

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14.5 Function explanations with electrical diagram 14.5.1

General

Signal Status Voltage level: „1“ = 24 V* between E (Input) and GND „0“ =

0 V** between E (Input) and GND

* 13 V up to actual supply voltage ** 0V up to 5 V

The left half of the picture shows so named PULL-DOWN resistors and the right half PULL-UP resistors. The resistors are installed to get a low ohmical input. A system with contacts only leads to a (high ohmical) input if dust or moisture bridges the contacts. PULL-DOWN resistors are installed with a normal NC contact (means with a de-energized relay or normal closed switch contact) thus the ECS recognize a fault after switching ON the system. PULL-UP resistors are installed with a normal NO contact (means with a deenergized relay or normal open switch contact) thus the ECS recognize a fault after switching ON the system.

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14.5 Function explanations with electrical diagram 14.5.2

Pressure Measuring (Hydraulic System), Illustration Z 22805 (study with the respective circuit diagram) (Program run see Flowchart)

Analog Inputs: „EW 14.1“ for pressure sensor B87A (0 up to 500 bar) Measuring channel: 0......10 V Function: - Voltage supply for the pressure sensor: 24 V - Output voltages Ua (OUT+, pin 2) of the pressure sensors: Sensor 0 – 0,4 bar ¿ K= 25 V / bar Sensor 0 – 60 bar ¿ K= 0,1667 V / bar Sensor 0 – 500 bar ¿ K= 0,02 V / bar (Pressure sensors with +1 V Offset) Possible voltage checks: 24 V Supply between supply line 15 (start at circuit breaker) and GND. Output voltage OUT (pin 2) of the sensor between GND. Use respective circuit diagram for terminal numbers. * How to calculate the Output voltage Ua: Ua = output voltage proportional to the pressure input. P = input pressure K = calculation factor for the respective pressure sensor. Ua = (P x K) + 1 V Example for 200 bar and a 0 – 500 bar sensor: Ua = (200 x 0,02) + 1 V = 5 V

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14.5.3 Temperature Measuring and trouble shooting Illustration Z22803a General: (study with the respective circuit diagram) The signal of the PT100 temperature probe can’t connect direct to the ANM – Module (Analog input of the PLC). A temperature transducer module change the PT100 signal (Ohm) into a suitable current (mA) signal for the ANM – Module. The temperature probe is connected with a four wire technique to compensate the line resistance of the long wire between the X2 switch board and the temperature probe. Analog Inputs (eg.: Hydraulic oil temperature sensor B15) The temperature probe B15 is with 4-wire technology (distorting compensation) connected to the transducer U15 terminal 1, 4, 2, and 3 (measuring range: -50° C......+150° C). The output terminal 5 and 6 of the transducer is connected to the ECS analog input „EW 2.1“ (input range 4 – 20 mA). The transducer need 24 V power supply via terminal 7 and 8 (+24V, ground). Function: The temperature transducer convert the measured values from the PT100 temperature probe into electrically standardized analog signals. With the four wire technique the length and the cross section of the wires are not important; because the electrical resistance of the two current lines gets compensated. The sensor is supplied with a low electrical current from the temperature transducer (I+ and I-). Additional to the temperature probe (PT100) resistance the line resistance influence the current “flow” what falsified the PT100 measurement. To compensate the line resistance there are two additional lines (U+ and U-) close to the PT100 connected. Via this lines the transducer measure exact a tension drop between in- and output of the PT100 probe witch is only created by the PT100 resistance. Because there is no current “flow” through this lines which are influenced by the line resistance (compared to hydraulic system- it’s like a test hose with a pressure gauge). The module convert this tension drop into a current signal (4-20mA) which is proportional to the temperature. In the interest of proper function must the line resistance not exceed 50 Ω. Additional the lines must be shielded according to the standards. The picture shows the wiring of a PT100 probe to a temperature transducer in four wire technique. continued

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Temperature Measuring and trouble shooting, illustration Z22803a Cont’d.: Possible measurements PT100: Disconnect the wires at the resistor and measure the resistance across the resistor. Compare the measured resistance with the values given in the table on next page. If the value correspond to the temperature measured with an other temperature gauge the PT100 resistor is OK.; otherwise replace resistor. Wiring: Disconnect the wires at the resistor and inside X2-box at the temperature transducer terminal 1, 2, 3, and 4. Measure the line resistance to the ground. All single wire resistance must be the same. Transducer: Connect a Ampere-meter in line between terminal 5 of the transducer and the disconnected wire to the ECS. Select mA range and check the current. The value must compare to the PT100 resistance with the following calculation: I = [( 50 + t ) x 0,08 ] + 4 t = temperature [°C] (Check temperature via PT100 resistance and temperature chart next page) I = current [mA] to the ECS

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Electronic Control System ECS 14.5 Function explanations with electrical diagram 14.5.4

Temperature – Resistance Chart PT100 Basic Values in Ohm according to DIN 43 76 For Measuring Resistor PT100

°C

-0

-1

-2

-3

-4

-5

-6

-7

-8

-9

-50

80,31

79,91

79,51

79,11

78,72

78,32

77,92

77,52

77,13

76,73

-40

84,27

83,88

83,48

83,08

82,69

82,29

81,89

81,50

81,10

80,70

-30

88,22

87,83

87,43

87,04

86,64

86,25

85,85

85,46

85,06

84,67

-20

92,16

91,77

91,37

90,98

90,59

90,19

89,80

89,40

89,01

88,62

-10

96,09

95,69

95,30

94,91

94,52

94,12

93,73

93,34

92,95

92,55

0

100,00

99,61

99,22

98,83

98,44

98,04

97,65

97,26

96,87

96,48

°C

0

1

2

3

4

5

6

7

8

9

0

100,00

100,39

100,78

101,17

101,56

101,95

102,34

102,73

103,12

103,51

10

103,90

104,29

104,68

105,07

105,46

105,85

106,24

106,63

107,02

107,40

20

107,79

108,18

108,57

108,96

109,35

109,73

110,12

110,51

110,90

111,28

30

111,67

112,06

112,45

112,83

113,22

113,61

113,99

114,38

114,77

115,15

40

115,54

115,93

116,31

116,70

117,08

117,47

117,85

118,24

118,62

119,01

50

119,40

119,78

120,16

120,55

120,93

121,32

121,70

122,09

122,47

122,86

60

123,24

123,62 124,01, 124,39

124,77

125,16

125,54

125,92

126,31

126,69

70

127,07

127,45

127,84

128,22

128,60

128,98

129,37

129,75

130,13

130,51

80

130,89

131,27

131,66

132,04

132,42

132,80

133,18

133,56

133,94

134,32

90

134,70

135,08

135,46

135,84

136,22

136,60

136,98

137,36

137,47

138,12

100

138,50

138,88

139,26

139,64

140,02

140,39

140,77

141,15

141,53

141,91

110

142,29

142,66

143,04

143,42

143,80

144,17

144,55

144,93

145,31

145,68

120

146,06

146,44

146,81

147,19

147,57

147,94

148,32

148,70

149,07

149,45

130

149,82

150,20

150,57

150,95

151,33

151,70

152,08

152,45

152,83

153,20

140

153,58

153,95

154,32

154,70

155,07

155,45

155,82

156,19

156,57

156,94

150

157,31

157,69

158,06

158,43

158,81

159,18

159,55

159,93

160,30

16067

Example:

84 ° C

Ì 80° + 4° = 132,42 Ω

124,4 Ω

Ì 124,4 ≈ 124,39 = 60° + 3° = 63 °C

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14.6 Hints for reading the functional flow charts 14.6.1

)

General

• Probably the best aid for trouble shooting is the confidence of knowing the system and how to use the ECS. Every component has a purpose in the system. The construction and operating characteristics of each one should be understood. • Use always the electric/hydraulic circuit diagram the flowchart and the operation manual for the specific machine.

1. Select on page 1 of the flow chart, (which contains the table of contents and the main program) the respective subprogram, for example the Power-Master lube system. 2. Components in the flow chart, have the same identification code as in the electric/hydraulic circuit diagram, as shown in cross reference list (page 2-4). For example: Relay K50 = ? On page 2 (cross reference list) you find out that relay K50 is shown on page 43 of the flowchart. 3. On each page of the respective subprogram you will find the functional description in plain text. In case of problems concerning reading the program loops, you may find answers in the frequently asked questions list on page 6 and 7 of the flow chart.

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14.6 Hints for reading the functional flow charts 14.6.2

Example: Monitoring the X1-pressure for pump control, illustration Z25072 Grey shaded fields in the table below shows the normal way , used from the program, if the excavator is in “standard condition”. Item 1)

query Sensor or cable defect?

Yes No B85-X : 5 sec. < --6bar B85-X : 5 sec. : Voltage i.e. <1V at EW13.3 between 1V and 11V at or EW13.3 B85-X : 5 sec. > +55,3bar i.e. > 11V at EW13.3

⇓

2) 3)

_running_motor-x > 15 sec ? X1-pressure to high?

Fault message No 1190 Motor X is running for more than 15 seconds B85-X : 2 sec. > 40bar i.e. > 6,5V at EW13.3

⇓

Motor X is not running B85-X : 5 sec. : Voltage below 6,5V at EW13.3

Fault message No 962

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Section 15.0 Page 1

Lubrication System

Table of contents Page General Function Oscillation Cylinder and Control Block Adjustments One line system Electrical function Capacitive analog sensor for lubricant level monitoring Adjustments End Line pressure switch Injectors

3 9 11 13 17 21

Function Pinion type (dummy wheel) system Electrical Function (dummy wheel) system Capacitive analog sensor for lubricant level monitoring Adjustments End-Of-Line Switch setting Injectors Components Hydraulically driven lube pump Injectors End-Line Switch In line Filter Vent valve (Solenoid valve)

27 31 35

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23 25

37 39 41 45 51 53 55

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Lubrication System

Section 15.0 Page 3

Lubrication System

General Function

Legend: illustration Z 24042a (1) Lubricant pump drive (Hydraulic cylinder) (2) Solenoid valve (Oil pressure supply) (3) Flow control valve (4) Pressure reducing valve (5) Hydraulic oil supply line (Pilot pressure) (6) Hydraulic oil return line (7) Vent valve (Solenoid valve, de-energized open to barrel) (8) Grease supply line to injectors (9) Lubricant level indication (capacitively analog sensor) (10) (11) (12) (13) (14) (15) (16) (17)

)

Lubricant barrel Pump mechanism Lubricant filter Hydraulic pressure test plug (Operating pressure) Lubricant pressure gauge (Operating pressure) Vent line to barrel Breather Electrical terminal box

• Cylinder pressure must not exceed 650 psi (45 bar)

continued

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Lubrication System

Cont'd.

X-axis Y-axis

Time Lubricant supply line pressure

PI S+ PH SPR PT

Pressure Increasing Switch point ON of the end of line pressure switch Pressure Holding Switch point OFF of the end of line pressure switch Pressure Relieve Pause Time

Section 15.0 Page 5

Lubrication System

Function of a lubrication cycle

illustration Z24042c and Z22023a

PT-phase With the pump and controller system in a rest state a pre-set pause time interval occurs as determined by the PLC. Diagram position (a): A 24 VDC signal from the PLC activate solenoid valve (2) that opens and activate the lubrication pump. (*). As solenoid valve (2) opens hydraulic oil flows through the pressure reducing valve (4), it lowers the hydraulically pilot oil pressure to the operating range of the hydraulic driven lube pump. The reduced pilot oil pressure operates now the grease pump. The oil cylinder shuttle’s the grease cylinder at 18 – 20 double strokes per minute and delivering 612 – 680 cm³ (37.3 – 41.5 in³) of lubricant per minute (approx. 550 – 612 g / 19.64 – 21.45 oz.) At the same time a 24 V signal energize release valve (7), it close now the release line to the lubrication container. PI-phase With energized release valve (7) (*) and solenoid valve (2) the pump continues to cycle until maximum pressure is achieved and the injectors have metered lubricant to the bearings. S+ point, diagram position (b) When the maximum system pressure is reached the end-of-line switch (*) open its contact. In the normal application is the end-of-line switch adjusted to 185 bar (2630 psi. ).The pressure increasing phase is now finished. The open pressure switch (*) signals the controller to stop the pumping cycle and the controller terminates the signal to the solenoid valves (2) The pilot oil flow to the pump stops.

Solenoid valve 2 Y7, CLS

Vent valve 7 Y7a, CLS (1)

end-of-line switch B43, CLS

Y8a, CLS (2) Y9, SLS

Y9a, SLS

B46, SLS

SLS = Slew Ring Teeth Lubrication System CLS = Central Lubrication System (*) check respective circuit diagram continued 29.12.05 rev.5

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Lubrication System

Cont'd.

X-axis Y-axis

Time Lubricant supply line pressure

PI S+ PH SPR PT

Pressure Increasing Switch point ON of the end of line pressure switch Pressure Holding Switch point OFF of the end of line pressure switch Pressure Relieve Pause Time

Lubrication System

Section 15.0 Page 7

Cont'd.

PH-phase Release valve (7) is still energized to keep the pressure in the lubricant line for a fix adjusted time (pressure holding time normally 5 min). Diagram position (c): With expired pressure holding time vent valve (7) de-energize. It opens the release line to the lubricant container. The lubricant line pressure drop to zero so the injectors can recharge for the next lubricant injection. (PR-phase). PR-phase In the pressure relieve phase the end of line switch (*) move back to neutral contact position it signals the PLC that the lube pressure relieve phase is now active. PT-phase The system is now at rest (pause time), ready for another lube cycle and the sequence repeats itself.

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Lubrication System

Section 15.0 Page 9

Lubrication System

Oscillation Cylinder and Control Block, illustration Z 21174

Description: Oscillation cylinder (6) is auto directional controlled, non pressure related. This differential cylinder is connected to the pilot pressure suppliy line (P) and a tank line (T). The speed is contolled by a flow contol valve (3) and the maximum working pressure is controlled by a pressure reducing valve (2).

Function: The Oscillatin cylinder (6) starts as soon pilot pressure is send via the connection (P) to the control block (1). Design related the cylinder (6) retract always first after start or from any position the piston has stopped before. When the cylinder reaches the fully retracted position the flow will be redirected automatically and the cylinders moves in the extending position. If the cylinder comes to an stop in between the end positions weather the oil supply get stopped or the cylinder is hold back by a higher work resistance than the supply pressure, the cylinder changes direction and retracts.

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Lubrication System

Lubrication System

Adjustments


(illustration Z21175b):

Stroke speed For a sufficient lube pump operation 18 – 20 double strokes / min for the pump drive cylinder are required. Therefore the flow reducing valve (3) has to be adjusted accordingly. Procedure: 1. Remove electrical plug connection form the discharge valve (7), so no pressure built up will take place during the following test. 2. Start motor. 3. Switch “ON” the lube system annually and count strokes per minute, visible on the moving up and down of pipe (1). If adjustment is required: a. Loosen lock nut (3.1) b. Turn adjustment (3) until the right number of strokes is achieved. turn set screw ccw for more speed and cw to reduce the speed c. Tighten lock nut (3.1). Working pressure The pressure reducing valve (2) mounted in the oscillation control block reduce the supply pressure internally to maximal allowed 45 bar. The pressure ration is 6,55 to 1, that means 45 bar supply pressure result in 295 bar maximum lubricant pressure. At the end of line pressure switch the pressure should be 180 ±0,5 bar. With the lubricant line resistance and different lubricant viscosity the pressure at the lubricant pump output must be higher as 180 bar. For standard condition adjust the maximum pump pressure to 220 bar –250 bar, depend on lubricant line resistance and different lubricant viscosity. Procedure: 1. Disconnect quick coupling (8), so the pump will be blocked when started. 2. Start motor. 3. Switch “ON” the lube system manually, the gauge should show 220-250 bar. If adjustment is required: a. Loosen lock nut (2.1) d. Turn adjustment (2) until the right pressure is shown at the gauge. turn set screw ccw for lower pressure and cw to increase the pressure b. Tighten lock nut (2.1). c. Reconnect quick coupling (8).

) 29.12.05 rev.5

• If the required pressure can’t be adjusted, check adjustment of the 60 bar pilot pressure valve (X-4 pressure) at the filter and control panel in the machinery house. PC8000-6-E_Sec_15-0_#12048_rev0.doc

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Lubrication System


Lubrication System

One line system Legend: illustr. Z 21176 (1) Lubricant pump drive (Hydraulic cylinder) (2) Solenoid valve (Oil pressure supply) (3) Flow control valve (4) Pressure reducing valve (5) Hydraulic oil supply line (Pilot pressure) (6) Hydraulic oil return line (7) Vent valve (Solenoid valve, de-energized open to barrel) (8) Grease supply line to injectors (9) Lubricant level indication (capacitively analog sensor) (10) Lubricant barrel (11) Pump mechanism (12) Lubricant filter (13) Hydraulic pressure test plug (Operating pressure) (14) Lubricant pressure gauge (Operating pressure) (15) Vent line to barrel (16) End-of-line switch (17) (Pressure check point) (18) Injector block (19) Lubricant feed line to bearing

Function: As soon as the adj. "Pause-Time" is finished the solenoid valves (2) and (7) are energized. The lubricant pump (1) start to pump lubricant in the lubricant supply line. By the function of the solenoid valve (7) the port to the vent line (15) (return line to the lubricant container) is closed, thus a pressure built up is possible. The high-pressure barrel pump (1) supplies lubricant into the supply line (8). It continuos through the lubricant filter (12) to the injectors (metering valves) (18).

)

• The picture shows an example only. The hole system includes much more injectors which are connected via pipes or hoses to the supply line (8).

In the Injectors the lubricant forced with full pump pressure via the feed lines (19) to the lube points. The actual operating pressure can be monitored at the pressure gauge (14) and checked at the pressure check point (17). continued

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Lubrication System

Lubrication System


Cont'd. Illustr. Z 21176 When all injectors pistons have reached there final position no more lubricant is accepted from the supply line which causes a pressure increase in the supply line (8). As soon as the pressure reaches the adjusted value of the end-of-line switch (16) the solenoid valves (2) de-energized and the lubricant pump switched Off. Depend on different factory settings vent valve (7) de energize together with solenoid valve (2) or after a fix adjusted time of max. 5 minutes. With de-energized solenoid valve (7) the port to vent line (15) ( return line to the lubricant container ) opened and release the lubricant and lubricant pressure in to the container. With the diminishing pressure in the main line the pistons of the injector (18) are forced by spring force in their initial position and the discharge chambers are filled with grease for the following lubrication cycle. The system is now prepared for a new lubrication cycle. The operation is reinitiated after the next "Pause Time" is elapsed. The proper build-up of the pressure in the supply line (8) is monitored by the end-of-line switch (16). If the pressure adjusted at the end-of-line switch will not reached within the adjusted "Monitoring Time" the fault message ”Central lubrication system fault” comes up on the text display and the system switch off

W

• Grease qualities to be used: According to NLGI classes 000, 00, 0 and 1 according to the lowest ambient temperature in the operation area

)

1. The content of molybdenum must not exceed 5 %. 2. Only synthetic graphite allowed in graphite contained lubricants

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Lubrication System

Lubrication System


Electrical function. illustr. Z 21177a

)

• It follows an exemplary explanation for a central lubrication system for machines equipped with PLC System. For details see the circuit diagram of the respective machine. The Lubrication Systems are PLC controlled. No relay adjustment necessary. Central lubrication system controlling : The PLC from the ECS System controls the whole lubrication systems. The solenoid valves (Y7, Y7A or Y9, Y9A) on top of the lubrication stations are direct connected to digital output ports of the PLC. On a few machines there are additional relays between PLC outputs and the solenoid valves. Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a PLC internal time counter the grease system start a lubrication cycle. The lubrication cycle starts. If the pause time elapsed the PLC energize both solenoid valves (Y7, Y7A or Y9, Y9A) of the respective lubrication system. The motor must run. The pilot pump pressure activate now the lubrication pump and the lubrication pressure to the injectors increase. If the lubricant pressure reach the adjusted pressure of the end-of-line pressure switch (B43 or B46) its contact change and the PLC input signal change. The PLC de energize the respective lubrication pump supply valve (Y7 or Y9) to stop the pump. For the next 5 min the respective pressure releasing valve (Y7A or Y9A) are continued energized to keep the lubricant pressure still on a high level to be able all injectors inject the hole adjusted amount of lubricant. After the 5 min. pressure holding time the PLC de energize the respective pressure releasing valve (Y7A or5 Y9A) The lubricant pressure drops and the injectors move by spring load back in its initial position. A PLC internal counter is still counting a additional decreasing time to monitor the end-of-line pressure switch (B43 or B46) position. The PLC internal time counter is still counting up to the next lubrication cycle. The lubrication cycle is finished. continued

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Lubrication System

Lubrication System


Cont'd: Illustr. Z 21177a The next lubrication cycle starts after the decreasing time and pause time has expired. With the switch S24 an additional lubrication can be carried out any time provided the end of line pressure switch (B43) contact is closed.

Monitoring: The orderly built-up of the pressure in the lubricant supply line is monitored by the end-of-line switch (B43 or B46). If the pressure adjusted at the end-of-line switch is not reached within the adjusted maximal increasing time the PLC switch off both solenoid (Y7 and Y7A or Y9 and Y9A) valves and send the fault message ”Central lubrication system fault” or “Swing ring lubrication system fault” to the text display at the dash board. If the excavator is still working additional four hours with faulty lubrication system the PLC stop the bucket function. This function is to prevent trouble depend on a lack of lubricant.

Continued

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Lubrication System


Lubrication System

Capacitive analog sensor for lubricant level monitoring, Illustration Z 21179f Task: A lubricant (L) maximum filling level monitoring is necessary to prevent an overfilling of the grease barrel (C) via the refilling system (only systems with refilling arm). The PLC use the analog level signal from the sensor to activate a lamp at the refilling arm just in the moment when the lubricant container is full. The sensor (S) is mounted on top of the lubricant container and reaches into the lubricant. The refilling level activate only a message at the text display to inform that the lubricant level must be filled up. The message comes up if the lubricant level reach 5% (910 mm from the cover plate). The minimum level stop the respective lubrication pump and release the lubricant pressure until the lubricant level reach the 0% mark (950 mm from the cover plate). It is necessary to stop the lubrication system with empty lubricant container to prevent the lubrication pump from running dry. With empty lubricant container the bucket motion will be switched off after four hours. Function: The capacitively level sensor (S) check continuous the lubricant level (L) and convert the capacitive signal into a current signal between 4 and 20mA. The current signal increase with increasing lubricant level. Use the specific electric circuit diagram and program flow charts.

)

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• The capacitively proximity switch used in our machines are programmed by the supplier and therefor no adjustment or settings required.

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Lubrication System

Lubrication System


Adjustments End line switch setting. Illustration Z 21180 1.

)

Connect pressure gauge to check point.

• Use an other gauge as for checking hydraulic pressures because the gauge remains filled with grease after the test 2. 3. 4.

Start motor. Start a lube cycle with the dashboard switch S24. + Watch pressure gauge. At a pressure of 180 10 bar the end-line switch must react and the lubricants pump must stop.*

*

)

If at the same time the pressure shown at the built-in gauge is noted down, this pressure can be taken for later on checks as a reference pressure. • 180 bar is the normal setting. Under particular circumstances it may be necessary to increase the pressure slightly If re-setting is required: 5. Screw out screw 1 and take off cover 2. 6. Alter the spring tension with adjustment screw 3 that the switch operates at 180 bar. 7. Install cover 2 and screw 1.

continued

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Lubrication System


Lubrication System

Cont'd: Injectors, illustr. 21181: Series SL-1 injector: Lubricant output adjustable from 0.13 up to 1.3 cm³ per cycle. Hydraulic type fitting with screw type cover cap is provided for initial filling of feeder line, and may also be used for visual check of injector operation. Series SL-1 injectors incorporate a stainless steel visual indicator. Series SL-11 injector: Lubricant output adjustable from 0.82 up to 8.2 cm³ per cycle. Designed for systems where a high amount of lubricant is required. Principle of operation similar to series SL-1. Adjusting the lubricant output: 1. Loosen lock nut (C). 2. Turn adjusting screw (A) counterclockwise (OUT) for more lubricant output or clockwise (IN) for less lubricant output. 3. Tighten lock nut (C).

)

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• The max. lubricant output is adjusted if the indicator stem (B) moves not more further outwards

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Lubrication System


Lubrication System

Function Pinion type (dummy wheel) system. Legend: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)

Z 21183a Lubricant pump drive (Hydraulic cylinder) Solenoid valve Y9 (Oil pressure supply) Flow control valve Pressure reducing valve Hydraulic oil supply line (Pilot pressure) Hydraulic oil return line Vent valve Y9A (Solenoid valve, de-energized open) Grease supply line to injectors Lubricant level indication Lubricant barrel Pump mechanism Lubricant filter Hydraulic pressure test plug (Operating pressure) Lubricant pressure gauge (Operating pressure) Vent line to barrel Breather Electrical terminal box

Principle of operation: By the lubricant pump, the lubricant is supplied to the centered bore hole (B) of the lubrication type pinion (R). Bore hole (B) must be perfectly aligned to the center of the lubrication type pinion (A) to be greased, so that lubricant leaves the tooth flank always when the gear tooth is in contact. The grease outlet (D) of the lubricating type pinion is arranged at a different angle for each tooth, so that the lubricant is distributed in a uniform and perfect manners on the tooth flank of the drive pinion to be lubricated. Function: As soon as the adjusted "Pause-Time" elapse the solenoid valves (2 + 7). energized and the lubricant pump (1) start to pump lubricant. By the function of the solenoid valve (8) the port to the vent line (15) (return line to the lubricant container) closed, thus a pressure built up is possible. The high-pressure lubricant pump (1) supplies lubricant into the supply line (8). It continuos through the lubricant filter (12) to the injectors (metering valves) (18). •

The picture shows an example with one pinion only. There are also machines which have more lubrication type pinion (dummy wheel). By the injectors the lubricant is forced with full pump pressure via the feed line (19) to the centered bore hole (B) of the lubricating type pinion (R). continued

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Lubrication System

Lubrication System


Cont'd. Illustr. Z 21183a The actual operating pressure can be monitored at the pressure gauge (14) and checked at the pressure check point (17). When all injector pistons have reached there final position no more lubricant will accepted from the supply line (8) which causes a pressure increase in the supply line. Depend on different factory settings vent valve (7) de energize together with solenoid valve (2) or after a fix adjusted time of max. 5 minutes. With de-energized solenoid valve (7) the port to vent line (15) ( return line to the lubricant container ) opened and release the lubricant and lubricant pressure in to the container. With the diminishing pressure in the main line the pistons of the injector (18) are forced by spring force in their initial position and the discharge chambers fill up with grease for the following lubrication cycle. The system is prepared for the next lubrication cycle. The operation is reinitiated after the next "Pause Time". The proper build-up of the pressure in the supply line (8) is monitored by the end-of-line switch (16). If the pressure adjusted at the end-of-line switch is not reached within the adjusted "Monitoring Time" the fault message ”Slew ring gear lubrication system fault” is shown on the text display and the pump switch off.

• Grease qualities to be used: According to NLGI classes 000, 00, 0 and 1 according to the lowest ambient temperature in the operation area

)

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1. The content of molybdenum must not exceed 5 %. 2. Only synthetic graphite must be contained in graphic lubricants

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Lubrication System

Lubrication System

Electrical function.

)


Illustration Z 21177b

• It follows an exemplary explanation for a Slew Ring Lubrication System for machines equipped with ECS System. For details see the circuit diagram of the respective machine. The Lubrication Systems are controlled through the ECS. No relay adjustment required. Slew Ring Gear Lubrication (Teeth lubrication) controlling : The PLC from the ECS System control the whole lubrication systems. Solenoid valves (Y9, Y9A) on top of the lubrication container are direct connected to digital output ports of the PLC. On few machines there are additional relays between PLC and the solenoid valves. Depend on a PLC input from the end-of-line pressure switch (B43 or B46) and a PLC internal time counter the grease system start a lubrication cycle. The lubrication cycle starts. If the pause time elapsed and the swing function was activated for a short time the PLC energize both solenoid valves ( Y9 , Y9A ). To start one swing ring gear lubrication cycle the swing function must be activated one time. If the lubricant pressure reach the adjusted pressure of the end of line pressure switch its contact change the position now the input port of the PLC change. The PLC de energize the respective lubrication pump supply valve (Y9) to stop the pump. For the next 5 min the respective pressure releasing valve (Y9A) are continued energized to keep the lubricant pressure still on a high level to be able all injectors inject the hole amount of lubricant. After 5 min. pressure holding time the PLC de energize the respective pressure releasing valve (Y9A) The lubricant pressure drops and the injectors move by spring load back in its initial position. A internal counter is still counting a additional decreasing time to prevent a to early new lubrication cycle with the risk of not complete reset injectors. The lubrication cycle is finished. continued

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Lubrication System

Lubrication System


Cont'd: Illustr. Z 21177b The next lubrication cycle starts after the decreasing time and pause time has expired. With the switch S26 an additional lubrication can be carried out any time provided the end of line pressure switch (B46) contact is closed.

Monitoring: The orderly built-up of the pressure in the lubricant supply line is monitored by the end-of-line switch (B46). If the pressure adjusted at the end-of-line switch is not reached within the adjusted maximal increasing time the PLC switch off both solenoid valves (Y9 and Y9A) and send the fault message ”Central lubrication system fault” to the text display at the dash board. If the excavator was working additional four hours with faulty lubrication system the PLC stop the bucket function. This function is to prevent trouble depend on a lack of lubricant.

Continued

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Lubrication System


Lubrication System

Capacitive analog sensor for lubricant level monitoring, Illustration Z 21179f Task: A lubricant (L) maximum filling level monitoring is necessary to prevent an overfilling of the grease barrel (C) via the refilling system (only systems with refilling arm). The PLC use the analog level signal from the sensor to activate a lamp at the refilling arm just in the moment when the lubricant container is full. The sensor (S) is mounted on top of the lubricant container and reaches into the lubricant. The refilling level activate only a message at the text display to inform that the lubricant level must be filled up. The message comes up if the lubricant level reach 5% (910 mm from the cover plate). The minimum level stop the respective lubrication pump and release the lubricant pressure until the lubricant level reach the 0% mark (950 mm from the cover plate). It is necessary to stop the lubrication system with empty lubricant container to prevent the lubrication pump from running dry. With empty lubricant container the bucket motion will be switched off after four hours. Function: The capacitively level sensor (S) check continuous the lubricant level (L) and convert the capacitive signal into a current signal between 4 and 20mA. The current signal increase with increasing lubricant level. Use the specific electric circuit diagram and program flow charts.

)

29.12.05 rev.5

• The capacitively proximity switch used in our machines are programmed by the supplier and therefor no adjustment or settings required.

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Lubrication System

Lubrication System


Adjustments End of line switch setting, illustration Z 21185 1.

)

• Use an other gauge as for checking hydraulic pressures because the gauge remains filled with grease after the test 2. 3. 4. 5.

*

)

Connect pressure gauge to check point close to the end of line pressure switch.

Block the swing function with the swing ring parking, use the switch at the dash board. Start motor. Start a lube cycle with the dashboard switch S26 and activate for a short time the swing function to the left or right. + Watch pressure gauge. At a pressure of 180 10 bar the end of line switch must react and the lubricants pump must be stopped.* If at the same time the pressure shown at the built-in gauge is noted down, this pressure can be taken for later on checks as a reference pressure. But be careful this pressure is higher than the pressure shown at the test gauge because of the long distance between pump and end of the supply line.

• 180 bar is the normal setting. Under particular circumstances it may be necessary to increase the pressure slightly If re-setting is required: 6. 7. 8.

Screw out screw (1) and take off cover (2). Alter the spring tension with adjustment screw (3) that the switch operates at 180 bar. Install cover (2) and screw (1). continued

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Lubrication System


Lubrication System

Cont'd: Injectors, illustr. 21181: Series SL-1 injector: Lubricant output adjustable from 0.13 up to 1.3 cm³ per cycle. Hydraulic type fitting with screw type cover cap is provided for initial filling of feeder line, and may also be used for visual check of injector operation. Series SL-1 injectors incorporate a stainless steel visual indicator. Series SL-11 injector: Lubricant output adjustable from 0.82 up to 8.2 cm³ per cycle. Designed for systems where a high amount of lubricant is required. Principle of operation similar to series SL-1. Adjusting the lubricant output: 1. Loosen lock nut (C). 2. Turn adjusting screw (A) counterclockwise (OUT) for more lubricant output or clockwise (IN) for less lubricant output. 3. Tighten lock nut (C).

)

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• The max. lubricant output is adjusted if the indicator stem (B) moves not more further outwards

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Lubrication System

Hydraulically driven “Power Master III” lube pump, illustr. Z 21186 Legend: (more detailed see parts list 90-0781) Fig.: 12 (P) Hydraulic oil supply (T) Hydraulic oil return (Pr) Pressure reducing valve (Q) Flow regulator valve (1) Hydr. actuator piston (2) Oscillator control block (3) Pump tube (4) Breather port (5) Grease outlet port (6) Piston rod (7) Breather plug (8) Ball, outlet check valve (9) Ball and seat, check valve (10) Main piston and plunger (11) Piston rod set (12) Inlet valve (13) Scoop piston (14) Grease inlet HINT: Loss of pressure or to short pump strokes indicates: A

Foreign material lodged under Piston Ball Checks or between Upper and Lower Inlet Checks (8 + 9). To correct this problem the upper lower inlet checks (8 + 9) and inlet valve (13) should be removed and cleaned thoroughly. If sealing surfaces between upper and lower inlet checks (8 + 9) are rough or pitted, replace or resurface if damages are slight.

B

Shovel rod packing worn or damaged. Before installing new packing, inspect surface of shovel rod and replace if rough or pitted. Do not grip shovel rod when disassembling lower pump tube assembly. continued

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Lubrication System


Trouble shooting, illustr. Z 21186 If the following procedures do not correct the problem, contact a factory authorized service center. PROBLEMS: CYLINDER PRESSURE GAUGE DOES NOT REGISTER PRESSURE. A. Check system pressure to pump. B. Check for 24 VDC signal at solenoids. C. Pressure reducing valve set too low. Check pressure. PUMP PRESSURE BUILT UP VERY SLOWLY OR NOT AT ALL. A. B. C. D. E. F. G. H.

29.12.05 rev.5

No oscillation of pump, check oscillation control block (2). Pressure reducing valve (Pr) may be setting too low. Grease viscosity may be too high for the actual ambient temperature. If pressure is not building up at all, solenoid valve (pilot pressure supply solenoid) may be inoperative. Pump piston (11) and inlet checks may have foreign matter trapped causing leakage. Remove, inspect and clean if necessary. Inspect sealing surface on upper and lower checks (8 + 9). Replace if rough or pitted. Replace scoop piston if rough or pitted. Replace rod packing (15) if it is leaking. Inspect lubricant supply line for leaks or breaks.

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Lubrication System

TS 12037-upE-GB-0

HYDRAULIC MINING EXCAVATOR PC8000E-6 Machine model

Serial numbers 12037 and up

PC8000E-6

40 Troubleshooting Troubleshooting procedures

® Copyright 2010 KOMATSU MINING GERMANY GmbH

PC8000E-6 S/N 12037 and up

1

SHOP MANUAL

SHOP 12037-xE-GB-0


Machine model

Serial number

PC8000-6

12037 and up

50 Assembly and disassembly

PC8000E-6

1

Overview

Overview 1 INTRODUCTION 2 SAFETY 3 SUPERSTRUCTURE 4 UNDERCARRIAGE 5 ATTACHMENT 6 SERVICE INFORMATION 7 TOOLS CATALOGUE 8 PARTS & SERVICE NEWS 9 SUPPLIER’S DOCUMENTATION

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Table of contents

1 INTRODUCTION........................................................................................ 1-1 1.1

CONTENTS OF THE BINDER ........................................................................................................... 1-2

1.2

FOREWORD ...................................................................................................................................... 1-3 1.2.1 SERVICE ............................................................................................................................... 1-4

2 SAFETY ..................................................................................................... 2-1 2.1

GENERAL INFORMATION ................................................................................................................ 2-2 2.1.1 METHOD OF USING THIS MANUAL .................................................................................... 2-2

2.2

SAFETY INSTRUCTIONS.................................................................................................................. 2-4 2.2.1 GENERAL PRECAUTIONS ................................................................................................... 2-4 2.2.2 PREPARATIONS BEFORE WORK ....................................................................................... 2-6 2.2.3 PRECAUTIONS DURING WORK.......................................................................................... 2-7 2.2.3.1 PRECAUTIONS WITH HIGH PRESSURE OIL ..................................................... 2-9 2.2.4 WARNING OF SPECIAL DANGERS................................................................................... 2-10 2.2.4.1 ELECTRICAL ENERGY ....................................................................................... 2-10 2.2.4.2 GAS, DUST, STEAM AND SMOKE..................................................................... 2-11 2.2.4.3 NOISE .................................................................................................................. 2-11 2.2.4.4 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES ................................... 2-11 2.2.4.5 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT................ 2-12 2.2.4.6 HEAT.................................................................................................................... 2-12 2.2.4.7 HEIGHT................................................................................................................ 2-12 2.2.5 SPECIAL SAFETY EQUIPMENT ........................................................................................ 2-15 2.2.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) ..................................................................... 2-15 2.2.5.2 INSTRUCTIONS FOR USE ................................................................................. 2-17 2.2.5.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS........................................... 2-19 2.2.5.4 INSTRUCTIONS FOR USING THE FALL ABSORBER ...................................... 2-21 2.2.6 SAFETY HINTS FOR HYDRAULIC HOSE INSTALLATION ............................................... 2-22 2.2.7 SAFETY HINTS FOR LIFTING HEAVY PARTS.................................................................. 2-25 2.2.8 SAFETY HINTS FOR WIRE ROPES................................................................................... 2-25 2.2.9 SAFETY HINTS FOR SLING ACCESSORY ....................................................................... 2-27

2.3

GROUNDING PROCEDURE OF THE HIGH VOLTAGE SYSTEM ................................................. 2-28

2.4

EXPLANATION OF ABBREVIATIONS ........................................................................................... 2-31

3 SUPERSTRUCTURE................................................................................. 3-1 3.1

SUPERSTRUCTURE OVERVIEW ..................................................................................................... 3-2

3.2

SERVICE CRANE (OPTIONAL) ........................................................................................................ 3-5 3.2.1 REMOVAL OF THE SERVICE CRANE ................................................................................. 3-5 3.2.2 REPLACEMENT OF THE SERVICE CRANE ....................................................................... 3-7

3.3

ENGINE HOUSE ROOF ..................................................................................................................... 3-8 3.3.1 REMOVAL OF THE ROOF PLATES ..................................................................................... 3-8 3.3.2 REPLACEMENT OF THE ROOF PLATES.......................................................................... 3-14 3.3.3 FRONT ROOF SECTION .................................................................................................... 3-15 3.3.3.1 REMOVAL OF THE FRONT ROOF PLATES ...................................................... 3-15 3.3.3.2 REPLACEMENT OF THE FRONT ROOF PLATES ............................................ 3-18

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3.4

BATTERIES...................................................................................................................................... 3-19 3.4.1 REMOVAL OF THE BATTERIES ........................................................................................ 3-19 3.4.2 REPLACEMENT OF THE BATTERIES ............................................................................... 3-21

3.5

ELECTRIC MOTORS ....................................................................................................................... 3.5.1 REMOVAL OF THE FRONT ELECTRIC MOTOR (MOTOR 1) ........................................... 3.5.2 REPLACEMENT OF THE FRONT ELECTRIC MOTOR (MOTOR 1).................................. 3.5.3 REMOVAL OF THE REAR ELECTRIC MOTOR (MOTOR 2) ............................................. 3.5.4 REPLACEMENT OF THE REAR ELECTRIC MOTOR (MOTOR 2) .................................... 3.5.5 FINAL ALIGNMENT OF THE ELECTRIC MOTORS ........................................................... 3.5.6 CAPACITOR ASSEMBLIES ................................................................................................ 3.5.6.1 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 1) ............................... 3.5.6.2 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 1) ...................... 3.5.6.3 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 2) ............................... 3.5.6.4 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 2) ......................

3-22 3-22 3-26 3-28 3-28 3-29 3-32 3-33 3-35 3-35 3-35

3.6

FLEXIBLE COUPLING..................................................................................................................... 3.6.1 VULKAN COUPLING ASSEMBLY....................................................................................... 3.6.1.1 REMOVAL OF THE VULKAN COUPLING .......................................................... 3.6.1.2 REPLACEMENT OF THE VULKAN COUPLING .................................................

3-36 3-36 3-37 3-39

3.7

PTO................................................................................................................................................... 3.7.1 MAIN PUMPS ...................................................................................................................... 3.7.1.1 REMOVAL OF MAIN PUMPS .............................................................................. 3.7.1.2 REPLACEMENT OF MAIN PUMPS..................................................................... 3.7.2 PTO OIL PUMPS (AUXILIARY PUMPS) ............................................................................. 3.7.2.1 REMOVAL OF THE PTO OIL PUMPS (AUXILIARY PUMPS)............................. 3.7.2.2 REPLACEMENT OF THE PTO OIL PUMPS (AUXILIARY PUMPS) ................... 3.7.3 PUMP DISTRIBUTOR GEARBOX (PTO)............................................................................ 3.7.3.1 REMOVAL OF THE PUMP DISTRIBUTOR GEARBOX (PTO) ........................... 3.7.3.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO) ..................

3-40 3-40 3-42 3-45 3-47 3-47 3-47 3-48 3-50 3-54

3.8

HYDRAULICS .................................................................................................................................. 3-55 3.8.1 HYDRAULIC COOLER FAN DRIVE PUMPS ...................................................................... 3-55 3.8.1.1 REMOVAL OF THE HYDRAULIC COOLER FAN DRIVE PUMPS...................... 3-56 3.8.1.2 REPLACEMENT OF THE HYDRAULIC COOLER FAN DRIVE PUMPS ............ 3-58 3.8.2 ADDITIONAL HYDRAULIC OIL COOLER ASSEMBLY ...................................................... 3-59 3.8.2.1 REMOVAL OF THE ADDITIONAL HYDRAULIC OIL COOLER FAN ASSEMBLY.................................................................................................. 3-62 3.8.2.2 REPLACEMENT OF ADDITIONAL HYDRAULIC OIL COOLER FAN ASSEMBLY.................................................................................................. 3-65 3.8.2.3 REMOVAL OF ADDITIONAL HYDRAULIC OIL COOLER FANS AND MOTORS 3-66 3.8.2.4 REPLACEMENT OF ADDITIONAL HYDRAULIC OIL COOLER FANS AND MOTORS ..................................................................................................... 3-67 3.8.2.5 REMOVAL OF THE ADDITIONAL HYDRAULIC OIL COOLERS ........................ 3-68 3.8.2.6 REPLACEMENT OF THE ADDITIONAL HYDRAULIC OIL COOLERS .............. 3-71 3.8.2.7 REMOVAL OF THE ADDITIONAL HYDRAULIC OIL COOLER ASSEMBLY ...... 3-72 3.8.2.8 REPLACEMENT OF ADDITIONAL HYDRAULIC OIL COOLER ASSEMBLY..... 3-74 3.8.3 HYDRAULIC OIL COOLER ASSEMBLY ............................................................................. 3-76 3.8.3.1 REMOVAL OF THE HYDRAULIC OIL COOLER FAN ASSEMBLIES ................. 3-80 3.8.3.2 REPLACEMENT OF HYDRAULIC OIL COOLER FAN ASSEMBLIES................ 3-84 3.8.3.3 REMOVAL OF THE HYDRAULIC OIL COOLER FAN AND MOTOR.................. 3-86 3.8.3.4 REPLACEMENT OF HYDRAULIC OIL COOLER FAN AND MOTOR ................ 3-88

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3.8.3.5 REMOVAL OF THE HYDRAULIC OIL COOLERS .............................................. 3-90 3.8.3.6 REPLACEMENT OF THE HYDRAULIC OIL COOLERS ..................................... 3-94 3.8.3.7 REMOVAL OF THE HYDRAULIC OIL COOLER ASSEMBLY ............................ 3-96 3.8.3.8 REPLACEMENT OF THE HYDRAULIC OIL COOLER ASSEMBLY ................. 3-100 3.8.4 PILOT OIL PUMP (GEAR PUMP) ..................................................................................... 3-101 3.8.4.1 REMOVAL OF THE PILOT OIL PUMP .............................................................. 3-101 3.8.4.2 REPLACEMENT OF THE PILOT OIL PUMP .................................................... 3-103 3.8.5 MAIN GATE VALVE........................................................................................................... 3-104 3.8.5.1 REMOVAL OF THE MAIN GATE VALVE .......................................................... 3-104 3.8.5.2 REPLACEMENT OF THE MAIN GATE VALVE................................................. 3-105 3.8.6 HYDRAULIC OIL RESERVOIR ......................................................................................... 3-106 3.8.6.1 REMOVAL OF THE HYDRAULIC OIL RESERVOIR......................................... 3-108 3.8.6.2 REPLACEMENT OF THE HYDRAULIC OIL RESERVOIR ............................... 3-111 3.8.7 MAIN CONTROL VALVE BLOCKS ................................................................................... 3-113 3.8.7.1 REMOVAL OF THE MAIN CONTROL VALVE BLOCKS................................... 3-114 3.8.7.2 REPLACEMENT OF THE MAIN CONTROL VALVE BLOCKS ......................... 3-117 3.8.8 MAIN RELIEF VALVES (MRV) .......................................................................................... 3-118 3.8.8.1 REMOVAL OF THE MRV ON THE MAIN CONTROL VALVE BLOCK ............. 3-118 3.8.8.2 REPLACEMENT OF THE MRV ON THE MAIN CONTROL VALVE BLOCK .... 3-119 3.8.9 SERVICE LINE RELIEF VALVES (SRV) ........................................................................... 3-120 3.8.9.1 REMOVAL OF THE SRV ON THE MANIFOLD ................................................. 3-120 3.8.9.2 REPLACEMENT OF THE SRV ON THE MANIFOLD ....................................... 3-122 3.8.9.3 REMOVAL OF THE SRV ON THE MAIN CONTROL VALVE BLOCK .............. 3-123 3.8.9.4 REPLACEMENT OF THE SRV ON THE MAIN CONTROL VALVE BLOCKS .. 3-125 3.8.10 ANTI-CAVITATION VALVES (ACV) ................................................................................. 3-126 3.8.10.1 REMOVAL OF THE ACV ON THE MANIFOLD ................................................. 3-127 3.8.10.2 REPLACEMENT OF THE ACV ON THE MANIFOLD ....................................... 3-131 3.8.10.3 REMOVAL OF THE ACV ON THE MAIN CONTROL VALVE BLOCKS............ 3-132 3.8.10.4 REPLACEMENT OF THE ACV ON THE MAIN CONTROL VALVE BLOCKS .. 3-133 3.8.11 THROTTLE CHECK VALVES .......................................................................................... 3-134 3.8.11.1 REMOVAL OF THE THROTTLE CHECK VALVES ON THE MANIFOLD......... 3-138 3.8.11.2 REPLACEMENT OF THE THROTTLE CHECK VALVES ON THE MANIFOLD 3-140 3.8.12 MANIFOLD ........................................................................................................................ 3-141 3.8.12.1 REMOVAL OF THE MANIFOLD ........................................................................ 3-141 3.8.12.2 REPLACEMENT OF THE MANIFOLD .............................................................. 3-143 3.9

SLEW SYSTEM.............................................................................................................................. 3.9.1 SLEW GEAR...................................................................................................................... 3.9.1.1 REMOVAL OF THE SLEW GEAR ..................................................................... 3.9.1.2 REPLACEMENT OF THE SLEW GEAR............................................................ 3.9.2 SWING MOTOR ................................................................................................................ 3.9.2.1 REMOVAL OF THE SWING MOTOR ................................................................ 3.9.2.2 REPLACEMENT OF THE SWING MOTOR ...................................................... 3.9.3 SLEW PARKING BRAKE .................................................................................................. 3.9.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE (L&S) ............. 3.9.3.2 REPLACEMENT/ASSEMBLY OF THE SLEW PARKING BRAKE (L&S) .......... 3.9.3.3 REMOVAL OF THE SLEW PARKING BRAKE (SIEBENHAAR) ....................... 3.9.3.4 REPLACEMENT OF THE SLEW PARKING BRAKE (SIEBENHAAR) .............. 3.9.4 DYNAMIC SLEW BRAKE .................................................................................................. 3.9.4.1 REMOVAL OF THE SLEW BRAKE VALVE ...................................................... 3.9.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE .............................................

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3.9.5

SWING CIRCLE................................................................................................................. 3-182 3.9.5.1 REMOVAL OF THE SWING CIRCLE ................................................................ 3-184 3.9.5.2 REPLACEMENT OF THE SWING CIRCLE ....................................................... 3-187

3.10 LUBRICATION SYSTEM ............................................................................................................... 3.10.1 SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL) ........................................... 3.10.1.1 REMOVAL OF THE LUBRICATION PINION ASSEMBLY................................. 3.10.1.2 REPLACEMENT OF THE LUBRICATION PINION ASSEMBLY ....................... 3.10.2 LUBRICATION PUMP STATION ....................................................................................... 3.10.2.1 REMOVAL OF THE LUBRICATION PUMP STATION ...................................... 3.10.2.2 REPLACEMENT OF THE LUBRICATION PUMP STATION ............................. 3.10.2.3 REMOVAL OF THE LUBRICATION PUMP ....................................................... 3.10.2.4 REPLACEMENT OF THE LUBRICATING PUMP..............................................

3-192 3-192 3-194 3-196 3-198 3-202 3-204 3-205 3-207

3.11 OPERATOR’S CAB ....................................................................................................................... 3.11.1 REMOVAL OF THE OPERATOR’S CAB........................................................................... 3.11.2 REPLACEMENT OF THE OPERATOR’S CAB ................................................................. 3.11.3 VISCOUS CAB-MOUNTS.................................................................................................. 3.11.3.1 REMOVAL OF THE VISCOUS CAB-MOUNTS ................................................. 3.11.3.2 REPLACEMENT OF THE VISCOUS CAB-MOUNTS........................................ 3.11.4 FRONT WINDOW (WINDSCREEN) .................................................................................. 3.11.4.1 REMOVAL OF THE FRONT WINDOW ............................................................. 3.11.4.2 REPLACEMENT OF THE FRONT WINDOW .................................................... 3.11.5 OPERATOR’S SEAT ......................................................................................................... 3.11.5.1 REMOVAL OF THE OPERATOR’S SEAT ......................................................... 3.11.5.2 REPLACEMENT OF THE OPERATOR’S SEAT ............................................... 3.11.6 ECS.................................................................................................................................... 3.11.6.1 REMOVAL OF THE ECS TEXT DISPLAY ......................................................... 3.11.6.2 REPLACEMENT OF THE ECS TEXT DISPLAY ...............................................

3-208 3-211 3-216 3-218 3-218 3-220 3-222 3-222 3-223 3-224 3-224 3-225 3-226 3-226 3-226

3.12 CAB BASE (MEDIUM VOLTAGE SWITCH CABINET)................................................................. 3.12.1 REMOVAL OF THE CAB BASE ........................................................................................ 3.12.2 REPLACEMENT OF THE CAB BASE ............................................................................... 3.12.3 PUMP CONTROLLER ....................................................................................................... 3.12.3.1 REMOVAL OF THE PUMP CONTROLLER....................................................... 3.12.3.2 REPLACEMENT OF THE PUMP CONTROLLER .............................................

3-227 3-227 3-230 3-233 3-233 3-234

3.13 ACCESS LADDER ......................................................................................................................... 3.13.1 REMOVAL OF THE ACCESS LADDER ............................................................................ 3.13.2 REPLACEMENT OF THE ACCESS LADDER................................................................... 3.13.3 REMOVAL OF THE ACCESS LADDER CYLINDER......................................................... 3.13.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER ...............................................

3-236 3-239 3-243 3-245 3-247

3.14 COUNTERWEIGHT........................................................................................................................ 3-248 3.14.1 REMOVAL OF THE COUNTERWEIGHT .......................................................................... 3-248 3.14.2 REPLACEMENT OF THE COUNTERWEIGHT ................................................................. 3-251 3.15 SUPERSTRUCTURE LIFTING ...................................................................................................... 3.15.1 LIFT THE SUPERSTRUCTURE (PLATFORM, PN 910 605 40 ONLY) ............................ 3.15.2 DUMP THE SUPERSTRUCTURE (PLATFORM, PN 910 605 40 ONLY) ......................... 3.15.3 REMOVE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE ........................... 3.15.4 INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE.............................

3-252 3-252 3-255 3-256 3-261

3.16 HIGH VOLTAGE SWITCH CABINET ............................................................................................ 3-265 3.16.1 REMOVAL OF THE HIGH VOLTAGE SWITCH CABINET................................................ 3-266 3.16.2 REPLACEMENT OF THE HIGH VOLTAGE SWITCH CABINET ...................................... 3-270 TOC - 4

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3.17 SLIP RING UNIT ............................................................................................................................ 3-272 3.17.1 REMOVAL OF THE SLIP RING UNIT ............................................................................... 3-273 3.17.2 REPLACEMENT OF THE SLIP RING UNIT...................................................................... 3-277

4 UNDERCARRIAGE.................................................................................... 4-1 4.1

UNDERCARRIAGE OVERVIEW ....................................................................................................... 4-2

4.2

TRAVEL SYSTEM.............................................................................................................................. 4-4 4.2.1 TRACK GROUP..................................................................................................................... 4-4 4.2.1.1 CHANGING OF THE TRACK GROUP .................................................................. 4-4 4.2.2 SPROCKET ........................................................................................................................... 4-9 4.2.2.1 REMOVAL OF THE SPROCKET ASSEMBLY ...................................................... 4-9 4.2.2.2 REPLACEMENT OF THE SPROCKET ASSEMBLY ........................................... 4-14 4.2.3 GUIDE WHEELS (IDLERS) ................................................................................................. 4-16 4.2.3.1 REMOVAL OF THE GUIDE WHEEL ASSEMBLY ............................................... 4-16 4.2.3.2 REPLACEMENT OF THE GUIDE WHEEL ASSEMBLY ..................................... 4-18 4.2.4 TRACK TENSIONING ACCUMULATORS .......................................................................... 4-19 4.2.4.1 REMOVAL OF THE LOW PRESSURE ACCUMULATORS ................................ 4-19 4.2.4.2 REPLACEMENT OF THE LOW PRESSURE ACCUMULATORS ....................... 4-21 4.2.4.3 REMOVAL OF THE HIGH PRESSURE ACCUMULATORS ............................... 4-22 4.2.4.4 REPLACEMENT OF THE HIGH PRESSURE ACCUMULATORS ...................... 4-23 4.2.5 TRACK TENSIONING VALVE BLOCK................................................................................ 4-24 4.2.5.1 REMOVAL OF THE TRACK TENSIONING VALVE BLOCK ............................... 4-24 4.2.5.2 REPLACEMENT OF THE TRACK TENSIONING VALVE BLOCK...................... 4-26 4.2.6 TRACK TENSIONING CYLINDERS .................................................................................... 4-27 4.2.6.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS ................................... 4-27 4.2.6.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS .......................... 4-29 4.2.7 SUBSTITUTE THE HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM......... 4-31 4.2.7.1 SUBSTITUTE THE HYDRAULIC HOSES INSIDE THE CAR BODY .................. 4-33 4.2.7.2 SUBSTITUTE THE HYDRAULIC HOSE BETWEEN CAR BODY AND CRAWLER FRAME ..................................................................................... 4-33 4.2.7.3 SUBSTITUTE THE HYDRAULIC HOSES INSIDE THE CRAWLER FRAME...... 4-35 4.2.7.4 SUBSEQUENT WORK ........................................................................................ 4-36 4.2.8 TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE).................................................. 4-37 4.2.8.1 REMOVAL OF THE TRAVEL BRAKE VALVE BLOCK ....................................... 4-40 4.2.8.2 REPLACEMENT OF THE TRAVEL BRAKE VALVE BLOCK .............................. 4-42 4.2.9 TRAVEL MOTOR................................................................................................................. 4-43 4.2.9.1 REMOVAL OF THE TRAVEL MOTORS.............................................................. 4-43 4.2.9.2 REPLACEMENT OF THE TRAVEL MOTORS .................................................... 4-45 4.2.10 TRAVEL PARKING BRAKE................................................................................................. 4-46 4.2.10.1 REMOVAL OF THE TRAVEL PARKING BRAKE ................................................ 4-48 4.2.10.2 REPLACEMENT OF THE TRAVEL PARKING BRAKE....................................... 4-51 4.2.11 TRAVEL GEARBOX ............................................................................................................ 4-57 4.2.11.1 REMOVAL OF THE TRAVEL GEARBOX............................................................ 4-58 4.2.11.2 REPLACEMENT OF THE TRAVEL GEARBOX .................................................. 4-61 4.2.12 CARRIER ROLLER ............................................................................................................. 4-63 4.2.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY ........................................ 4-63 4.2.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY ............................... 4-66 4.2.13 TRACK ROLLER ................................................................................................................. 4-67 4.2.13.1 REMOVAL OF THE TRACK ROLLER ASSEMBLY ............................................ 4-67 4.2.13.2 REPLACEMENT OF THE TRACK ROLLER ASSEMBLY ................................... 4-69

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4.3

4.4

CAR BODY....................................................................................................................................... 4.3.1 REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH MOUNTING PINS) ......................................................................................... 4.3.2 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH MOUNTING PINS) ......................................................................................... 4.3.3 REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH BOLTED CONNECTION)............................................................................... 4.3.4 REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH BOLTED CONNECTION)............................................................................... 4.3.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS 4.3.5 ROTARY JOINT................................................................................................................... 4.3.5.1 REMOVAL OF THE ROTARY JOINT .................................................................. 4.3.5.2 REPLACEMENT OF THE ROTARY JOINT .........................................................

4-70 4-70 4-74 4-78 4-81 4-84 4-88 4-90 4-93

CABLE DRUM ASSEMBLY............................................................................................................. 4-94 4.4.1 REMOVAL OF THE CABLE DRUM ASSEMBLY ............................................................... 4-95 4.4.2 REPLACEMENT OF THE CABLE DRUM ASSEMBLY ....................................................... 4-97

5 ATTACHMENT........................................................................................... 5-1 5.1

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FACE SHOVEL (FSA)........................................................................................................................ 5-2 5.1.1 FSA OVERVIEW.................................................................................................................... 5-2 5.1.2 USING THE INSTALLATION TOOLS FOR HYDRAULIC CYLINDERS................................ 5-3 5.1.3 BOOM .................................................................................................................................... 5-4 5.1.3.1 REMOVAL OF THE BOOM.................................................................................... 5-4 5.1.3.2 REPLACEMENT OF THE BOOM .......................................................................... 5-9 5.1.3.3 REMOVAL OF THE BOOM CYLINDERS ............................................................ 5-14 5.1.3.4 REPLACEMENT OF THE BOOM CYLINDERS................................................... 5-19 5.1.4 STICK................................................................................................................................... 5-22 5.1.4.1 REMOVAL OF THE STICK .................................................................................. 5-22 5.1.4.2 REPLACEMENT OF THE STICK......................................................................... 5-26 5.1.4.3 REMOVAL OF THE STICK CYLINDERS ............................................................ 5-30 5.1.4.4 REPLACEMENT OF THE STICK CYLINDERS ................................................... 5-35 5.1.5 BULL CLAM BUCKET.......................................................................................................... 5-38 5.1.5.1 REMOVAL OF THE BULL CLAM BUCKET ......................................................... 5-40 5.1.5.2 REPLACEMENT OF THE BULL CLAM BUCKET................................................ 5-44 5.1.5.3 REMOVAL OF THE BUCKET CYLINDERS ........................................................ 5-46 5.1.5.4 REPLACEMENT OF THE BUCKET CYLINDERS ............................................... 5-51 5.1.5.5 REMOVAL OF THE CLAM CYLINDERS ............................................................. 5-56 5.1.5.6 REPLACEMENT OF THE CLAM CYLINDERS.................................................... 5-60 5.1.6 GROUND ENGAGING TOOLS (GET)................................................................................. 5-64 5.1.6.1 REMOVAL AND REPLACEMENT OF THE GET................................................. 5-66 5.1.7 HYDRAULIC HOSES AT THE FACE SHOVEL ATTACHMENT ......................................... 5-68 5.1.7.1 SUBSTITUTE THE BOOM ARC HOSES............................................................. 5-68 5.1.7.2 SUBSTITUTE THE BOOM CYLINDER HOSES .................................................. 5-72 5.1.7.3 SUBSTITUTE THE STICK ARC HOSES ............................................................. 5-76 5.1.7.4 SUBSTITUTE THE STICK CYLINDER HOSES .................................................. 5-82 5.1.7.5 SUBSTITUTE THE BUCKET CYLINDER HOSES .............................................. 5-86 5.1.7.6 SUBSTITUTE THE CLAM CYLINDER HOSES ................................................... 5-92

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5.2

METERING VALVES (GREASE INJECTORS) AT THE ATTACHMENT ..................................... 5.2.1 CHECK THE OPERATION OF THE METERING VALVES (GREASE INJECTORS) ....... 5.2.2 REMOVAL OF THE METERING VALVES (GREASE INJECTORS)................................. 5.2.3 REPLACEMENT OF THE METERING VALVES (GREASE INJECTORS) .......................

5-100 5-101 5-102 5-103

5.3

CYLINDER BYPASS TEST ........................................................................................................... 5-104

6 SERVICE INFORMATION ......................................................................... 6-1 6.1

FLUIDS AND LUBRICANTS.............................................................................................................. 6-2

6.2

FILLING CAPACITIES ....................................................................................................................... 6-3

6.3

WORK INSTRUCTIONS .................................................................................................................... 6-4 6.3.1 REMOVE / INSTALL THE CRAWLER CARRIER ................................................................. 6-4

6.4

WEIGHT TABLES .............................................................................................................................. 6.4.1 SUPERSTRUCTURE ............................................................................................................ 6.4.1.1 UNDERCARRIAGE................................................................................................ 6.4.1.2 FACE SHOVEL ATTACHMENT (FSA) ..................................................................

6.5

TORQUE CHARTS ACCORDING TO ISO ...................................................................................... 6.5.1 METRIC STANDARD THREAD........................................................................................... 6.5.2 METRIC FINE THREAD ...................................................................................................... 6.5.3 SAE FLANGE CONNECTIONS ...........................................................................................

6-10 6-10 6-11 6-12

6.6

BLIND PLUGS ................................................................................................................................. 6.6.1 DUMMY PLATES FOR SAE–FLANGES ............................................................................. 6.6.2 CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH ........................................... 6.6.3 PLUGS AND FITTINGS ACCORDING TO EN ISO 84 34-1 ...............................................

6-14 6-14 6-16 6-17

6.7

CONVERSION TABLE..................................................................................................................... 6.7.1 METHOD OF USING THE CONVERSION TABLE ............................................................. 6.7.2 MILLIMETER - INCH & KILOGRAM - POUND.................................................................... 6.7.3 LITER - U.S. GALLON & LITER - U.K. GALLON................................................................. 6.7.4 NM- FT.LB ........................................................................................................................... 6.7.5 BAR - PSI - KPA - MPA ....................................................................................................... 6.7.6 BASIC VALUES IN OHM ACCORDING TO DIN 4376 / IEC 751 ........................................ 6.7.7 TEMPERATURE..................................................................................................................

6-18 6-18 6-19 6-20 6-21 6-22 6-23 6-24

6.8

TOOLS ............................................................................................................................................. 6-25 6.8.1 STANDARD TOOL CASE.................................................................................................... 6-25 6.8.2 USED SPECIAL TOOLS (OVERVIEW) ............................................................................... 6-27

6-5 6-5 6-8 6-9

7 TOOLS CATALOGUE................................................................................ 7-1 8 PARTS & SERVICE NEWS ....................................................................... 8-1 AH00511 Installation procedure for the swing circle / Slew Ring (SR) AH00514 Track group - Hints for sprocket exchange AH00515 Final drive: Wear and tear measurements Mounting procedures AH00519 Adhesive lubricants for the Slew Ring Gear

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AH01513 Bleeding of hydraulic pumps AH01516 Lift off the superstructure platform from the undercarriage for instance to change the swing circle (slew ring) AH01523 Replacement of the elastic coupling (Electro drive shovels) AH01531 Hydraulic accumulators - testing and refilling AH02513 Testing wear and tear of swing circle bearing AH02521 Track group – wear measurement AH03506 Hydraulic oil cooler and water cooler fan bearings AH03510 ESCO bucket tooth system AH03528 Pilot control safety line AH04518 Welding procedure for welded counterweight AH05501 Abnormal vibration on hydraulic pipes AH05510 Bearing flushing of the A4VS variable displacement axial piston pump AH05511 Dual cone seal ring mounting AH05518 Swing circle pinion AH05525 Suction elbows of the main Pumps AH05535 Hints for replacing by the slewing gear of an other manufacturer AH05546 Automatic lubrication system - Vent valve (PN 769 879 73) AH06512 Travel gears - Brake and motor adapter housings - Oil Change AH06524 Hydraulic cylinder AH06530 Relieving of the track chain tension AH06544 Hydraulic track tensioning system –Pressure increasing valve AH06545 Hydraulic cylinder bushings AH08504 Windscreen AH08507 Steel structure AH08508 Bushings of the attachment and at the undercarriage

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AH08516 Hoses between boom and stick AH08532 Hoses between boom and stick

9 SUPPLIER’S DOCUMENTATION ............................................................. 9-1 AVANTI HYTORQUE

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Introduction

1 INTRODUCTION

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Contents of the binder

1.1

Introduction

CONTENTS OF THE BINDER

Assembled in this file are the R&R Procedures with explanations of removing, installing, and adjustments of the major components and circuits for your KOMATSU Hydraulic Mining Shovel.

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Foreword

FOREWORD

Observe the instructions in this manual for: z

Your Personal SAFETY

z

Operating SAFETY, and

z

READY and EFFICIENT PERFORMANCE of your KOMATSU Hydraulic Mining Shovel.

With this R&R Procedures Manual, KOMATSU provides you with the description of proper removal and replacement procedures of main components.

How do you find "your" desired information? In the TABLE OF CONTENTS all R&R PROCEDURES are shown in their sequence of description.

CAUTION Periodic preventive inspections and maintenance are the surest means of keeping the machine in proper working order. Prompt detection and correction of minor irregularities and immediate replacement of worn out or broken parts will prevent failures and avoid expenses.

Replace damaged graphics and symbols. Observe safety precautions to prevent injury and damage. If, after reading this R&R Procedures Manual, you can give us suggestions and comments for improvements - please do not hesitate to contact us.

Komatsu Mining Germany GmbH Service Training and Manuals Department 8151.30 P.O. Box 18 03 61 D - 40570 Düsseldorf GERMANY

WARNING Personnel entrusted with work on the machine must have read the section 2 SAFETY before beginning work. Reading the instructions after work has begun is too late.

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Introduction

Damages and defects caused by incorrect operation and maintenance are not covered by the manufacturer’s guarantee. In order to keep your shovel in first-class operating condition only use genuine spare and wear parts. The use of any part other than the genuine part releases the KOMATSU MINING GERMANY GmbH from any guarantee.

1.2.1

SERVICE

In all your written or phoned inquiries, please indicate the model and serial number of your shovel.

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2 SAFETY

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General information

Safety

2.1

GENERAL INFORMATION

2.1.1

METHOD OF USING THIS MANUAL

When removing or installing a unit assembly, the order of work and techniques used are given for the removal procedure. The order of work for the installation is only given if the installation procedure differs from installation in reverse order of removal, for example any special technique needs to be applied. Tightening torques according to ISO are not explicitly given in the installation procedures. For tightening torques according to ISO, refer to section 6.5 on page 6-10. Figure references that appear in the operation procedures use the format (Fig. 4-12, Pos. 4), which means position number 4 in figure 12 of section 4. Special requirements such as listing of special tools or size or numbers of blind plugs etc. are listed in a table at the beginning of each operation procedure. Special tools that appear in the lists are given with part name, part number, and quantity (2 x thread protector, PN 409 329 40). For the special tools list, refer to section 6.8.2 on page 6-27. The following text designations are used in the manual with the following intend: –

Refers to listings of none particular order.

z

Refers to working steps within the procedures.

The following symbols are used in the manual to designate additional information as shown in the following examples: Kind and amount of drained fluids (e.g. drain oil, 1500 liters).

Lifting weight of an assembly (e.g. 140 kg). Kind and amount of fluids to fill (e.g. fill oil, 1500 liters). Special tightening torques for bolts etc., if not according to ISO (e.g. 129 Nm). General information concerning a section, e.g. tightening torques according to ISO, refer to section 6.5 on page 6-10.

Special authorized personnel is required.

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General information

All PARTS & SERVICE NEWS which are mentioned in the procedures are listed in chapter 8. The numbers of the PARTS & SERVICE NEWS do not label the latest edition. Ensure that the latest edition is always filed to the binder of this manual. The following symbols and designations are used in the manual to designate instructions of particular importance: DANGER Refers to orders and prohibitions designed to prevent serious injury or death.

WARNING Refers to orders and prohibitions designed to prevent injury or extensive damage.

CAUTION Refers to special information and/or orders and prohibitions directed towards preventing damage.

NOTE: Refers to special information on removing or installing assemblies, for example if any special technique needs to be applied.

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Safety instructions

Safety

2.2

SAFETY INSTRUCTIONS

2.2.1

GENERAL PRECAUTIONS CAUTION

Proper service and repair is important for safe machine operation. The service and repair techniques recommended by Komatsu Mining Germany and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu Mining Germany for the specific purpose.

NOTE: Always attend to local regulations regarding the Personal Protective Equipment. WARNING z

Mistakes in operation and service are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

z

Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.

z

When carrying out any operation, always wear safety shoes and a helmet. Do not wear loose work clothes or clothes with buttons missing.

z

Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.

z

Assure fire prevention according to the Operation & Maintenance Manual.

z

If welding repairs are needed, refer to the welding precautions given in the Operation & Maintenance Manual.

z

When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's cab.

z

Keep all tools in good condition and learn the correct way to use them.

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WARNING Decide on a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. An pilot control safety line monitores all safety relevant components at the high voltage system. This pilot control safety line must be connected properly at the excavator and at the power plant / external transformer station. For further information about the monitored components, refer to the PARTS & SERVICE NEWS No. "AH03528" and the wiring diagram of the excavator.

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Safety instructions

2.2.2

Safety

PREPARATIONS BEFORE WORK WARNING

Before beginning any work operations set the maintenance safety switch (Fig. 2-1, Pos. 3) to -0- position to prevent starting of the engines during the work. Fold up the flap (Fig. 2-1, Pos. 2) and secure this position by inserting a padlock into the holes (Fig. 2-1, Pos. 4) of the flap (Fig. 2-1, Pos. 2) and the safety switch (Fig. 2-1, Pos. 1).

Fig. 2-1 WARNING z

Before adding oil or making repairs, park the machine on hard, level ground large enough to accommodate the machine, boom, and additional working equipment (crane mobile working platforms, forklift etc.).

z

If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane mobile working platforms, forklift etc.), make sure that the machine is moved to a place with appropriate ground conditions. Block the tracks to prevent the machine from moving.

z

Before starting work, lower bucket, hammer, or any other work equipment to the ground. If this procedure is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. Additionally, be sure to lock all the control levers and hang warning signs on them.

z

When disassembling or assembling, support the machine with blocks, jacks, or supports before starting work.

z

Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders, or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders, or steps, use a stand to provide safe footing.

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Safety instructions

DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only. Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.

2.2.3

PRECAUTIONS DURING WORK WARNING

z

When removing the oil filler cap, drain plug, or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. The oil can be very hot, so be careful not to get burnt. Wait for the oil to cool down before carrying out work.

z

Before starting work, isolate the machine according to local regulations. Remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.

z

When raising heavy components (25 kg or more), use a hoist or crane.

z

Check that the wire rope, chains, and hooks are free from damage.

z

Always use lifting equipment which has ample capacity.

z

Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

z

When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.

z

When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.

z

When removing any piping, stop the fluids from spilling out. If any oil drips on to the floor, wipe it up immediately. Oil on the floor can cause you to slip, or can even start fires.

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Safety

WARNING z

As a general rule, do not use gasoline to wash parts.

z

Be sure to assemble all parts in their original places again. Replace any damaged parts with new parts.

WARNING z

When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.

z

When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.

z

When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.

z

When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

DANGER Danger of explosion! Serious injury, permanent disfigurement, and scarring may result! Special care must be taken before welding, flame-cutting, and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can create explosive gases which will accumulate in the chambers of the counterweight. These gases must be expelled before welding, flame-cutting, and grinding operations are carried out on the counterweight. Follow the instructions given in PARTS & SERVICE NEWS No. "AH04518" for expelling the gases from the counterweight chambers.

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Safety instructions

2.2.3.1 PRECAUTIONS WITH HIGH PRESSURE OIL DANGER The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to serious injury. do not carry out any inspection or replacement operation.

If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping and hoses and for swelling in the hoses. WARNING When carrying out inspections, wear full-face protection and penetration resistant clothing and gloves.

DANGER There is a hazard that high-pressure oil leaking from small holes may penetrate your skin or cause blindness if it contacts your eyes directly. If you are hit by a jet of high-pressure oil and suffer injury to your skin or eyes, wash the place with clean water, and consult a doctor immediately for medical attention.

Fig. 2-2

WARNING Leaks in high-pressure hoses may cause fire or defective operation, which may lead to serious injury. z

Replace the hose if a damaged or leaking hydraulic fitting is found.

z

Replace the hose if a frayed or cut covering or an exposed reinforcement wire layer is found.

z

Replace the hose if a covering is swollen in places.

z

Replace the hose if movable portions are wisted or crushed.

z

Replace the hose if foreign material (splinters etc.) is embedded in the covering of the hose.

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Safety instructions

2.2.4

Safety

WARNING OF SPECIAL DANGERS

2.2.4.1 ELECTRICAL ENERGY WARNING z

Use only original fuses and circuit breakers with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system.

z

Work on the electrical system or equipment may only be carried out by a skilled electrician himself or by specially instructed personnel under the control and supervision of such electrician and in accordance with the applicable electrical engineering rules.

z

If provided for in the regulations, the power supply to parts of the machine, on which inspection, maintenance, and repair work is to be carried out must be cut off. Before starting any work, check the de-energized parts for the presence of power and ground or short-circuit them in addition to insulating adjacent live parts and elements.

z

If your machine comes into contact with a live wire: z

do not leave the machine.

z

drive the machine out of the hazard zone.

z

warn others against approaching and touching the machine.

z

have the live wire de-energized.

z

do not leave the machine until the damaged line has been safely de-energized.

z

The electrical equipment of the machine is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

z

Necessary work on live parts and elements must be carried out only in the presence of a second person who can cut off the power supply in case of danger by actuating the emergency shut-off or main power switch. Secure the working area with a red-and-white safety chain and a warning sign. Use insulated tools only.

z

Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

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Safety instructions

2.2.4.2 GAS, DUST, STEAM AND SMOKE WARNING z

Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly approved, as there may be a risk of explosion and fire.

z

Special care must be taken before welding, flame-cutting and grinding operations are carried out on the counterweight. The filling of the counterweight chambers can create explosive gases which will accumulate in the chambers of the counterweight. These gases must be expelled before welding, flame-cutting and grinding operations are carried out on the counterweight. Danger of explosion. Follow the instructions given in PARTS & SERVICE NEWS No. "AH04518" for expelling the gases from the counterweight chambers.

z

Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surrounding from dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).

2.2.4.3 NOISE WARNING z

During operation, all sound baffles must be closed.

z

Always wear the prescribed ear protectors.

2.2.4.4 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES WARNING When handling oil, grease, and other chemical substances, observe the product-related safety regulations given in the material safety data sheet (MSDS).

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Safety instructions

Safety

2.2.4.5 HYDRAULIC, AIR CONDITIONING AND PNEUMATIC EQUIPMENT WARNING z

Work on hydraulic equipment and the air conditioning system may only be carried out by persons having special knowledge and experience in this systems.

z

Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair any damage immediately. Splashed oil may cause injury and fire.

z

Depressurize all system sections and pressure pipes (hydraulic system, compressed-air system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

z

Refrigerant in the air conditioning system must be sucked off by authorized service specialists only before opening the refrigerant loop (e.g. removing pipes).

z

Hydraulic, air conditioning and compressed-air lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths, and quality of the hoses must comply with the technical requirements.

2.2.4.6 HEAT WARNING z

Do not start working on hot machine parts until the temperature is below 50 °C.

z

Be careful when handling hot materials (risk of burning or scalding) such as:

z

z

Hot cables

z

Hydraulic oil

z

Grease

Use gloves when handling hot machine parts.

2.2.4.7 HEIGHT WARNING When working in heights above 1.00 m, a special safety harness is required, refer to section 2.2.5 on page 2-15.

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Fig. 2-3 2 - 14

Safety

Safety harness in conformity with EN 361 PC8000-6E

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2.2.5

Safety instructions


2.2.5.1 SAFETY HARNESS IN CONFORMITY WITH EN 361 (EUROPEAN STANDARD) The safety harness (Fig. 2-3) should only be used together with connectors according to EN 354, and fall arrest according to EN 355, or fall protection devices according to EN 360. Legend for Fig. 2-3: (1)

Safety harness according to EN 361

(2)

Strap-type fall absorber according to EN 355

(3)

Ladder to cab roof and railings (attachment points)

(4)

Protection hoods for roof mounted air conditioning, if so equipped

(A)

Shoulder strap

(B)

Back plate

(C)

Catching hook

(D)

Shoulder-strap fixing

(E)

Belly strap

(F)

Holding hook

(G)

Hold-back hook

(H)

Pelvis strap

(J)

Leg strap

WARNING Always use the safety harness (Fig. 2-3, Pos. 1) in conjunction with strap-type fall absorber (Fig. 2-3, Pos. 2), before mounting onto the loader attachment or other unsecured places of the shovel.

NOTE: The illustration (Fig. 2-3) shows a typical use of the safety harness. Shovels with the new type operator’s cab are not equipped with ladder (Fig. 2-3, Pos. 3), because the air conditioner unit of the new type cab is located on the back wall of the cab.

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Safety instructions

Fig. 2-4 2 - 16

Safety


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Safety instructions

2.2.5.2 INSTRUCTIONS FOR USE Open the lock and lift the harness by the catch hook (Fig. 2-4, Pos. C). The blue straps (leg straps Fig. 2-4, Pos. J) must be at the bottom. The harness is being put on just like a jacket. Pull the belly strap (Fig. 2-4, Pos. E) through the lock, as shown in the illustration, and secure it. By closing the breast strap, you avoid the shoulder straps to sideslip. Bring the leg straps (Fig. 2-4, Pos. J) around the legs to the front, pull them in, as shown in the illustration, and tighten them. Adapt the harness to body form, seeing to perfect fit, in particular that the catching hook (Fig. 2-4, Pos. C) is aligned in the centre of the back. The safety harness should belong to its wearer personally. The safety harness should only be used together with connectors according to EN 354, and fall arrest according to EN 355, or fall protection devices according to EN 360. The attachment point for the safety harness should be above the wearer, and the carrying capacity of the attachment point should be sufficient to correspond with the minimum carrying capacity according to EN 795. z

Before using the harness: z

Carry out a visual check of the system or components. The correct functioning and perfect working order have to be assured.

z

Make sure that the recommendations for use with other components of the system are observed in conformity with the instructions for use. WARNING

The system or component must no longer be used, if there are any doubts in respect of its safe condition. The equipment has to be inspected by the manufacturer or by a qualified person. It is essential for safety reasons that a fall protection system or system component which has already been subjected to fall is removed from the service and sent back to the manufacturer or to an authorized qualified repair shop for maintenance and renewed testing.

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Safety instructions

Fig. 2-5 2 - 18

Safety


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Safety

Safety instructions

Fall protection systems have to be treated with care and to be kept clean and ready for use. It has to be warned against bringing the systems into contact with acids or other caustic liquids and gases, oils, detergents, or sharp-edged objects. If the harness has become wet during use or cleaning, do not dry near a fire or other sources of heat, but rather in a natural way in not too warm rooms. Keep the harness freely suspended or loosely rolled up. When using the fall protection systems, the pertaining safety regulations in force and the "Rules for Use of Personal Fall Arrest Systems" have to be observed for protection against danger. WARNING At least every 12 months, the safety harness and its components have to be inspected by a competent person authorized by the manufacturer and they have to be maintained, if the manufacturer considers it to be necessary.

2.2.5.3 RECOMMENDATIONS FOR USE OF THE HOLDING HOOKS AND HOLD-BACK HOOKS OF THE SAFETY HARNESS During the holding function, the connectors may only be placed around a mast or any other construction between the two holding hooks, so that the free fall is limited to max. 0.5 m. It should be strictly seen to it that the connector is not slung around constructions with too small diameters or sharp edges. With the lateral holding hooks, work may only be carried out on horizontal or almost horizontal surfaces (roofs). The connectors have to be adjusted in such a way that the area, where danger of falling down prevails, cannot be reached.

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Safety instructions

Fig. 2-6 2 - 20

Safety


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Safety instructions

2.2.5.4 INSTRUCTIONS FOR USING THE FALL ABSORBER Strap-type fall absorber according to EN 355 (type E.K.N.-BFD) Use Within a fall-arrest system, the strap-type fall absorber (Fig. 2-6, Pos. 2) has to be used in conjunction with a safety harness (Fig. 2-6, Pos. 1) according to EN 361. The maximum length including the safety rope must not exceed 2.0 m. For longer ropes, a rope-shortening device has to be applied in addition. Fix the rope to the attachment point and attach the strap-type fall absorber to the catching hook in the back of the safety harness. The attachment point should be above the wearer and its minimum carrying capacity should be 10 kN, according to EN 795. The strap-type fall absorber and the safety rope must not be damaged, e.g. never pull them over sharp edges nor get them burnt by welding sparks. Storing and maintenance The strap-type fall absorber has to be kept dry in an airy and shady room. It must not be exposed to acids, caustic chemicals, nor to an aggressive atmosphere, and contact with any oil has to be avoided. If the strap-type fall absorber is dirty, it may be cleaned with a little water and a light-duty detergent. Dry it in a shady place (nowhere near fire or other sources of heat). Protect it from sharp-edged objects. Inspection Prior to use, all parts have to be inspected for safe condition and damages. At least once a year, the strap-type fall absorber has to be tested by a competent person. A damaged or used strap-type fall absorber has to be removed from the service immediately. The strap-type fall absorber must not be changed in any way. Repair work has to be done by the manufacturer or by an authorized qualified repair shop.

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Safety instructions

2.2.6

Safety

SAFETY HINTS FOR HYDRAULIC HOSE INSTALLATION WARNING

The hydraulic hoses undergo natural aging. Hence, as they are safety critical parts, their usable lifetime is limited. For further information refer to the Operation and Maintenance Manual, chapter 4, section "REPLACEMENT OF HYDRAULIC HOSE LINES AND FUEL HOSE".

To avoid damage to the hydraulic hose lines, follow the installation procedures listed below: CAUTION Pay attention to the Natural curvature of the hose!

Fig. 2-7

CAUTION Do not twist the hoses during installation!

Fig. 2-8

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Safety instructions

CAUTION Mount angled flanges at first!

Fig. 2-9

CAUTION Pay attention to the changing in hose length, depending on the pressure inside the hose!

Fig. 2-10

CAUTION Pay attention to the bending radius!

Fig. 2-11

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Safety instructions

Safety

CAUTION Pay attention to the bending radius!

Fig. 2-12

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Safety

2.2.7

Safety instructions

SAFETY HINTS FOR LIFTING HEAVY PARTS

NOTE: In order to avoid damage to the lifting devices or parts that have to be lifted, use edge protection at all sharp edges. CAUTION Heavy parts (25 kg or more) must be lifted with a hoist etc.

CAUTION If any part cannot be removed from the machine smoothly by hoisting, the following checks should be made: Check for the removal of all bolts fastening the component to other parts. Check for existence of another part causing interference with the component to be removed.

2.2.8 z

SAFETY HINTS FOR WIRE ROPES

Use adequate ropes depending on the weight of the parts to be hoisted, referring to the below table: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter [mm]

10.0

11.2

12.5

14.0

16.0

18.0

20.0

22.4

30.0

40.0

50.0

60.0

Allowable load [Metric tons]

1.0

1.4

1.6

2.2

2.8

3.6

4.4

5.6

10.0

18.0

28.0

40.0

CAUTION The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used.

WARNING The table above may differ from local standards. Always attend to local standards when using wire ropes.

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Safety instructions

Safety

z

Sling wire ropes around the middle portion of the hook. Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting, which may cause a serious accident. Hooks have the maximum strength at the middle portion, see Fig. 2-13.

z

Do not sling a heavy load with one rope alone, but sling it with two or more ropes wound symmetrically around the load. WARNING

Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which may cause a serious accident.

z

Fig. 2-13

Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. Figure 2-14 shows the variation of allowable load (kg) where hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be lifted. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°. Fig. 2-14

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Safety

2.2.9

Safety instructions

SAFETY HINTS FOR SLING ACCESSORY WARNING

Always attend to local standards when using sling accessory.

z

Do not use rigid eye bolts from steel C 15 for lifting (e.g. DIN 580). These eye bolts may only be loaded vertically or with a maximum permissible angle of 45° to the ring.

z

Always use suitable swivel hoist rings according to local standards or Vario-Starpoint hoist rings recommended by Komatsu, see following table: Thread

Komatsu Part Number

Tightening Torque

M8

941 650 40

10 Nm

M10

941 651 40

10 Nm

M12

906 519 40

25 Nm

M16

906 780 40

60 Nm

M20

906 782 40

115 Nm

M24

906 783 40

190 Nm

M30

906 421 40

330 Nm

M36

906 233 40

590 Nm

DANGER Vario-Starpoint hoist rings are not suited for turning under load. After installing Starpoint hoist ring disengage the star key. Adjust ring plane in direction of pull before attaching sling accessory.

DANGER Eye bolts or sling accessory which is not suitable can result in serious accidents.

z

Check that the wire rope, chains, and hooks are free from damage.

z

Always use lifting equipment which has ample capacity.

z

Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

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Grounding procedure of the high voltage system

2.3

Safety

GROUNDING PROCEDURE OF THE HIGH VOLTAGE SYSTEM

Special tools:

Measuring rod, PN 232 390 40 (for voltage range 3...6 kV) Measuring rod, PN 232 389 40 (for voltage range 5...10 kV) Universal grounding short-circuting device, PN 232 386 40

Additional equipment:

n/a

Electrician with permission to work on high voltage systems

The below procedure must be carried out for safety reasons, before any work is carried out on the high voltage system of the excavator. DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. z

The following safety measures have to be carried out before any work on the high voltage system by authorized electricians having the permission to work on high voltage systems only.

z

Carry out the work according to the local safety regulations.

z

All safety devices requested by the local safety regulations must be available and used for any work on the high voltage systems.

Safety Measures z

Switch off the power supply from the power station and ground the power supply line securely.

z

Remove the padlock or the bolt (Fig. 2-1, Pos. 1) and open the flap (Fig. 2-1, Pos. 2) at the high voltage switch cabinet (Fig. 2-1, Pos. 3) to gain access to the load cut-off. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Do not open the high voltage switch cabinet door (Fig. 2-1, Pos. 4) until the load cut-off is in OFF position.

Fig. 2-1

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z


Turn the load cut-off (Fig. 2-2, Pos. 2) to OFF position using the key (Fig. 2-2, Pos. 1). DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Do not open the switch cabinet door (Fig. 2-2, Pos. 4) until the load cut-off is in OFF position.

z

Remove the padlock and open high voltage switch cabinet door (Fig. 2-2, Pos. 4).

z

Make sure that the power supply from the power station is switched off by placing a measuring rod (Fig. 2-2, Pos. 5) to the ball headed stud (Fig. 2-2, Pos. 3) of the load cut-off switch copper bar. The indication on the measuring rod must show zero potential.

z

Fig. 2-2

Make sure the grounding harness (Fig. 2-3, Pos. 4) is ready for use.

NOTE: The grounding harness is part of the universal grounding short-circuting device, PN 232 386 40. z

Connect the grounding harness (Fig. 2-3, Pos. 4) as follows: z

Connect the long single cable (Fig. 2-3, Pos. 6) of the harness to a threaded stud (Fig. 2-3, Pos. 8) and secure it with the wing nut (Fig. 2-3, Pos. 7).

z

Connect the three remaining cables of the grounding harness to the ball headed studs (Fig. 2-3, Pos. 1) of the load cut-off switch copper bars by means of the clamps (Fig. 2-3, Pos. 2), using the insulated extension rod (Fig. 2-3, Pos. 5).

z

Secure the clamps (Fig. 2-3, Pos. 2) by tightening the Fig. 2-3 screws (Fig. 2-3, Pos. 3) using the insulated extension rod.

NOTE: The insulated extension rod is part of the universal grounding short-circuting device, PN 232 386 40.

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Safety

DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Carry out the next steps after relieving the residual voltage from load cut-off switch bars only.

z

Remove one cable (Fig. 2-4, Pos. 1) of the grounding harness from its ball headed stud at the load cut-off switch copper bars using the insulated extension rod (Fig. 2-4, Pos. 3).

z

Touch all mounting bolts (Fig. 2-4, Pos. 4) of the phase lines (L1, L2 and L3) at each current transformer (Fig. 2-4, Pos. 1), located on the opposed wall of the high voltage switch cabinet with the cable (Fig. 2-4, Pos. 1) alternately. Fig. 2-4

NOTE: These connections will also relief the residual voltage from the capacitors. z

Reconnect the cable to the ball headed stud at the load cut-off switch copper bar.

z

Make sure the grounding harness remains connected as long as any work at the excavator is carried out.

After work: z

After work is finished, remove the grounding harness from the load cut-off switch and store it in a safe place. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. For safety reasons, the access to the high voltage switch cabinet must be blocked for unauthorized personnel. Lock the switch cabinet door with an appropriate padlock.

z

Close the door (Fig. 2-5, Pos. 4) of the high voltage switch cabinet and lock the door with the provided padlock.

z

Close the flap (Fig. 2-5, Pos. 2) of the load cut-off switch and secure the flap with the provided padlock or a bolt (Fig. 2-5, Pos. 1).

z

Fig. 2-5

Switch on the power supply from the power station.

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2.4

Explanation of abbreviations

EXPLANATION OF ABBREVIATIONS

Abbrev.

Definition

A

Ampere

AC

Alternating Current

ACV

Anti-Cavitation Valve

API

American Petroleum Institute

BHA

Backhoe Attachment

°C

Degree Celsius

CLS

Central Lubrication System

CO

Cut Off function (main pump)

DC

Direct Current

DFT

Dry paint Film Thickness [1/1000 inch]

FSA

Front Shovel Attachment

GET

Ground Engaging Tools

HP

High Pressure

HT

High Tension

kV

Kilo Volt (1000 Volt)

LED

Light Emitting Diode

MRV

Main Relief Valve

PIV


PTO

Power Take-Off (Pump Distributor Gear)

Qmax

Maximum pump delivery = maximum swash plate angle

Qmin

Minimum pump delivery = minimum swash plate angle

1/2 Qmax

1/2 pump delivery

SLS

Swing circle pinion Lubrication System

SRV

Secondary Relief Valve

V

Volt

WFT

Wet paint Film Thickness [1/1000 inch]

1/min

Revolutions Per Minute (RPM)

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Explanation of abbreviations

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PC8000-6E

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Superstructure

3 SUPERSTRUCTURE

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3 -1

Superstructure overview

Superstructure

3.1

SUPERSTRUCTURE OVERVIEW

Fig. 3-1

PC8000-6E, Superstructure - top view

3 -2

PC8000-6E

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Superstructure


Legend for Fig. 3-1: (1)

Hydraulically operated access ladder

(2)

Operator’s cab

(3)

Slew gears

(4)

Hydraulic oil coolers

(5)

Main hydraulic oil reservoir

(6)

Return oil reservoir with return oil filters

(7)

Main control valve block

(8)

Front PTO (pump distributor gear)

(9)

Flexible coupling with protection cover

(10)

Front electric motor (motor 1)

(11)

Cooling air intake

(12)

Main hydraulic pumps

(13)

Rear PTO (pump distributor gear)

(14)

Rear electric motor (motor 2)

(15)

Motor connecting box

(16)

Counter weight

(17)

Slip ring unit

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Fig. 3-2

Superstructure

PC8000-6E, Superstructure - side view

(1)

Operator’s cab

(2)

Support frame

(3)

Cab base (medium voltage switch cabinet)

(4)

Swing circle

(5)

Cooling air intake

(6)

Hydraulically operated access ladder

(7)

Counterweight

(8)

Cooling air outlet

(9)

Stairway

(10)

High voltage switch cabinet

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Version 2010/1

Superstructure

service crane (optional)

3.2

SERVICE CRANE (OPTIONAL)

3.2.1

REMOVAL OF THE SERVICE CRANE

Special tools:

n/a


Crane Service crane MGK: 2050 kg

Dogman/rigger Electrician with permission to work on high voltage systems

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane.

z

Park the machine on the prepared flat ground area.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. z

Isolate the machine according to local regulations. DANGER

Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z

Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.

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z

Superstructure

Make sure that the safety hook of the service crane is safely connected to the crane base (Fig. 3-3, arrow). DANGER

Hazardous Voltage! Risk of electric shocks. Death or burns may result. Every work at the switch box has to be carried out by authorized electricians only.

z

Disconnect the wire harness from the switch box (Fig. 3-3, Pos. 4) at the hydraulic power unit.

z

Sling the service crane at the crane base (Fig. 3-3, Pos. 1). and the upper part of the crane. Fig. 3-3 WARNING

Observe the center of gravity. Make sure that the crane can not knock over while lifting off.

z

Remove the bolts (Fig. 3-3, Pos. 2) and lift the service crane off the mounting blocks (Fig. 3-3, Pos. 3) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the service crane, make sure that nobody steps below the weight.

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3.2.2


REPLACEMENT OF THE SERVICE CRANE

Special tools:

n/a


Crane Compound "KP2K", PN 324 969 40 Service crane MGK: 2050 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

DANGER Hazardous Voltage! Risk of electric shocks. Death or burns may result. Every work at the switch box has to be carried out by authorized electricians only.

z

Carry out installation in reverse order to removal.

NOTE: Always use new mounting bolts (Fig. 3-3, Pos. 2) of grade 10.9. Apply compound "KP2K", PN 324 969 40 on the bolts.

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Engine house roof

Superstructure

3.3

ENGINE HOUSE ROOF

3.3.1

REMOVAL OF THE ROOF PLATES

Fig. 3-4

Roof plate overview (engine house)

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PC8000-6E

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Superstructure

Engine house roof


Roof plate "cooling air intake"

(2)

Roof plate "motor"

(3)

Roof plate "PTO"

(4)

Roof plate "main pumps"

(5)

Threaded rail

(6)

Roof plate "cooling air outlet"

(7)

Bolt

(8)

Nut

(9)

Bolt

(10)

Resilient sleeve

(11)

Bolt

(12)

Lock washer

(13)

Profiled joint

(14)

Moulding material

(15)

Roof carrier

NOTE: Remove the roof plates to perform the following individual tasks: Removal of the electric motors -Roof plate "cooling air intake" (Fig. 3-4, Pos. 1) -Roof plates "motor" (Fig. 3-4, Pos. 2) -Roof plate "cooling air outlet" (Fig. 3-4, Pos. 6)

Removal of the PTO - Roof plate "PTO" (Fig. 3-4, Pos. 3) - Roof plate "main pumps" (Fig. 3-4, Pos. 4)

Removal of the main pump assemblies - Roof plate "main pumps" (Fig. 3-4, Pos. 4)

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Engine house roof

Fig. 3-5

3 - 10

Superstructure

Roof plate removal

PC8000-6E

Version 2010/1

Superstructure

Engine house roof

Special tools:

n/a


Crane Safety harness in conformity with EN 361 Swivel hoist rings: 4 x M12 Compound "KP2K", PN 324 969 40 Roof plate "motor": 185 kg Roof plate "cooling air intake": 175 kg Roof plate "cooling air outlet": 250 kg Roof plate "PTO": 156 kg Roof plate "main pumps": 175 kg

Dogman/rigger

z


z



Isolate the machine according to local regulations. WARNING

Always wear a safety harness when working at the roof.

z

Clear all wire harnesses from the roof plates (Fig. 3-5, Pos. 1...4 and 6) to be removed. WARNING

Pay attention to the Fire Detection and Suppression System. Refer to the separate manuals "Fire Detection and Actuating System" and "Fire Suppression System" The wires of the Fire Detection and Suppression System must not be bent excessively or be damaged to remain functional.

z

If equipped, remove the extinguishing tanks of the Fire Detection and Suppression System from the roof plate(s) to be removed.

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Engine house roof

Fig. 3-6

3 - 12

Superstructure

Roof plate removal

PC8000-6E

Version 2010/1

Superstructure

z

Engine house roof

It is recommended to remove the air outlets (Fig. 3-7, Pos. 1) from the roof plate "cooling air outlet" (Fig. 3-6, Pos. 6).

NOTE: Check the moldings (Fig. 3-7, Pos. 2) and replace them if required.

Fig. 3-7 z

Remove the bolts (Fig. 3-6, Pos. 7) and the nuts (Fig. 3-6, Pos. 8) to clear all attached parts from the roof plates (Fig. 3-6, Pos. 1...4 and 6) inside the engine house.

z

Remove the bolts (Fig. 3-6, Pos. 9) and the resilient sleeves (Fig. 3-6, Pos. 10) of the roof plate(s) to be removed.

z

Remove the roof plates (Fig. 3-6, Pos. 1...4 and 6) from the roof carrier (Fig. 3-6, Pos. 13) with a crane using swivel hoist rings. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the roof plates, make sure that nobody steps below the weight.

z

Check the profiled joint (Fig. 3-6, Pos. 11) and the moulding material (Fig. 3-6, Pos. 12) at the roof plates. Replace if required.

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3 - 13

Engine house roof

3.3.2

Superstructure

REPLACEMENT OF THE ROOF PLATES

Special tools:

n/a


Crane Safety harness in conformity with EN 361 Swivel hoist rings: 4 x M12 Compound "KP2K", PN 324 969 40 Roof plate "motor": 185 kg Roof plate "cooling air intake": 175 kg Roof plate "cooling air outlet": 250 kg Roof plate "PTO": 156 kg Roof plate "main pumps": 175 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. z


NOTE: Always use new roof plate mounting bolts of grade 8.8. Apply compound "KP2K", PN 324 969 40 on the bolts.

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Version 2010/1

Superstructure

3.3.3

Engine house roof

FRONT ROOF SECTION

3.3.3.1 REMOVAL OF THE FRONT ROOF PLATES Special tools:

n/a


Safety harness in conformity with EN 361 Crane Compound "KP2K", PN 324 969 40 Front roof plate (max): 162 kg Front roof frame: 310 kg Front wall: 136.5 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. In order to gain free access to the assemblies hidden by the front roof, it is necessary to remove the complete front roof frame. For some procedures this has to be done for safety reasons, just to avoid an inclined hoist while using a crane. WARNING Always wear a safety harness when working at the front roof.

z


z




Pay attention to the Fire Detection and Suppression System. Refer to the separate manuals "Fire Detection and Actuating System" and "Fire Suppression System". The wires of the Fire Detection and Suppression System must not be bent excessively or be damaged to remain functional.

z

If equipped, remove the extinguishing tanks (Fig. 3-8, Pos. 1) of the Fire Detection and Suppression System.

z

Remove the hand rails (Fig. 3-8, Pos. 2) at the front roof.

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Fig. 3-8

3 - 15

Engine house roof

Fig. 3-9

3 - 16

Superstructure

Front roof section, overview

PC8000-6E

Version 2010/1

Superstructure

z

Engine house roof

Disconnect the hoses leading to the lubrication pump stations from both sides of the left roof plate (Fig. 3-9, Pos. 3).

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Undo the roof plate mounting bolts (Fig. 3-9, Pos. 4) and the 4 bolts (Fig. 3-9, Pos. 5) in the roof plates, then remove the roof plates (Fig. 3-9, Pos. 1 to 3).

z

Clear the side wall (Fig. 3-9, Pos. 9) and the front wall part (Fig. 3-9, Pos. 11) from the front roof frame (Fig. 3-9, Pos. 8).

z

Remove the front wall (Fig. 3-9, Pos. 10).

z

Sling the front roof frame (Fig. 3-9, Pos. 8).

z

Remove the bolts (Fig. 3-9, Pos. 6 and 7) connecting the front roof frame to the engine house and to the posts. The connecting points are indicated (arrows).

z

Remove the front roof frame using a crane. WARNING

Risk of falling weights! Death or serious injury may result. When removing the front roof frame, make sure that nobody steps below the weight.

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Engine house roof

Superstructure

3.3.3.2 REPLACEMENT OF THE FRONT ROOF PLATES Special tools:

n/a


Safety harness in conformity with EN 361 Crane Compound "KP2K", PN 324 969 40 Front roof plate (max): 162 kg Front roof frame: 310 kg Front wall: 136.5 kg

Dogman/rigger


WARNING Always wear a safety harness when working at the front roof.

z


NOTE: Always use new roof plate mounting bolts of grade 10.9. Apply compound "KP2K", PN 324 969 40 on the bolts.

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Superstructure

Batteries

3.4

BATTERIES

3.4.1

REMOVAL OF THE BATTERIES

Special tools:

n/a


Crane or forklift Battery: 62 kg

Dogman/rigger Certified electrician

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and crane or forklift.

z



Isolate the machine according to local regulations.

z

Remove the keys from the battery main switches (Fig. 3-10, Pos. 1). DANGER

Danger of explosion due to hydrogen gas! Blindness, serious injury, permanent disfigurement, and scaring may result. Never allow sparks or open flame near the batteries! DO NOT short circuit or ground any terminals of the batteries!

NOTE: The batteries (Fig. 3-10, Pos. 2) are located below the hinged floor plats (Fig. 3-10, Pos. 3) in separate boxes. z

Remove floor plate fastening bolts and open the hinged floor plates (Fig. 3-10, Pos. 3).

Fig. 3-10

NOTE: Wash the dirt of the floor plates (Fig. 3-10, Pos. 3) as they can be very heavy. z

Secure the open floor plates against falling down using the safety chains provided.

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Batteries

Superstructure

DANGER Risk of electrical and fire hazard! Death, serious injury, shock, or burns may result. Disconnecting the batteries has to be done by a certified electrician only. Disconnect the ground cables (-) of both batteries first.

z

Disconnect the cables from the batteries (Fig. 3-11, Pos. 1).

z

Remove the angles (Fig. 3-11, Pos. 2) from the batteries.

z

Take the batteries out of the battery boxes. WARNING Fig. 3-11

Use the provided loops to carry the batteries. Do not drop the battery.

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Superstructure

3.4.2

Batteries

REPLACEMENT OF THE BATTERIES

Special tools:

n/a


n/a Battery: 62 kg

Dogman/rigger Certified electrician If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. z

Carry out installation in reverse order to removal. DANGER

Risk of electrical and fire hazard! Death, serious injury, shock, or burns may result. Connecting the batteries has to be done by a certified electrician only. Connect the positive cables (+) of the batteries first.

WARNING Avoid spilling any electrolyte on hands or clothing. Clean hands or clothing immediately if electrolyte was spilled. Repair or replace all broken wires immediately. All terminals must be clean and securely fastened. Never paint connections.

DANGER Danger of explosion due to hydrogen gas! Blindness, serious injury, permanent disfigurement, and scaring may result. Never allow sparks or open flame near the batteries! DO NOT short circuit or ground any terminals of the batteries!

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Electric motors

3.5

Superstructure

ELECTRIC MOTORS

The excavator is powered by two ABB electric motors: Model:

AMA 500L4A BAHXYH

Type:

ABB induction motor

Rated power:

1450 kW

3.5.1

REMOVAL OF THE FRONT ELECTRIC MOTOR (MOTOR 1)

Special tools:

n/a


Crane Electric motor: 5600 kg

Dogman/rigger Electrician with permission to work on high voltage systems For further information about the needed blind plugs, refer to section 6.6 on page 6-14. z


z





z


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Superstructure

Electric motors

WARNING Do not carry out the following work on a hot motor. Wait until the temperature of the motor is below 50 °C. Disobedience may result in personal injury from heated parts.

z

Remove the necessary roof plates for motor removal, refer to section 3.3.1 on page 3-8.

z

Remove the cover (Fig. 3-12, Pos. 1) of the motor connecting box.

z

Disconnect the tree phase cables (Fig. 3-12, Pos. 3) in the motor connecting box and pull the cables out of the housing.

z

Open the cable clamps (Fig. 3-12, Pos. 2) to clear the phase cables from the motor connecting box.

Fig. 3-12

z

Remove the cover of the auxiliary terminal box (Fig. 3-13, Pos. 1).

z

Disconnect and remove the wire harnesses (e.g. temperature monitoring) from the auxiliary terminal box. Clear the wire harnesses from the electric motor.

z

Disconnect the protective earth from the electric motor.

Fig. 3-13

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Electric motors

Superstructure

Fig. 3-14 Removal of the electric motor z

Loosen the adjusting bolts (Fig. 3-14, arrows) and the jacking bolts (Fig. 3-14, Pos. 1) on both sides of the motor.

z

Unscrew the nut (Fig. 3-14, Pos. 2) and remove the motor fixing bolt (Fig. 3-14, Pos. 3).

z

Remove the flexible type coupling (Fig. 3-14, Pos. 4), refer to section 3.6 on page 3-36.

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Superstructure

z

Electric motors

Attach the motor (Fig. 3-15, Pos. 1) to a crane using two lifting bars (Fig. 3-15, Pos. 3). CAUTION

Make sure not to damage the motor cooler assembly (Fig. 3-15, Pos. 2). z

Use the Lifting eyes at the motor (Fig. 3-15, Pos. 1) only.

z

Use suitable lifting bars (Fig. 3-15, Pos. 3) which are long enough that the lifting accessory does not come in contact with the motor cooler assembly. Fig. 3-15

z

Lift the motor out of the engine house using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the motor, make sure that nobody steps below the weight.

z

Remove the compensation plates (Fig. 3-14, Pos. 5).

NOTE: The compensation plates should be used as pattern for some new plates which may be needed in the alignment procedure.

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Electric motors

3.5.2

Superstructure

REPLACEMENT OF THE FRONT ELECTRIC MOTOR (MOTOR 1)

Special tools:

n/a


Crane Electric motor: Electric motor: 5600 kg

Dogman/rigger Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z

Prepare the motor seats before mounting.

NOTE: The seats must be free from dirt and rust. z

Attach the new motor (Fig. 3-16, Pos. 1) to a crane using two lifting bars (Fig. 3-16, Pos. 3). CAUTION

Make sure not to damage the motor cooler assembly (Fig. 3-16, Pos. 2). z

Use the Lifting eyes at the motor (Fig. 3-16, Pos. 1) only.

z

Use suitable lifting bars (Fig. 3-16, Pos. 3) which are long enough that the lifting accessory does not come in contact with the motor cooler assembly. Fig. 3-16

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Electric motors

Fig. 3-17 Replacement of the electric motor z

Lift the motor into the engine house using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the motor, make sure that nobody steps below the weight.

z

Screw in the jacking bolts (Fig. 3-17, Pos. 1) completely.

z

Insert new motor fixing bolts (Fig. 3-17, Pos. 3) of the grade 10.9 and secure the bolts with the nuts (Fig. 3-17, Pos. 2). Tighten the nut hand-tight.

z

If required, install the coupling’s input drive hub onto the motor power take-off shaft (H7 drive fit), refer to section 3.6.1.2 on page 3-39.

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Electric motors

z

Superstructure

Carry out the alignment procedure, refer to section 3.5.5 on page 3-29. DANGER


z

De-isolate the machine according to local regulations and according to the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28.

z

Check the direction of the electric motor’s rotation. Change the connection of the phase lines if required.

z


z

Install a new flexible type coupling (Fig. 3-17, Pos. 4), refer to section 3.6 on page 3-36.

z

Carry out further installation in reverse order to removal. WARNING

Before each motor starting make sure that all controls are in neutral position. Be sure to sound the signal horn before starting to make your intention clear.

NOTE: Before starting the motors pay attention to the hydraulic oil temperature. Refer to the Operation & Maintenance Manual, chapter 3, section "STARTING PROCEDURE".

3.5.3

REMOVAL OF THE REAR ELECTRIC MOTOR (MOTOR 2)

The removal of the rear electric motor is analogously the same as the removal of the front electric motor, refer to section 3.5.1 on page 3-22.

3.5.4

REPLACEMENT OF THE REAR ELECTRIC MOTOR (MOTOR 2)

The replacement of the rear electric motor is analogously the same as the replacement of the front electric motor, refer to section 3.5.2 on page 3-26.

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Superstructure

3.5.5

Electric motors

FINAL ALIGNMENT OF THE ELECTRIC MOTORS

Special tools:

n/a


2 x Dial gauge (minimum requirement) Laser alignment set (recommended), PN 232 713 40 + PN 232 714 40

For the alignment procedure the following preconditions are considered: A new electric motor is installed. The new motor is jacked up by the jacking bolts. The flexible coupling is not installed yet. The coupling’s hubs are already installed at the motor power takeoff shaft and at the PTO drive shaft. NOTE: Due to higher accuracy, it is recommended to make all measurements in the alignment procedure with a laser alignment set instead of dial gauges. Observe the instructions given in the manual of the laser alignment set. z

Rotate the motor’s rotor and check the axial clearance.

NOTE: The sleeve bearings of the motor must be lubricated properly before turning the motor. Rough adjustment z

Move the motor (Fig. 3-18, Pos. 1) by using the adjusting bolts (Fig. 3-18, Pos. 3) and the jacking bolts (Fig. 3-20, Pos. 1) until the drive shaft center line and the center line at the PTO drive shaft are aligned roughly.

z

Adjust the desired mounting distance between the hubs by using the adjusting bolts (Fig. 3-18, Pos. 3). For the proper mounting distance for the coupling, refer to the PARTS & SERVICE NEWS No. "AH01523".

NOTE: Leave all adjusting screws only lightly tightened. Fig. 3-18 Run-out check The alignment procedure is started by measuring the run-out of the coupling hubs. This measurement will show any inaccuracy of the shaft and / or hubs. z

The run-out of the coupling hub in respect to the bearing housing of the motor is measured.

z

Place the dial gauges according to Fig. 3-19 to measure the run-out at the coupling hub.

z

Similarly check the run-out of the coupling hub at the PTO drive shaft in respect to its bearing housing.

z

A simple lever arm is needed to turn the rotor of the electric motor.

Fig. 3-19

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Electric motors

Superstructure

Fig. 3-20 Alignment of the electric motors Final alignment: z

Mount the dial gauges as shown in Fig. 3-21.

NOTE: It is practical to adjust the dial gauges in such way that approximately half of the scale is available in either direction. Check the rigidity of the gauge brackets in order to eliminate the possibility of sag. z

Measure and record readings for parallel (Fig. 3-21, Pos. 1), angular (Fig. 3-21, Pos. 2) and axial misalignment in four different positions: top, bottom, right and left, i.e. every 90°, while both shafts are turned simultaneously.

NOTE: For the permissible alignment tolerances for the coupling, refer to the PARTS & SERVICE NEWS No. "AH01523".

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Fig. 3-21

Version 2010/1

Superstructure

Electric motors

z

Align the motor vertically by turning the jacking bolts (Fig. 3-20, Pos. 1).

z

Measure the distance between the bottom of the motor feet and the powerframe.

z

Manufacture corresponding compensation plates (Fig. 3-20, Pos. 5) and position the compensation plates between powerframe and motor feet.

z

Loosen the jacking bolts and tighten the fixing bolts /nuts (Fig. 3-20, Pos. 2 and 3) to the specified torque: Tightening torque for motor fixing bolts and nuts (Fig. 3-20, Pos. 2 and 3): 3100 Nm

z

Check the alignment again. Make corrections if necessary.

z

Record the data for future checks.

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Electric motors

3.5.6

Superstructure

CAPACITOR ASSEMBLIES

Fig. 3-22 Capacitor assemblies, overview (1)

Capacitor assembly

(2)

Motor connecting box

(3)

Cooling air intake

(4)

Junction cable

(5)

Cable clamp

(6)

Bolt

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Version 2010/1

Superstructure

Electric motors

The capacitor assembly is a 3-phase capacitor bank, in Y-connection. Each capacitor in the bank has a built in pressure monitoring device. The capacitor assembly operates as an operating capacitor to generate the phase displacement for the electric motor. NOTE: it is not nessecary to dismantle the cooling air intake (Fig. 3-22, Pos. 3) before removing the capacitor assembly (Fig. 3-22, Pos. 1). Therefore a second person is required to handle the assembly.

3.5.6.1 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 1) Special tools:

n/a


Crane Capacitor assembly: 50 kg

Electrician with permission to work on high voltage systems 2nd. person to handle the assembly

z


z





z


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3 - 33

Electric motors

Superstructure

WARNING Do not carry out the following work on a hot capacitor assembly. Wait until the temperature of the capacitor assembly is below 50 °C. Disobedience may result in personal injury from heated parts.

z

Disconnect the wire harnesses from the pressure monitoring devices (Fig. 3-23, Pos. 1).

z

Disconnect the ground wire from the cable cland (Fig. 3-23, Pos. 2).

Fig. 3-23

z

Remove the cover (Fig. 3-24, Pos. 1) of the connecting box (Fig. 3-24, Pos. 2).

z

Disconnect the phase lines of the junction cable (Fig. 3-24, Pos. 4).

z

Open the cable clamp (Fig. 3-24, Pos. 3) and remove the junction cable from the connecting box.

z

Remove the mounting bolts (Fig. 3-24, Pos. 5) and lift the capacitor assembly off its mounting position.

NOTE: A second person is required to handle the assembly. Fig. 3-24

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Version 2010/1

Superstructure

Electric motors

3.5.6.2 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 1) Special tools:

n/a


Crane Capacitor assembly: 50 kg

Electrician with permission to work on high voltage systems 2nd. person to handle the assembly If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.


z

Carry out installation in reverse order to removal. WARNING

Before each motor starting make sure that all controls are in neutral position. Be sure to sound the signal horn before starting to make your intention clear.

NOTE: Before starting the motors pay attention to the hydraulic oil temperature. Refer to the Operation & Maintenance Manual, chapter 3, section "STARTING PROCEDURE".

3.5.6.3 REMOVAL OF THE CAPACITOR ASSEMBLY (MOTOR 2) The removal of the capacitor assembly for the rear electric motor (Motor 2) is analogously the same as the removal of the capacitor assembly for the front electric motor (Motor 1), refer to section 3.5.6.1 on page 3-33.

3.5.6.4 REPLACEMENT OF THE CAPACITOR ASSEMBLY (MOTOR 2) The replacement of the capacitor assembly for the rear electric motor (Motor 2) is analogously the same as the replacement of the capacitor assembly for the front electric motor (Motor 1), refer to section 3.5.6.2 on page 3-35.

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Flexible coupling

Superstructure

3.6

FLEXIBLE COUPLING

3.6.1

VULKAN COUPLING ASSEMBLY

Fig. 3-25 Vulkan coupling assembly The Vulkan coupling is a torsionally flexible rubber coupling, that compensates axial, angular and, to a certain degree, radial displacement of the connected machines. The Vulkan coupling transfers the torque without any slippage. The disc-shaped elastic element with "plug-in" teeth at the outer radius (PTO side) can be replaced without dismantling the motor and the pump distributor gearbox (PTO) respectively.

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Version 2010/1

Superstructure

Flexible coupling


Coupling assembly

(2)

Bolt

(3)

Bolt

(4)

Bolt

(5)

Nut

(6)

Cover ring

(7)

PTO drive hub

(8)

Motor drive hub

(9)

Key

(10)

Bolt

(11)

Ring

(12)

Bolt

(13)

Motor power take-off shaft

(a)

Mounting distance Refer to PARTS & SERVICE NEWS No "AH01523".

3.6.1.1 REMOVAL OF THE VULKAN COUPLING Special tools:

n/a


Chain hoist Coupling assembly: 38 kg Cover ring: 94 kg

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine.

z


NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition.

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Flexible coupling

z

Superstructure


NOTE: Check if a lifting eye (Fig. 3-26, Pos. 1) is installed at the roof plate over the coupling. Use the lifting eye to hook a chain hoist. If no lifting eye is installed, it has to be welded to the roof plate. WARNING For welding follow the welding precautions given in the Operation & Maintenance Manual, chapter 4, section "WELD REPAIRS" and refer to the PARTS & SERVICE NEWS No. "AH08507". Fig. 3-26

z

Remove the coupling protection cover (Fig. 3-27, Pos. 1).

Fig. 3-27 z

Remove the vulkan coupling according to PARTS & SERVICE NEWS No "AH01523".

NOTE: The motor drive hub (Fig. 3-28, Pos. 5) is a component part of the electric motor and is not delivered with the coupling. z

Carry out the next three steps only if required. z

Remove the bolts (Fig. 3-28, Pos. 1) and take the PTO drive hub (Fig. 3-28, Pos. 2) off the PTO.

z

Remove the bolt (Fig. 3-28, Pos. 3) and the ring (Fig. 3-28, Pos. 4).

z

Draw the motor drive hub (Fig. 3-28, Pos. 5) off the motor power take-off shaft (Fig. 3-28, Pos. 6) and remove the Fig. 3-28 key (Fig. 3-28, Pos. 7).

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Version 2010/1

Superstructure

Flexible coupling

3.6.1.2 REPLACEMENT OF THE VULKAN COUPLING Special tools:

n/a


Chain hoist Compound "KP2K", PN 324 969 40 Coupling assembly: 38 kg Cover ring: 94 kg

Dogman/rigger


NOTE: The motor drive hub (Fig. 3-28, Pos. 5) is a component part of the electric motor and is not delivered with the coupling. z

Carry out the next three steps only if required. z

Insert the key (Fig. 3-29, Pos. 7) into the motor power take-off shaft (Fig. 3-29, Pos. 6).

z

Press the motor drive hub (Fig. 3-29, Pos. 5) onto the motor power take-off shaft (H7 drive fit) (Fig. 3-28, Pos. 6) using the bolt (Fig. 3-29, Pos. 3) and the ring (Fig. 3-29, Pos. 4).

z

Install the PTO drive hub (Fig. 3-29, Pos. 2) to the PTO Fig. 3-29 and insert the mounting bolts (Fig. 3-29, Pos. 1).

NOTE: Use new mounting bolts (Fig. 3-29, Pos. 1) of grade 10.9. Apply compound "KP2K", PN 324 969 40 to the bolts. Use a new mounting bolt (Fig. 3-29, Pos. 3) of grade 8.8. Apply oil SAE 10 to the mounting bolt Tighten all mounting bolts to the specified tightening torque. Tightening torques for mounting bolt (Fig. 3-29, Pos. 3): 2170 Nm for mounting bolts (Fig. 3-29, Pos. 1): 360 Nm z

Install the new vulkan coupling according to PARTS & SERVICE NEWS No "AH01523".

z

Carry out further installation in reverse order to removal.

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3 - 39

PTO

Superstructure

3.7

PTO

3.7.1

MAIN PUMPS

Fig. 3-30 Main pumps assembly

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Version 2010/1

Superstructure

PTO


Main pump 1

(2)

Main pump 2

(3)

Main pump 3

(4)

Main pump 4

(5)

Main pump 5

(6)

Main pump 6

(7)

Main pump 7

(8)

Main pump 8

(9.1 to 9.4)

Gear pumps (PTO-oil, pilot oil)

(10.1 and 10.3)

Auxiliary pumps (hydraulic cooler fan drive pumps)

The rotative energy from each main motor propels the gears in the pump distributor gear boxes (Fig. 3-30, Pos. 9, Pos. 10) and the gears propel the main pumps (Fig. 3-30, Pos. 1 to 8) and auxiliary pumps (Fig. 3-30, Pos. 10.1 and 10.3). The pumps create a hydraulic oil flow to the cylinders or hydraulic motors. The main high pressure hydraulic circuits are supplied by eight swash plate type variable displacement pumps (Fig. 3-30, Pos. 1 to 8). The main pumps 2, 4, 6, and 8 are additionally equipped with gear pumps (Fig. 3-30, 9.1 to 9.4).

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3 - 41

PTO

Superstructure

3.7.1.1 REMOVAL OF MAIN PUMPS Special tools:

n/a


Crane Oil drain pans Main pump assembly with flanged gear pump: 524 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-14.

NOTE: The removal of all main pumps is analogously always the same.

Fig. 3-31 z


z



Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z


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Version 2010/1

Superstructure

PTO

z

Close the hand wheel (Fig. 3-32, Pos. 1) of the main gate valve between the suction oil reservoir and the main oil reservoir.

z

To accelerate the draining of oil from the pumps, loosen the vent plugs on the main pumps, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z

Transfuse the oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "TRANSFUSION PROCEDURE". Fig. 3-32

z

Remove the roof plate "main pumps", refer to section on page 3-11.

z

If equipped, remove fasteners for the hoses of the main pump assembly to be removed. Drain the oil of the resp. drive shaft housing (Fig. 3-33, Pos. 6), approx. 1.5 liters by removing the drain plug (Fig. 3-33, Pos. 2). Remove the level opening plug (Fig. 3-33, Pos. 1) to speed up the draining procedure.

NOTE: When the plugs are removed, the oil inside the drive shaft housing will flow out. Catch it in an oil pan. z

Mark all pipes and hoses at that main pump assembly of the main pump to be removed.

Fig. 3-33 WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

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3 - 43

PTO

z

Superstructure

Disconnect the SAE-flanges of the pressure hose and the suction hose from the gear pump (Fig. 3-34, Pos. 4) of the main pump to be removed.

NOTE: When the pump hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Disconnect the leak oil hose and all control hoses from the control block (Fig. 3-34, Pos. 1).

z

Disconnect the bearing flushing/lubrication hose from the right side of the pump mounting flange.

z

Disconnect the high pressure hose (Fig. 3-34, Pos. 2) from the main pump assembly.

z

Disconnect the suction hose (Fig. 3-34, Pos. 3) at the bottom side of the pump.

Fig. 3-34


Sling pump assembly as shown in Fig. 3-35.

z

Remove mounting bolts. Then remove pump assembly by pulling it out of the pump distributor gear box. DANGER

Risk of falling weights! Death or serious injury may result. When removing the main pump assembly, make sure that nobody steps below the weight.

NOTE: To simplify the removal, move the pump assembly lightly up and down.

Fig. 3-35

When the pump assembly is removed, oil will flow out of the drive shaft housing. Catch it in an oil pan. z

Check the O-ring (Fig. 3-35, Pos. 1) at the pump assembly flange and replace it if required.

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Version 2010/1

Superstructure

PTO

3.7.1.2 REPLACEMENT OF MAIN PUMPS Special tools:

n/a


Crane Paste Optimol White, PN 999 039 Main pump assembly with flanged gear pump: 524 kg

Dogman/rigger

Observe the safety hints for hydraulic hose installation, refer to section 2.2.6 on page 2-22. If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. NOTE: When mounting a new pump, activate the external flushing of bearing. Refer to the PARTS & SERVICE NEWS No. "AH05510". z


NOTE: Use "Optimol White" on the spline shaft of the pump. Use new bolts with grade 8.8 at the mounting flanges of the main pump. Tighten the bolts to the specified tightening torque. Tightening torque for the mounting bolts: 510 Nm NOTE: For connecting the suction hose, refer to the PARTS & SERVICE NEWS No. "AH05525". Always use new O-rings at the SAE-flange connections and hose fittings. Refill specified lubricant in the drive shaft housing, approx. 1.5 liters, refer to the Operation & Maintenance Manual, chapter 4, section "PTO’s (PUMP DISTRIBUTOR GEARS) AND OIL RESERVOIR - CHECK OIL LEVEL". Fill up to the lower edge of the level plug opening (Fig. 336, Pos. 1). For the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS".

Fig. 3-36

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3 - 45

PTO

Superstructure

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and the PARTS & SERVICE NEWS No. "AH01513".

z

Add specified hydraulic oil up to the specified level.

z

Adjust main pump, refer to the Service Manual.

z

Check for leaks and proper operation.

z

Check the hydraulic oil level again and correct the oil level if required.

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Version 2010/1

Superstructure

3.7.2

PTO

PTO OIL PUMPS (AUXILIARY PUMPS)

The PTO gear oil pumps (Fig. 3-37, Pos. 9.2 and 9.4) for the PTO gear lubrication aspirate gear oil from the PTO gear boxes sump and pump it through filters and coolers back to the PTOs. The Pumps are mounted at main pump 4 and 8.

Fig. 3-37 NOTE: The removal of the PTO gear oil pump (front electric motor, Fig. 3-38, Pos. 1) is analogously the same as the removal of the PTO gear oil pump (rear electric motor, Fig. 3-38, Pos. 2).

Fig. 3-38

3.7.2.1 REMOVAL OF THE PTO OIL PUMPS (AUXILIARY PUMPS) z

The removal of the PTO gear oil pumps (Fig. 3-37, Pos. 9.2 and 9.4) is analogously the same as the removal of the pilot oil pumps, refer to section 3.8.4.1 on page 3-101.

3.7.2.2 REPLACEMENT OF THE PTO OIL PUMPS (AUXILIARY PUMPS) z

The replacement of the PTO gear oil pumps (Fig. 3-37, Pos. 9.2 and 9.4) is analogously the same as the removal of the pilot oil pumps, refer to section 3.8.4.2 on page 3-103.

Version 2010/1

PC8000-6E

3 - 47

PTO

3.7.3

Superstructure

PUMP DISTRIBUTOR GEARBOX (PTO)

Fig. 3-39 Pump distributor gearbox

3 - 48

PC8000-6E

Version 2010/1

Superstructure

PTO


Oil level gauge

(2)

Oil filler plug

(3)

Breather filter

(4)

Oil level sight gauge

(5)

Flange for heater studs

(6)

Main pump drive shaft housing

(7)

Oil level plug of pump drive shaft housing

(8)

Oil filler plug with breather pipe of pump drive shaft housing

(9)

Oil drain plug of pump drive shaft housing

(10)

Oil drain plug of PTO gear

(11)

Suction line connection for gear oil cooling

(12)

Gear oil temperature probe mounting bore

(13)

Thermostat switch mounting cover plate

(14)

Return line connection from gear oil cooler

(15)

Return line connection from cooling system relief valve

(D)

Drive flange

(M)

Power take-off for main pumps

(R)

Power take-off not used and sealed with a blind plate

(C)

Power take-off for hydraulic oil cooler fan drive pump

NOTE: Detail "S". The arrows at detail "S" indicate the spray direction of the jet borings. Pay attention when disassembling / assembling. The pump distribution gear (PTO gear) is from a spur gear design and driven by an electric motor. It is equipped with an external lubrication/cooling system. The PTO gear runs in anti-friction bearings and it has been provided with a splash lubrication system. The oil supply of the bearings and tooth contacts takes place by an injection. The gearwheels are of case-hardened steel. The hydraulic pumps are directly attached to the gearbox. The O-rings included in the delivery seal the unit statically and reliably. The gearbox housing is a one-piece design and made of grey cast iron. The Gearbox design allows a direct attachment to the electric motor via a connection flange. The gearbox has been provided with connections for a separate cooling system or for a preheating system. Always check the gearbox oil level with unlocked dip stick and stopped electric motors. Version 2010/1

PC8000-6E

3 - 49

PTO

Superstructure

3.7.3.1 REMOVAL OF THE PUMP DISTRIBUTOR GEARBOX (PTO) Special tools:

n/a


Crane Oil drain pans PTO: 2450 kg Control and filter plate assembly: 237 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-14. z

Remove the roof plates "PTO" and "main pumps", refer to section on page 3-11.

NOTE: The removal of the pump distributor gearbox 1 (Fig. 3-40, Pos. 1) and pump distributor gearbox 2 (Fig. 3-40, Pos. 2) is analogously the same. Drain the gear oil of the PTO to be removed, approx. 140 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL". z

Remove main pump assemblies, refer to section 3.7.1 on page 3-40.

Fig. 3-40 z

Remove the hydraulic cooler fan drive pump from the PTO to be removed, refer to section 3.8.1.1 on page 3-56.

z

Relieve the pilot pressure at the pressure check point M40 for the accumulator, refer to the Service Manual.

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PC8000-6E

Version 2010/1

Superstructure

PTO

Fig. 3-41 PTO 1+2 with control and filter plates

z

(1)

Pump distributor gearbox (PTO), electric motor 1

(2)

Control and filter plate (electric motor 1)

(3)

Pump distributor gearbox (PTO), electric motor 2

(4)

Control and filter plate (electric motor 2)

Mark and disconnect all hydraulic lines and electrical wires leading to the control- and filter plate assembly of the PTO to be removed (Fig. 3-41, Pos. 2 respectively Fig. 3-41, Pos. 4).

NOTE: When the hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

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PC8000-6E

3 - 51

PTO

Superstructure

z

Attach the control and filter plate assembly (Fig. 3-42, Pos. 3) of the PTO to be removed to a crane.

z

Remove the mounting bolts (Fig. 3-42, Pos. 1) with resilient sleeves (Fig. 3-42, Pos. 2).

z

Remove the control and filter plate assembly (Fig. 3-42, Pos. 3) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the control frame assembly make sure that nobody steps below the weight.

Fig. 3-42 z

Disconnect all hydraulic hoses (Fig. 3-43, Pos. 1) from the PTO (Fig. 3-43, Pos. 2).

NOTE: When the hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Disconnect and clear all retainers for hydraulic hoses and electrical wires from the PTO.

Fig. 3-43

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Superstructure

PTO

z

Disconnect the temperature sensor (Fig. 3-44, B49-1 and B49-2).

z

Disconnect the heating and the thermal switch if equipped.

z

Remove the torsion type coupling, refer to section 3.6 on page 3-36.

Fig. 3-44 z

Attach the PTO to a crane, using the lifting eyes (Fig. 3-45, arrows).

z

Remove the bolts (Fig. 3-45, Pos. 2) with resilient sleeves (Fig. 3-45, Pos. 2) attaching the PTO to the support.

Fig. 3-45 z

Remove the PTO using the crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the PTO, make sure that nobody steps below the weight.

Version 2010/1

PC8000-6E

3 - 53

PTO

Superstructure

3.7.3.2 REPLACEMENT OF THE PUMP DISTRIBUTOR GEARBOX (PTO) Special tools:

Hydraulic testing kit, PN 232 591 40


Paste "Optimol White" PN 999 039 Crane Compound "KP2K", PN 324 969 40 PTO: 2450 kg Control and filter plate assembly: 237 kg

Dogman/rigger


If required, install the temperature sensor, the heating, and the thermal switch to the replacement PTO.

z


NOTE: Always use new O-rings at all SAE-flange connections. NOTE: Use new mounting PTO bolts of the grade 10.9. Apply compound "KP2K", PN 324 969 40 on the PTO mounting bolts (Fig. 3-46, Pos. 2) and tighten the bolts to the specified tightening torque. Tightening torque for the PTO mounting bolts: 1770 Nm

Fig. 3-46

Refill specified gear oil into the PTO, approx. 140 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "PTO (PUMP DISTRIBUTOR GEAR) - CHANGE OIL". z

Warm up the machine, test the pressure of the circulation pump and adjust if required. Refer to the Service Manual for further information.

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Superstructure

Hydraulics

3.8

HYDRAULICS

3.8.1

HYDRAULIC COOLER FAN DRIVE PUMPS

The hydraulic cooler fan drive pump is a fixed displacement pump with variable setting. The pump of the type A7F0 is a variable displacement pump, designed to operate in open circuits. It has an internal case drain return. The rotary group is a robust self aspirating unit. External forces may be applied to the drive shaft The hydraulic cooler fan drive pumps are mounted at both PTOs (Fig. 3-47, Pos.1 and Pos. 2).

Fig. 3-47 Each hydraulic fan drive pump (Fig. 3-48, Pos. 10.1 and 10.3) supplies one hydraulic oil cooler fan drive, one additional oil cooler fan drive, and one PTO cooler fan drive.

Fig. 3-48 Changing the swivel angle of the rotary group is achieved by sliding the control lens along a cylindrical formed track by means of an adjusting screw. z

With an increase in the swivel angel, the pump output increases together with the necessary drive torque.

z

With a decrease in the swivel angel, the pump output decreases together with the necessary drive torque.

NOTE: When increasing to maximum swivel angle, there is a danger of cavitation and over-speeding the hydraulic motor.

Version 2010/1

PC8000-6E

3 - 55

Hydraulics

Superstructure

3.8.1.1 REMOVAL OF THE HYDRAULIC COOLER FAN DRIVE PUMPS Special tools:

n/a


Chain hoist Crane Oil drain pan Hydraulic cooler fan drive pump: 74 kg

Dogman/rigger



z




z


z


z

Transfuse the oil from the suction oil reservoir into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "TRANSFUSION PROCEDURE".

Fig. 3-49

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Hydraulics

NOTE: Check if a lifting eye (Fig. 3-50, Pos. 1) is installed at the roof plate over the pump. Use the lifting eye to hook a chain hoist. If no lifting eye is installed, it has to be welded to the roof plate. WARNING For welding follow the welding precautions given in the Operation & Maintenance Manual, chapter 4, section "WELD REPAIRS" and refer to the PARTS & SERVICE NEWS No. "AH08507". Fig. 3-50

WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Disconnect the pressure hose (Fig. 3-51, Pos. 2) and the suction hose (Fig. 3-51, Pos. 1) from the hydraulic cooler fan drive pump (Fig. 3-51, Pos. 3).

NOTE: When the hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Connect the pump to by a chain hoist and remove the four mounting bolts (Fig. 3-51, Pos. 4).

z

Remove the hydraulic cooler fan drive pump (Fig. 3-51, Pos. 3) by pulling it out of the PTO.

Fig. 3-51

NOTE: To simplify the removal, move the pump lightly up and down. When the pump is removed, oil will flow out of the spline shaft housing. Catch it in an oil pan. z

Check the O-ring at the pump flange and replace it if required.

z

Remove the hydraulic cooler fan drive pump.

Version 2010/1

PC8000-6E

3 - 57

Hydraulics

Superstructure

3.8.1.2 REPLACEMENT OF THE HYDRAULIC COOLER FAN DRIVE PUMPS Special tools:

Rotational speed infrared probe DS03, PN 793 788 73


Crane Chain Hoist Paste "Optimol White" PN 999 039 Hydraulic cooler fan drive pump: 74 kg

Dogman/rigger

Observe the safety hints for hydraulic hose installation, refer to section 2.2.6 on page 2-22. If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. z


NOTE: Use "Optimol White" on the spline shaft of the pump. Always use new O-rings at the SAE-flange connections. Use new bolts (Fig. 3-51, Pos. 4) with grade 8.8 at the mounting flanges. Tighten the bolts to the specified tightening torque. Tightening torque for the mounting bolts: 179 Nm

Refill the pump drive shaft housing (Fig. 3-52, Pos. 1) up to the specified level. For the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS".

z


Fig. 3-52 z


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Version 2010/1

Superstructure

z

Hydraulics

Check and adjust the speed of the hydraulic cooler fan, refer to the Operation and Maintenance Manual, chapter 3, section "ELECTRONIC MONITORING AND CONTROL SYSTEM ECS".

3.8.2

ADDITIONAL HYDRAULIC OIL COOLER ASSEMBLY

There are two cooler elements mounted in one frame on top of the standard hydraulic oil cooler. The air stream needed for the cooling is produced by hydraulically driven fans. The air flows from inside to outside through the coolers. For better cleaning, the cooler frames are mounted via hinges to the cooler support so the cooler frames can be opened ("swing out cooler").

Fig. 3-53 The two cooler fans are driven by hydraulic motors. Each motor is supplied by one hydraulic pump. The hydraulic pump (Fig. 3-54, Pos. 2) on PTO 1 (Fig. 3-54, Pos. 1) supplies the first hydraulic fan motor (Fig. 3-54, Pos. 3). The hydraulic pump (Fig. 3-54, Pos. 5) on PTO 2 (Fig. 3-54, Pos. 4) supplies the second hydraulic fan motor (Fig. 3-54, Pos. 6) at the additional cooler fan assembly. The fans are mounted directly to the hydraulic motor fan shaft.

Fig. 3-54

Version 2010/1

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3 - 59

Hydraulics

Superstructure

Fig. 3-55 Additional hydraulic oil cooler circuit 3 - 60

PC8000-6E

Version 2010/1

Superstructure

Hydraulics


Lines to cooler (hot oil)

(2)

Lines to hydraulic oil reservoir

(3)

Line to fan motor

(4)

Line to fan motor

Oil delivery of both fan drive pumps is directed to the additional cooler elements after leaving the four driven motors and flows back into the filter chamber of the main oil reservoir. This ensures that a constant oil volume circulates through the additional cooler, independent of the main return oil flow.

Version 2010/1

PC8000-6E

3 - 61

Hydraulics

Superstructure

3.8.2.1 REMOVAL OF THE ADDITIONAL HYDRAULIC OIL COOLER FAN ASSEMBLY Special tools:

n/a


Oil drain pan Crane Additional hydraulic oil cooler fan assembly: 104 kg

Dogman/rigger


Fig. 3-56 Additional hydraulic oil cooler fan assembly

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Version 2010/1

Superstructure

Hydraulics


Fan motor

(2)

Bolt

(3)

Fan cross-head

(4)

Fan

(5)

Locking plate

(6)

Bolt

(7)

Bolt

(8)

Washer

(9)

Adapter

z


z




z


Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement or scaring may result. The hydraulic system may pressurized. Make sure, that the pressure is relieved before any hydraulic line will be removed.

Version 2010/1

PC8000-6E

3 - 63

Hydraulics

z

Superstructure

Disconnect all hydraulic hoses and leak oil hoses from the hydraulic motors at the additional hydraulic oil cooler fan assembly.

NOTE: When the hoses are removed, the oil inside the hoses and the hydraulic motors will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the protective gratings (Fig. 3-57, Pos. 1).

z

Remove the additional hydraulic oil cooler fan assembly (Fig. 3-57, Pos. 2) from the additional hydraulic oil cooler using a crane. WARNING

Fan blades could have sharp edges. Use gloves!

CAUTION

Fig. 3-57

Remove the assembly carefully in order not to damage the oil cooler or the fan blades.

DANGER Risk of fallen weights! Death or serious injury may result. When removing the additional hydraulic cooler fan assembly make sure, that nobody steps below the weight.

3 - 64

PC8000-6E

Version 2010/1

Superstructure

Hydraulics

3.8.2.2 REPLACEMENT OF ADDITIONAL HYDRAULIC OIL COOLER FAN ASSEMBLY Special tools:

n/a


Oil drain pan Crane Additional hydraulic oil cooler fan assembly: 104 kg

Dogman/rigger




CAUTION Install the assembly carefully in order not to damage the oil cooler or the fan blades.

z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and the PARTS & SERVICE NEWS "AH01513".

z


z


Version 2010/1

PC8000-6E

3 - 65

Hydraulics

Superstructure

3.8.2.3 REMOVAL OF ADDITIONAL HYDRAULIC OIL COOLER FANS AND MOTORS Special tools:

n/a


Oil drain pan Hydraulic oil cooler fan assembly: 104 kg Fan: 17 kg Adapter: 3 kg Fan cross-head: 44 kg Fan motor: 10 kg

Dogman/rigger


Remove the additional hydraulic oil cooler fan assembly, refer to section 3.8.2.1 on page 3-62.

Fig. 3-58 Additional hydraulic oil cooler fan assembly

3 - 66

PC8000-6E

Version 2010/1

Superstructure

Hydraulics

WARNING Fan blades could have sharp edges. Use gloves!

z

Remove the attaching bolts (Fig. 3-58, Pos. 6) with the locking plates (Fig. 3-58, Pos. 5). Discard the locking plates.

z

Remove the bolt (Fig. 3-58, Pos. 7), the washer (Fig. 3-58, Pos. 8) and the adapter (Fig. 3-58, Pos. 9).

z

Remove the cooler fan (Fig. 3-58, Pos. 4).

z

Remove the four bolts (Fig. 3-58, Pos. 2) and remove the hydraulic motor (Fig. 3-58, Pos. 1) from the fan cross-head (Fig. 3-58, Pos. 3).

3.8.2.4 REPLACEMENT OF ADDITIONAL HYDRAULIC OIL COOLER FANS AND MOTORS Special tools:

n/a


Oil drain pan Hydraulic oil cooler fan assembly: 104 kg Fan: 17 kg Adapter: 3 kg Fan cross-head: 44 kg Fan motor: 10 kg

Dogman/rigger



z

Use new locking plates (Fig. 3-58, Pos. 5) and a new washer (Fig. 3-58, Pos. 8). WARNING


z


Version 2010/1

PC8000-6E

3 - 67

Hydraulics

Superstructure

3.8.2.5 REMOVAL OF THE ADDITIONAL HYDRAULIC OIL COOLERS Special tools:

n/a


Safety harness in conformity with EN 361 Oil drain pan Crane Mobile elevator working platform Additional hydraulic oil cooler: 230 kg

Dogman/rigger



z




z


z


z


Fig. 3-59 WARNING z

Always wear a safety harness when working at the additional hydraulic oil cooler.

z

Most of the following operations require the use of men safety cages on elevator working Platforms.

3 - 68

PC8000-6E

Version 2010/1

Superstructure

z

Hydraulics

Open the additional hydraulic oil cooler door. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY". WARNING


z

Disconnect the hoses (Fig. 3-60, Pos. 1 and 2) from the additional hydraulic oil cooler.

NOTE: When the hoses are removed, oil will flow out of the oil coolers. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-60 z

Sling the oil cooler (Fig. 3-61).

Fig. 3-61

Version 2010/1

PC8000-6E

3 - 69

Hydraulics

Superstructure

Fig. 3-62 Removal of the additional hydraulic oil coolers z

Remove the bolts (Fig. 3-62, Pos. 3) and the resilient sleeve (Fig. 3-62, Pos. 2) from the angle (Fig. 3-62, Pos. 1).

z

Lift the additional hydraulic oil cooler (Fig. 3-62, Pos. 5) out of the cooler frame (Fig. 3-62, Pos. 6) using a crane. DANGER

Risk of fallen weights! Death or serious injury may result. When removing the additional hydraulic cooler make sure, that nobody steps below the weight.

z

Check the condition of the buffer element (Fig. 3-62, Pos. 7) and replace it if required.

3 - 70

PC8000-6E

Version 2010/1

Superstructure

Hydraulics

3.8.2.6 REPLACEMENT OF THE ADDITIONAL HYDRAULIC OIL COOLERS Special tools:

n/a


Safety harness in conformity with EN 361 Oil drain pan Crane Mobile elevator working platform Additional hydraulic oil cooler: 230 kg

Dogman/rigger

Observe the safety hints for hydraulic hose installation, refer to section 2.2.6 on page 2-22. If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

WARNING z


z


z

Use new moulding material (Fig. 3-62, Pos. 4) between the oil cooler and the cooler frame (Fig. 3-62, Pos. 6).

z


z


z


Version 2010/1

PC8000-6E

3 - 71

Hydraulics

Superstructure

3.8.2.7 REMOVAL OF THE ADDITIONAL HYDRAULIC OIL COOLER ASSEMBLY Special tools:

n/a


Safety harness in conformity with EN 361 Oil drain pan Crane Mobile elevator working platform Additional hydraulic oil cooler assembly: 1300 kg

Dogman/rigger



z




z


z


z

Most of the following operations require the use of men safety cages on elevator working platforms.


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Version 2010/1

Superstructure

Hydraulics

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement or scaring may result. The hydraulic system may pressurized. Make sure, that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect all hydraulic pressure hoses (Fig. 3-63, Pos. 3), the return hoses (Fig. 3-63, Pos. 4) and the leak oil hoses from the additional hydraulic fan drive motors.

z

Disconnect the hydraulic hoses (Fig.3-63, Pos. 1 and 2) from the additional oil cooler assembly.

NOTE: When the hoses are disconnected, the oil inside the hoses and the hydraulic motor will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. Fig. 3-63

z

Remove the rail and the steps (Fig. 3-64, Pos. 1 and 2) from the hydraulic oil cooler assembly.

z

Attach the additional cooler frame assembly (Fig. 3-64, Pos. 5) to a crane.

z

Remove the screws (Fig. 3-64, Pos. 3) and the washers (Fig. 3-64, Pos, 4) from the additional oil cooler frame assembly (Fig. 3-64, Pos. 5).

z

Remove the additional hydraulic cooler assembly (Fig. 3-64, Pos. 5) from the hydraulic oil cooler assembly (Fig. 3-64, Pos. 6), supported using a crane. DANGER

Risk of fallen weights! Death or serious injury may result. When removing the additional hydraulic cooler fan assembly make sure, that nobody steps below the weight. Fig. 3-64

Version 2010/1

PC8000-6E

3 - 73

Hydraulics

Superstructure

3.8.2.8 REPLACEMENT OF ADDITIONAL HYDRAULIC OIL COOLER ASSEMBLY Special tools:

n/a


Safety harness in conformity with EN 361 Oil drain pan Crane Mobile elevator working platform Additional hydraulic oil cooler assembly: 1300 kg

Dogman/rigger


WARNING z


z


z


z


z


z

Check and adjust the speed of the hydraulic oil cooler fan, refer to the Operation and Maintenance Manual, chapter 3, section "ELECTRONIC MONITORING AND CONTROL SYSTEM ECS."

Fig. 3-65

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Hydraulics


Version 2010/1

PC8000-6E

3 - 75

Hydraulics

3.8.3

Superstructure

HYDRAULIC OIL COOLER ASSEMBLY

Fig. 3-66 Hydraulic oil cooler circuit

3 - 76

PC8000-6E

Version 2010/1

Superstructure

Hydraulics


Solenoid valve (4/2-directional control valve)

(2)

Back pressure valve

(3)

Return lines from control blocks

(4)

Return oil collector tube

(5)

Lines to oil cooler (hot oil)

(6)

Lines to tank (cold oil)

(7)

Restrictor (shock absorbers for the hydraulic oil cooler)

(8)

Hydraulic oil cooler

(9)

Hydraulic oil reservoir

The returning oil from the system flows via the lines (Fig. 3-66, Pos. 3) into the collector tube (Fig. 3-66, Pos. 4). On the top side of it the back pressure valve (Fig. 3-66, Pos. 2) is installed. The back pressure valve causes a back pressure which forces most of the relative hot oil via the lines (Fig. 3-66, Pos. 5) to the oil cooler (Fig. 3-66, Pos. 8). On the flow to the hydraulic oil cooler the hydraulic oil passes the restrictor (Fig. 3-66, Pos. 7), gets cooled in the oil cooler and then flows through the lines (Fig. 3-66, Pos. 6) into the filter chamber of the hydraulic oil reservoir (Fig. 3-66, Pos. 9). The restrictors acts as shock absorbers to prevent cooler cracks created from pressure peaks. Besides the back pressure valve acts as an oil flow control valve as far as the oil temperature has not reached its steady temperature. During the warm-up period (1/2 Qmax) the back pressure valve (Fig. 3-66, Pos. 2) is wide open, because the solenoid valve (Fig. 3-66, Pos. 1) is energized, which results in less oil flow through the cooler which causes the oil getting its optimum operating temperature quicker. With increasing oil temperature the oil gets thinner, so that the main pumps can be shifted to Qmax position and simultaneously the solenoid valve (Fig. 3-66, Pos. 1) will be de-energized, so that the valve piston will be closed further by the force of the spring resulting in more oil passing the cooler.

Version 2010/1

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Hydraulics

Superstructure

There are eight hydraulic oil cooler elements in front of the hydraulic oil reservoir on the left-hand side of the platform. Four cooler elements (Fig. 3-67, Pos. 3) are mounted in one frame at a time. So two frames (Fig. 3-67, Pos. 4) are installed with four cooler elements in each frame. The air stream needed for the cooling is produced by hydraulically driven fans. The air flows from inside to outside through the coolers For better cleaning, the cooler frames are mounted via hinges to the cooler support so the cooler frames can be opened. ("swing out cooler"). The two cooler fans (Fig. 3-67, Pos. 1 and 2) are driven by hydraulic motors.

Fig. 3-67 Each fan drive motor is supplied by one hydraulic pump. The hydraulic pump (Fig. 3-68, Pos. 2) on PTO 1 (Fig. 3-68, Pos. 1) supplies the lower hydraulic fan motor (Fig.3-67, Pos. 2). The hydraulic pump (Fig. 3-68, Pos. 4) on PTO 2 (Fig. 3-68, Pos. 3) supplies the upper hydraulic fan motor (Fig. 3-67, Pos. 1). The fans are mounted directly to the hydraulic motors drive shaft.

Fig. 3-68

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Hydraulics


Version 2010/1

PC8000-6E

3 - 79

Hydraulics

Superstructure

3.8.3.1 REMOVAL OF THE HYDRAULIC OIL COOLER FAN ASSEMBLIES

Fig. 3-69 Hydraulic oil cooler fan assembly

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PC8000-6E

Version 2010/1

Superstructure

Hydraulics


Bolt

(2)

Locking plate

(3)

Cooler fan

(4)

Drive shaft

(5)

Shaft protecting sleeve

(6)

Drive shaft seal

(7)

Bearing

(8)

Distance sleeve

(9)

Bearing group carrier

(10)

Bearing

(11)

Circlip

(12)

O-ring

(13)

Hydraulic motor

(14)

Bolt

(15)

Fan bar

Special tools:

n/a


Safety harness in conformity with EN 361 Oil drain pan Crane Hydraulic cooler fan assembly: 262 kg

Dogman/rigger



z




Version 2010/1

PC8000-6E

3 - 81

Hydraulics

z

Superstructure


Always wear a safety harness when working at the hydraulic oil cooler assembly.

z

Attach the rail (Fig. 3-70, Pos. 3) to a crane and remove the grating (Fig. 3-70, Pos. 4) from the platform (Fig. 3-70, Pos. 5).

z

Remove the bolts (Fig. 3-70, Pos. 1 and 6), the resilient sleeve (Fig. 3-70, Pos. 2) and the nuts (Fig. 3-70, Pos. 7).

z

Remove the rail (Fig. 3-70, Pos. 3) from the hydraulic oil cooler assembly (Fig. 3-70, Pos. 8), using a crane.

Fig. 3-70 z

Remove the fan cages (Fig. 3-71, Pos. 1) from the cooler housing (Fig. 3-71, Pos. 3). WARNING


DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed. Fig. 3-71 z

Disconnect all hydraulic hoses and the leak oil hoses from the fan drive motors (Fig. 3-71, Pos. 2).

NOTE: When the hoses are removed, the oil inside the hoses and the motors will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. 3 - 82

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Superstructure

Hydraulics


z

Remove the hydraulic oil cooler fan assembly (Fig. 3-71, Pos. 2) from the cooler housing (Fig. 3-71, Pos. 3), supported using a crane. CAUTION

Remove the hydraulic oil cooler fan assembly carefully in order not to damage the oil cooler or the fan blades.

DANGER Risk of fallen weights! Death or serious injury may result. When removing the hydraulic oil cooler fan assembly make sure, that nobody steps below the weight.

Version 2010/1

PC8000-6E

3 - 83

Hydraulics

Superstructure

3.8.3.2 REPLACEMENT OF HYDRAULIC OIL COOLER FAN ASSEMBLIES Special tools:

Rotational speed infrared probe DS03, PN 793 788 73


Safety harness in conformity with EN 361 Oil drain pan Crane Hydraulic oil cooler fan assembly: 262 kg

Dogman/rigger


WARNING Always wear a safety harness when working at the hydraulic oil cooler assembly.

z



CAUTION Install the assembly carefully in order not to damage the oil cooler or the fan blades.

z


z


z


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Version 2010/1

PC8000-6E

3 - 85

Hydraulics

Superstructure

3.8.3.3 REMOVAL OF THE HYDRAULIC OIL COOLER FAN AND MOTOR Special tools:

n/a


Crane Oil drain pan Fan: 78 kg Fan bearing block: 61 kg Fan bar: 74 kg Fan motor: 49 kg

Dogman/rigger

Fig. 3-72 Hydraulic oil cooler fan assembly

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Hydraulics


z

Remove the hydraulic oil cooler fan assembly, refer to section 3.8.3.1 on page 3-80.

NOTE: Carry out the two following two steps only if the cooler fan needs to be removed.

z

z

Remove the attaching bolts (Fig. 3-72, Pos. 1) with the locking plates (Fig. 3-72, Pos. 2). Discard the locking plates.

z

Remove the cooler fan (Fig. 3-72, Pos. 3) from the drive shaft (Fig. 3-72, Pos. 4).

Remove the four bolts (Fig. 3-72, Pos. 14) and remove the hydraulic motor (Fig. 3-72, Pos. 13) from the bearing group carrier (Fig. 3-72, Pos. 9). Discard the O-ring (Fig. 3-72, Pos. 12).

NOTE: When the hydraulic motor is disconnected from the bearing group carrier, the oil inside the bearing group carrier will flow out. Catch it in an oil pan. z

If required remove the circlip (Fig. 3-72, Pos. 11), extract the drive shaft (Fig. 3-72, Pos. 4) out of the bearing group carrier (Fig. 3-72, Pos. 9), and remove the drive shaft seal (Fig. 3-72, Pos. 6), the bearings (Fig. 3-72, Pos. 7 and 10), and the sleeves (Fig. 3-72, Pos. 5 and 8).

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Hydraulics

Superstructure

3.8.3.4 REPLACEMENT OF HYDRAULIC OIL COOLER FAN AND MOTOR Special tools:

n/a


Crane Fan: 78 kg Fan bearing block: 61 kg Fan bar: 74 kg Fan motor: 49 kg

Dogman/rigger


Fig. 3-73 Hydraulic oil cooler fan assembly 3 - 88

PC8000-6E

Version 2010/1

Superstructure

z

Hydraulics

Carry out installation in reverse order to removal. Refer to the PARTS & SERVICE NEWS No. "AH03506".

NOTE: If the drive shaft (Fig. 3-73, Pos. 4) is removed, check the drive shaft. Check drive shaft seal (Fig. 3-73, Pos. 6) for wear and damage. Replace if required. NOTE: Use a new O-ring (Fig. 3-73, Pos. 12) and new locking plates (Fig. 3-73, Pos. 2). WARNING Fan blades could have sharp edges. Use gloves!

z

Install the hydraulic oil cooler fan assembly, refer to section 3.8.3.2 on page 3-84.

NOTE: Check the oil level in the bearing group carrier (Fig. 3-73, Pos. 9) and add oil if required, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC OIL COOLER FAN BEARINGS - CHECK FOR LEAKAGE AND CLEAN BREATHER FILTER". z


z


z


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Hydraulics

Superstructure

3.8.3.5 REMOVAL OF THE HYDRAULIC OIL COOLERS Special tools:

n/a


Safety harness in conformity with EN 361 Crane Mobile elevator working platform Oil drain pans Hydraulic oil cooler: 230 kg each

Dogman/rigger



z



Relieve the pressure in the hydraulic system, refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM"

z


z


z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "TRANSFUSION PROCEDURE".

z

Open the hydraulic oil cooler door. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY".

Fig. 3-74 WARNING z

Always wear a safety harness when working at the hydraulic oil cooler frame.

z


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Hydraulics


z

Disconnect all inlet hoses (Fig. 3-75, Pos. 1), all outlet hoses (Fig. 3-75, Pos. 2) and all connecting hoses (Fig. 3-75, Pos. 3) from the hydraulic oil cooler.

NOTE: When the hoses are removed, oil will flow out of the oil coolers. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-75

z

Sling the oil cooler (Fig. 3-76).

Fig. 3-76

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Superstructure

Fig. 3-77 Removal of the oil coolers z

Remove the bolts (Fig. 3-77, Pos. 5), the resilient sleeves (Fig. 3-77, Pos. 4), and clear the oil cooler (Fig. 3-77, Pos. 1) from the angles (Fig. 3-77, Pos. 3).

z

Lift the oil cooler (Fig. 3-77, Pos. 1) out of the radiator frame (Fig. 3-77, Pos. 6 and 7) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the hydraulic oil cooler, make sure that nobody steps below the weight.

z

Check the buffer element (Fig. 3-77, Pos. 9) and replace it if required.

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Superstructure

3.8.3.6 REPLACEMENT OF THE HYDRAULIC OIL COOLERS Special tools:

n/a


Safety harness in conformity with EN 361 Crane Mobile elevator working platform Glue PN 256 952 40 Hydraulic oil cooler: 230 kg each

Dogman/rigger


Fig. 3-78 Installation of the oil coolers

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WARNING z


z


z

Apply glue PN 256 952 40 to the profiled joints (Fig. 3-78, Pos. 2) and attach them in the same manner as they were fixed to the old oil cooler.

z


z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and the PARTS & SERVICE NEWS No."AH01513".

z


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Hydraulics

Superstructure

3.8.3.7 REMOVAL OF THE HYDRAULIC OIL COOLER ASSEMBLY Special tools:

n/a


Safety harness in conformity with EN 361 Crane 4 x Swivel hoist rings: M36 Mobile elevator working platform Oil drain pans Hydraulic oil cooler frame: 7320 kg

Dogman/rigger



z




z


z


z


z

Open the hydraulic oil cooler door. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC OIL COOLERS - INSPECT AND CLEAN IF NECESSARY".

Fig. 3-79

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WARNING z


z


z


z

Remove the additional hydraulic cooler assembly, refer to section 3.8.2.7 on page 3-72.

z

Remove the rail (Fig. 3-80, Pos. 1) from the hydraulic oil cooler assembly (Fig. 3-80, Pos. 3).

z

Remove the lighting equipment (Fig. 3-80, Pos. 2) from the hydraulic oil cooler assembly (Fig. 3-80, Pos. 3).

Fig. 3-80 z

Disconnect all hydraulic pressure hoses (Fig. 3-81, Pos. 3), all return hoses (Fig. 3-81, Pos. 1), and all leak oil hoses (Fig. 3-81, Pos. 2) from the upper and the lower hydraulic oil cooler fan motor.

NOTE: When the hoses are disconnected, oil will flow out of the hoses. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-81

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z

Superstructure

Disconnect the hydraulic hoses (Fig. 3-82, Pos. 1 and 2) at the shown joints from the hydraulic oil reservoir.

NOTE: When the hoses are disconnected, oil will flow out of the hoses. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-82

z

Insert the swivel hoist rings (M36) into the threads (Fig. 3-83, Pos. 1) at the hydraulic oil cooler frame.

z

Sling the hydraulic oil cooler frame at the hoist rings.

Fig. 3-83

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z

Hydraulics

Remove the mounting bolts and washers (Fig. 3-84, Pos. 2 up to 5) and remove the hydraulic oil cooler assembly (Fig. 3-84, Pos. 1) from the superstructure using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the hydraulic oil cooler assembly, make sure that nobody steps below the weight.

z

Rest the hydraulic oil cooler assembly on the ground on an appropriate stand.

Fig. 3-84 z

Carry out the following steps if required. z

Remove the rail from the hydraulic oil cooler assembly.

z

Attach the rail (Fig. 3-85, Pos. 3) to a crane and remove the grating (Fig. 3-85, Pos. 4) from the platform (Fig. 3-85, Pos. 5).

z

Remove the bolts (Fig. 3-85, Pos. 1 and 6), the resilient sleeves (Fig. 3-85, Pos. 2), and the nuts (Fig. 3-85, Pos. 7).

z

Remove the rail (Fig. 3-85, Pos. 3) from the hydraulic oil cooler assembly (Fig. 3-85, Pos. 8), using a crane.

z

Disconnect all wiring harness connectors from the hydraulic oil cooler assembly (Fig. 3-85, Pos. 8).

z

If required, remove the hydraulic oil cooler fan assembly from the hydraulic oil cooler assembly, refer to section 3.8.3.1 on page 3-80.

z

If required, remove the hydraulic oil cooler from the hydraulic oil cooler assembly, refer to section 3.8.3.5 on page 3-90. Fig. 3-85

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Hydraulics

Superstructure

3.8.3.8 REPLACEMENT OF THE HYDRAULIC OIL COOLER ASSEMBLY Special tools:

n/a


Safety harness in conformity with EN 361 4 x Swivel hoist rings: M36 Crane Mobile elevator working platform Compound "KP2K", PN 324 969 40 Hydraulic oil cooler frame: 7320 kg

Dogman/rigger


WARNING Always wear a safety harness when working at the hydraulic oil cooler frame. Most of the following operations require the use of men safety cages on elevator working platforms.

z


NOTE: Use new mounting bolts and new washers (Fig. 3-86, Pos. 2 up to 5) of grade 10.9. Apply compound "KP2K", PN 324 969 40 and tighten the mounting bolts to the specified tightening torque. Tightening torque for mounting bolts (Fig. 3-86, Pos. 2 and 5): 3100 Nm

z


z


Fig. 3-86 3 - 100

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Version 2010/1

Superstructure

3.8.4

Hydraulics

PILOT OIL PUMP (GEAR PUMP)

3.8.4.1 REMOVAL OF THE PILOT OIL PUMP Special tools:

n/a


n/a Pilot oil pump: 34 kg For further information about the needed blind plugs, refer to section 6.6 on page 6-14.

z


z




z


z


z


Fig. 3-87

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Hydraulics

Superstructure

The pilot oil pumps (Fig. 3-88, Pos. 9.2 and 9.4) generate the pilot pressure that is used for all hydraulic control operations. The pilot oil pumps (Fig. 3-88, Pos. 9.2 and 9.4) are attached to both PTOs. WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Disconnect the SAE-flanges of pressure hose and suction hose from the pilot oil pump (Fig. 3-88, Pos. 9.2 or 9.4).


Remove the four bolts (Fig. 3-89, Pos. 1) and pull the pilot oil pump (Fig. 3-89, Pos. 2) and the joint element (Fig. 3-89, Pos. 3 up to 6) out of the main pump (Fig. 3-89, Pos. 7).

z

Discard the O-rings (Fig. 3-89, Pos. 3 and 6).

Fig. 3-88

NOTE: Check the joint element (Fig. 3-89, Pos. 4) for wear and replace it if required.

Fig. 3-89

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Hydraulics

3.8.4.2 REPLACEMENT OF THE PILOT OIL PUMP Special tools:



Paste "Optimol White" PN 999 039 Pilot oil pump: 34 kg

Dogman/rigger


z

Remove the four bolts (Fig. 3-90, Pos. 1) at the new pilot oil pump and disconnect the joint elements (Fig. 3-90, Pos. 3 up to 6) carefully.

z

To avoiding of corrosion coat the joint element surfaces and the pump surface with Optimol White, PN 999 039.

z


Fig. 3-90 NOTE: Use "Optimol White" on the spline shaft of the pump. NOTE: Use new O-rings (Fig. 3-90, Pos. 3 and 6) and new mounting bolts (Fig. 3-90, Pos. 1) with grade 8.8 at the mounting flanges of the pump. Tighten the mounting bolts to the specified tightening torque. Tightening torque for the mounting bolts: 74 Nm z


z


NOTE: Check and adjust the pilot pressure if required. Refer to the Service Manual.

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Hydraulics

3.8.5

Superstructure

MAIN GATE VALVE

The connection between the suction reservoir and the hydraulic oil reservoir can be closed with the main gate valve to prevent oil flow during repairs. This unit is monitored by the switch S31. It makes sure that a motor start is not possible with a closed main gate valve. Fault message „Start blocked because of main shut-off (gate) valve“ is displayed on the operator’s dashboard.

3.8.5.1 REMOVAL OF THE MAIN GATE VALVE Special tools:

n/a


Hydraulic oil tank (8350 liters) Main gate valve: 54 kg

z


z




z


z


Fig. 3-91

Drain hydraulic oil from the hydraulic oil reservoir, approx. 8350 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

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z

Disconnect the harness connector S31 from the proximity switch at the main gate valve. Refer to Fig. 3-99 on page 3-110.

z

Remove all bolts (Fig. 3-92, Pos. 2), dismantle the compensator (Fig. 3-92, Pos. 3), and the main gate valve (Fig. 3-92, Pos. 1).

NOTE: When the main gate valve (Fig. 3-92, Pos. 1) and the compensator (Fig. 3-92, Pos. 3) are removed some oil inside the piping will flow out. Catch it in an oil pan. z

Check the compensator (Fig. 3-92, Pos. 3) and replace it if required.

Fig. 3-92

3.8.5.2 REPLACEMENT OF THE MAIN GATE VALVE Special tools:

n/a


Hydraulic oil tank (8350 liters) Main gate valve: 54 kg If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

z


NOTE: Tighten the self locking nuts (Fig. 3-93, Pos. 1) at the compensator (Fig. 3-93, Pos. 2) to the specified tightening torque. Tightening torque for the self locking nuts: 70 Nm

Fill specified hydraulic oil into the hydraulic oil reservoir, approx. 8350 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER". z


z


Version 2010/1

PC8000-6E

Fig. 3-93

3 - 105

Hydraulics

3.8.6

Superstructure

HYDRAULIC OIL RESERVOIR

Fig. 3-94 Hydraulic oil reservoir

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Hydraulics



(2)

Oil level sight gauge

(3)

Breather filter

(4)

Back-pressure valve, temperature controlled

(5)

Man hole cover

(6)

Collector pipe

(7)

Return pipe

(8)

Oil reservoir outlet (suction line)

(9)

Drain coupling

(10)

Mounting brackets

(11)

Leak oil filter

(12)

Oil reservoir outlet

(13)

Return oil filter

(14)

Compensator

(15)

Main gate valve

(16)

Leak oil line connectors

Version 2010/1

PC8000-6E

3 - 107

Hydraulics

Superstructure

3.8.6.1 REMOVAL OF THE HYDRAULIC OIL RESERVOIR Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump aggregate, PN 232 613 40 46 mm hexagon impact socket wrench, PN 232 265 40


Safety harness in conformity with EN 361 Crane Mobile elevator working platform 4 x Swivel hoist rings: M 36 Hydraulic oil reservoir incl. back pressure valve: 7170 kg

Dogman/rigger



z




z

Always wear a safety harness when working at the hydraulic oil reservoir.

z


Drain hydraulic oil from the hydraulic oil reservoir, approx. 8350 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM" z

Remove the main gate valve, refer to section 3.8.5.1 on page 3-104.

z

Remove all attached parts, e.g. emergency ladder, steps, rails, plates, etc. from the hydraulic oil reservoir.

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z

Hydraulics

Insert swivel hoist rings (M 36) into the threads (Fig. 3-95, Pos. 1).

Fig. 3-95 z

Disconnect the hydraulic outlet hoses (Fig. 3-96, Pos. 1), leading from the hydraulic coolers, from the hydraulic oil reservoir.

z

Disconnect the hydraulic inlet hoses (Fig. 3-96, Pos. 2), leading to the hydraulic coolers, from the hydraulic oil reservoir.

z

Disconnect all hydraulic hoses from the return oil connector pipe.

z

Loosen all clamps at the hydraulic oil reservoir to disconnect all hydraulic hoses from the hydraulic oil reservoir.

z

Able and disconnect all hydraulic hoses.

NOTE: When the hydraulic hoses/pipes are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-96

z

Disconnect and remove the electrical wiring (Fig. 3-97, Pos. 1) from the transfer pump and the hydraulic oil reservoir.

Fig. 3-97

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Superstructure

z

Shut the cock valves at the hydraulic hoses (Fig. 3-97, Pos. 1) and disconnect the hydraulic hoses from the union (Fig. 3-97, Pos. 2).

z

Clear all hydraulic hoses from the hydraulic oil reservoir.

NOTE: When the hydraulic hoses/pipes are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-98

z

Disconnect all wiring harness connectors (Fig. 3-99, Pos. Bxx, Y101) and the head light assembly (Fig. 3-99, Pos. H50 and H50a).

z

Remove the wiring harnesses from the hydraulic oil reservoir.

Fig. 3-99 z

Attach the hydraulic oil reservoir to a crane.

z

Remove two mounting bolts (Fig. 3-100, Pos. 1) from each mounting flange (Fig. 3-100, Pos. 3) of the hydraulic oil reservoir (Fig. 3-100, Pos. 2).

z

Lift the hydraulic oil reservoir (Fig. 3-100, Pos. 2) off the superstructure using the crane and place it on the ground. DANGER

Risk of falling weights! Death or serious injury may result. When removing the hydraulic oil reservoir, make sure that nobody steps below the weight.

z

Remove all provided parts from the hydraulic oil reservoir if required.

Fig. 3-100

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Version 2010/1

Superstructure

Hydraulics

3.8.6.2 REPLACEMENT OF THE HYDRAULIC OIL RESERVOIR

Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump aggregate, PN 232 613 40 46 mm hexagon impact socket wrench, PN 232 265 40 Hydraulic testing kit, PN 232 591 40


Safety harness in conformity with EN 361 Crane Mobile elevator working platform Hydraulic oil reservoir incl. back pressure valve: 7170 kg

Dogman/rigger


Install all provided parts from the old hydraulic oil reservoir to the new one.

NOTE: Use new filter units at the new hydraulic oil reservoir. Check the O-rings and replace if required. z

Replace the return oil strainer (Fig. 3-101, Pos. 4). Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

NOTE: Use new gaskets (Fig. 3-101, Pos. 3 and 5) at the return oil strainer. Use new gaskets (Fig. 3-101, Pos. 1 and 2) at the back pressure valve. Check the O-rings and replace if required. CAUTION Replace return oil strainer (Fig. 3-101, Pos. 4) after major repairs on the hydraulic system and after every 6000 operating hours.

Fig. 3-101 WARNING Always wear a safety harness when working at the hydraulic oil reservoir.

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Hydraulics

z

Superstructure


NOTE: Use new bolts (Fig. 3-102, Pos. 1) with grade 10.9 at the mounting flanges (Fig. 3-102, Pos. 3) of the hydraulic oil reservoir (Fig. 3-102, Pos. 2). Tighten the bolts (Fig. 3-102, Pos. 1) to the specified tightening torque. Tightening torque for the mounting bolts: 1770 Nm

Fill specified hydraulic oil into the hydraulic oil reservoir, approx. 4450 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and to the Operation & Maintenance Manual, chapter 3, section "CENTRAL REFILLING SYSTEM". z


z


z

Check and adjust the back pressure if required, refer to the Service Manual.

3 - 112

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Fig. 3-102

Version 2010/1

Superstructure

3.8.7

Hydraulics

MAIN CONTROL VALVE BLOCKS

Fig. 3-103 Main control valve blocks overview (1)

Main control valve block I

(2)

Main control valve block III

(3)

Main control valve block II

(4)

Main control valve block IV

(5- 8)

High pressure filters

There are four main control valve blocks (I - IV) installed at the machine. Individual valve plugs are mounted on each main control valve block. These valves are anti-cavitation valves (Fig. 3-104, ACV), service line relief valves (Fig. 3-104, SRV), or main relief valves (Fig. 3-104, MRV).

Fig. 3-104

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Superstructure

3.8.7.1 REMOVAL OF THE MAIN CONTROL VALVE BLOCKS Special tools:

n/a


Crane Oil drain pan main control valve blocks: 683 kg High pressure filter: 50 kg

Dogman/rigger



z




z


z


z


Fig. 3-105 z

Remove the front roof plates, refer to section 3.3.3.1 on page 3-15.

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Hydraulics


z

Disconnect all hydraulic lines (Fig. 3-106, Pos. 3) at the respective main control valve block.

z

Disconnect all pilot lines from the spool valves (Fig. 3-106, Pos. 4) at the respective main control valve block.

NOTE: When the hydraulic lines are removed, the oil inside the lines will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Discard the O-rings (Fig. 3-106, Pos. 1) and the collar ring (Fig. 3-106, Pos. 2) of the SAE-flanges.

z

Disconnect the return line (Fig. 3-107, Pos. 1) at the respective main control valve block (I - IV) and discard the O-ring (Fig. 3-107, Pos. 2) of the SAE-flange.

NOTE: When the return line is removed, the oil inside the line will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-107

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Hydraulics

z

Superstructure

Sling the main control valve block (Fig. 3-108). WARNING

Risk of falling weights! Death or serious injury may result. When removing the main control valve blocks, make sure that nobody steps below the weight.

Fig. 3-108

z

Remove the mounting bolts (Fig. 3-109, Pos. 1 and 3), the nuts (Fig. 3-109, Pos. 2) and remove the respective main control valve block (Fig. 3-109, Pos. 5) from the control valve carrier (Fig. 3-109, Pos. 4) using a crane.

Fig. 3-109 z

If required remove all SRVs from the main control valve block, refer to section 3.8.9.3 on page 3-123.

z

If required remove all ACVs from the main control valve block, refer to section 3.8.10.3 on page 3-132.

z

If required remove the MRV from the main control valve block, refer to section 3.8.8.1 on page 3-118.

z

If required remove the load holding valves from the main control valve block.

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Superstructure

Hydraulics

3.8.7.2 REPLACEMENT OF THE MAIN CONTROL VALVE BLOCKS Special tools:



Crane Compound "KP2K", PN 324 969 40 Main control valve blocks: 683 kg High pressure filter: 50 kg

Dogman/rigger

Observe the safety hints for hydraulic hose installation, refer to section 2.2.6 on page 2-22. If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings. z


NOTE: Use new mounting bolts (Fig. 3-110, Pos. 1 and 3) of grade 10.9 and new nuts (Fig. 3-110, Pos. 2) for the respective main control valve block (Fig. 3-110, Pos. 5). Apply compound "KP2K", PN 324 969 40 on the bolts and tighten the bolts to the specified tightening torque. Tightening torque for the mounting bolts (Fig. 3-110, Pos. 1 and 3) at the main control valve blocks: 510 Nm NOTE: When connecting the hydraulic piping to the main control valve blocks, refer to the PARTS & SERVICE NEWS No. "AH05501". z


Fig. 3-110 z


z

Check the pressure of all circuits of the valve control blocks (use a 400 bar gauge).

Version 2010/1

PC8000-6E

3 - 117

Hydraulics

3.8.8

Superstructure

MAIN RELIEF VALVES (MRV)

MRV (main relief valves) are pilot operated relief valves. The MRV limit the maximum pump supply line pressure. The valves are designed with an opening characteristic. That means, if the valve is activated after the response procedure, no further pressure increase is possible and damage is avoided. The valves are installed in the main control valve blocks.

3.8.8.1 REMOVAL OF THE MRV ON THE MAIN CONTROL VALVE BLOCK Special tools:

Socket wrench 36 mm, PN 232 274 40


n/a

z


z


z


z


Fig. 3-111


z

Remove the MRV (Fig. 3-112, Pos. 1, 2, 3 or 4) from the main control valve block.

NOTE: When the MRV is removed, oil will flow out of the main control valve block. Catch it in an oil pan. Fig. 3-112

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Version 2010/1

Superstructure

Hydraulics

3.8.8.2 REPLACEMENT OF THE MRV ON THE MAIN CONTROL VALVE BLOCK Special tools:

Socket wrench 36 mm, PN 232 274 40 Hydraulic testing kit, PN 232 591 40


n/a

NOTE: Fit new O-rings to the MRV. z


NOTE: Tighten the MRV to the specified tightening torque. Tightening torque for MRV: 300 Nm z


z


z

Check and adjust the MRV. Refer to the Service Manual. WARNING

Wear ear protection when checking the relief pressure.

Version 2010/1

PC8000-6E

3 - 119

Hydraulics

3.8.9

Superstructure

SERVICE LINE RELIEF VALVES (SRV)

The service line relief valves are pilot operated relief valves. The SRV limit the maximum possible pressure in the service lines created by external force. The valves are designed with an opening characteristic. That means, if the valve is activated after the response procedure, no further pressure increase is possible and damage is avoided. Service relief valves are located on the main control valve blocks on the manifold and in the throttle check valves, refer to section 3.8.11.1 on page 3-138. NOTE: SRVs are also installed in the travel system, refer to section 4.2.8.1 on page 4-40.

3.8.9.1 REMOVAL OF THE SRV ON THE MANIFOLD Special tools:

n/a


Crane Oil drain pan Double-SRV: 50 kg

Dogman/rigger

For further information about the needed blind plugs, refer to section 6.6 on page 6-14. The SRV on the manifold controls the pressure for the clam cylinder piston side. z


z




z


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z


z


Fig. 3-113 z

It is recommended to remove the front wall to avoid an inclined hoist while using a crane, refer to section 3.3.3 on page 3-15. WARNING


z

Disconnect the hydraulic lines from the SRV (Fig. 3-114, Pos. 2).

NOTE: When the hydraulic lines are disconnected, the oil inside the lines will flow out. Catch it in an oil pan. Cap the openings to avoid contamination. z

Remove the four bolts (Fig. 3-114, Pos. 1) attaching the SRV to the manifold (Fig. 3-114, Pos. 3).

z

Remove the SRV (Fig. 3-114, Pos. 2) and cap the openings with blind plugs to avoid contamination.

Fig. 3-114

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z

Superstructure

Discard the O-ring (Fig. 3-115, Pos. 1).

NOTE: Carry out the following step only if required: z

Remove the pressure relief valve (Fig. 3-115, Pos. 1) from the valve body (Fig. 3-115, Pos. 2).

Fig. 3-115

3.8.9.2 REPLACEMENT OF THE SRV ON THE MANIFOLD Special tools:

n/a


Crane Double-SRV: 50 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. Ensure that the mating surfaces are clean and free of paint before assembly. z

Use a new O-ring (Fig. 3-116, Pos. 3).

z


NOTE: If the build-in SRV (Fig. 3-116, Pos. 1) were removed from the valve body (Fig. 3-116, Pos. 2) tighten the valves to the specified tightening torque. Tightening torque for the built-in SRV: 300 Nm

Fig. 3-116 z


z


z

Check and adjust the SRV. Refer to the Service Manual.

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3.8.9.3 REMOVAL OF THE SRV ON THE MAIN CONTROL VALVE BLOCK Special tools:

n/a


Oil drain pan

z

Relieve the pressure in the hydraulic system. Refer to the Operation & Maintenance Manual, chapter 3, section "RELIEVE PRESSURE IN THE HYDRAULIC SYSTEM".

z


z


z

Transfuse the oil from the return manifold into the main oil reservoir. Refer to the Operation & Maintenance Manual, chapter 3, section "TRANSFUSION PROCEDURE".


z

Disconnect the hydraulic hose from the SRV (Fig. 3-118, Pos. 2).

NOTE: When the hydraulic hose is disconnected, the oil inside the hose will flow out. Catch it in an oil pan. Cap the openings to avoid contamination. z

Remove the four bolts (Fig. 3-118, Pos. 1) attaching the SRV to the main control valve block.

z

Remove the SRV (Fig. 3-118, Pos. 2) and cap the openings with blind plugs to avoid contamination.

Fig. 3-118

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z

Superstructure

Discard the O-rings (Fig. 3-119, Pos. 1).

NOTE: Carry out the following steps only if required: z

Remove the support rings (Fig. 3-119, Pos. 2) from the valve body (Fig. 3-119, Pos. 4).

z


Fig. 3-119 CAUTION Different SRVs with different pressures are installed. If removing more than one SRV at the same time, mark the SRV and the position where it is installed.

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3.8.9.4 REPLACEMENT OF THE SRV ON THE MAIN CONTROL VALVE BLOCKS Special tools:



n/a If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. z

Fit new O-rings (Fig. 3-120, Pos. 1) and support rings (Fig. 3-120, Pos. 2) to the valve body (Fig. 3-120, Pos. 4).

z


NOTE: If the build-in SRV (Fig. 3-119, Pos. 3) was removed from the valve body (Fig. 3-119, Pos. 4) tighten the valve to the specified tightening torque. Tightening torque for the built-in SRV: 300 Nm

Fig. 3-120 z


z


z

Check and adjust the SRV. Refer to the Service Manual.

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3.8.10 ANTI-CAVITATION VALVES (ACV)

Fig. 3-121 Anti cavitation valve (ACV) (1)

ACV housing

(2)

Valve cone

(3)

Spring

(4)

O-ring

(5)

Control leak oil bore

(6)

Cap screw (torque 900 Nm)

(S)

Supply line

(A/B)

Line connections

The anti-cavitation valves (ACV) are installed to avoid cavitation damages on users (hydraulic cylinders) by compensating a lack of oil when the SRV at the opposite side of the cylinder opens. See hydraulic circuit diagram. The circuit pressure in the line (Fig. 3-121, Pos. A/B) keeps the valve cone (Fig. 3-121, Pos. 2) closed. The pressure of the supply line (Fig. 3-121, Pos. S) forces onto the valve cone. The valve cone opens, whenever the pressure at the A and B side is lower than the back pressure at the return oil port S, to allow the necessary oil supply to get into the circuit.

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The ACVs are installed at the manifold and at the main control valve blocks.

3.8.10.1 REMOVAL OF THE ACV ON THE MANIFOLD Special tools:

n/a


Crane Oil drain pan Single-ACV: 32 kg Double-ACV: 50 kg

Dogman/rigger



z




z


z


z


Fig. 3-122 z

It is recommended to remove the front wall to avoid an inclined hoist while using a crane, refer to section 3.3.3 on page 3-15.

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Fig. 3-123 Positions of the ACVs at the manifold

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Double-ACV, Boom (section A - B)

(109.2)

Single-ACV, Stick cylinder rod side (section G)

(143)

Double-ACV, Stick cylinder (section H - J)

(144)

Double-ACV, Bucket cylinder (section M - N)

(145)

Double-ACV, Boom cylinder (section P -Q)

NOTE: The numbers (Fig. 3-123) are the component numbers in the hydraulic diagram. For further information about the ACV at the manifold, refer to the hydraulic diagram and the Service Manual. WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

In the following procedure a double-ACV (Fig. 3-124, Pos. 1) of the manifold is removed exemplarily. The procedure is also identical for the single-ACV (Fig. 3-124, Pos. 2), except the removal of the throttle check valve (Fig. 3124, Pos. 3). z

Remove the throttle check valve (Fig. 3-124, Pos. 3), refer to section 3.8.11.1 on page 3-138.

z

Disconnect the oil pipe from the ACV.

NOTE: When the pipe is disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-124

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z

Superstructure

Remove the four bolts (Fig. 3-125, Pos. 1) attaching the double-ACV (Fig. 3-125, Pos. 2) to the manifold.

Fig. 3-125 z z

Discard the O-rings (Fig. 3-126, Pos. 3). If required, remove the build-in ACV (Fig. 3-126, Pos. 1) from the valve body (Fig. 3-126, Pos. 1).

Fig. 3-126

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3.8.10.2 REPLACEMENT OF THE ACV ON THE MANIFOLD Special tools:

n/a


Crane Single-ACV: 32 kg Double-ACV: 50 kg

Dogman/rigger



Fit a new O-ring (Fig. 3-127, Pos. 3).

z


NOTE: If the build-in ACV (Fig. 3-127, Pos. 2) was removed from the valve body (Fig. 3-127, Pos. 1) tighten the valve to the specified tightening torque. Tightening torque for the built-in ACV: 300 Nm

Fig. 3-127 z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER" and the PARTS & SERVICE NEWS No. "AH01513".

z


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3.8.10.3 REMOVAL OF THE ACV ON THE MAIN CONTROL VALVE BLOCKS Special tools:

n/a


Oil drain pan

NOTE: For additional information about the ACV on the main control valve blocks, refer to section 3.8.7 on page 3-113. z


z


z


z



z

Disconnect the hydraulic hose from the ACV (Fig. 3-129, Pos. 3).

z

Remove the four bolts (Fig. 3-129, Pos. 1) attaching the ACV to the main control valve block.

z

Remove the block (Fig. 3-129, Pos. 2) and the ACV (Fig. 3-129, Pos. 3).

NOTE: When the ACV is removed, the oil inside the valves will flow out. Catch it in an oil pan. Cap the openings to avoid contamination.

Fig. 3-129 NOTE: For further information about the ACV at the main control valve blocks, refer to the hydraulic diagram and the Service Manual.

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z

Hydraulics

Remove the O-rings (Fig. 3-130, Pos. 1) and discard them.

NOTE: Carry out the following steps only if required: z

Remove the support rings (Fig. 3-130, Pos. 2) from the valve body (Fig. 3-130, Pos. 3).

z


Fig. 3-130

3.8.10.4 REPLACEMENT OF THE ACV ON THE MAIN CONTROL VALVE BLOCKS Special tools:

n/a


n/a If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.


Fit new O-rings (Fig. 3-131, Pos. 1) and support rings (Fig. 3-131, Pos. 2) to the valve body (Fig. 3-131, Pos. 3).

z


NOTE: If the build-in ACV (Fig. 3-131, Pos. 4) was removed from the valve body (Fig. 3-131, Pos. 3) tighten the valve to the specified tightening torque. Tightening torque for the built-in ACV: 300 Nm

Fig. 3-131 z


z


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3.8.11 THROTTLE CHECK VALVES

Fig. 3-132 Throttle check valve with built-in SRV

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Legend for Fig. 3-132: NOTE: The illustration shows the valve block upside down. (1)

Throttle adjustment pin

(2)

Back-up ring

(3)

O-ring

(4)

Retainer

(5)

Back-up ring

(6)

O-ring

(7)

Spring

(8)

Spring cup

(9)

Throttle valve sleeve

(9.1)

Adjustable throttle holes

(9.2)

Permanent throttle holes (safety channel)

(10)

O-ring

(11)

Housing

(12)

Return line port, T

(13)

SRV

(14)

Bolt

(15)

Clip ring

(16)

Lock nut

(A)

Line ports from the control valve

(B)

Line port to the cylinder

(M)

Pressure check point

(Y)

Control oil drain port

The maximum permissible cylinder speed is set by the pin (Fig. 3-132, Pos.1). Depending on the pin setting, the radial holes (Fig. 3-132, Pos. 9.1) in the valve sleeve (Fig. 3-132, Pos. 9) will be opened partially to achieve the required throttling of the oil flow. The safety holes (Fig. 3-132, Pos. 9.2) prevent the valve from becoming completely closed. For the lifting operation the valve sleeve which is guided by the spindle (Fig. 3-132, Pos. 1) is pressed against the spring (Fig. 3-132, Pos. 7) so that the valve will be completely open. The build-in SRV (Fig. 3-132, Pos. 13) limits the maximum system pressure from the cylinder and relieves oil to the tank line when the pressure reaches the valve setting.

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Fig. 3-133 Positions of the Throttle check valves at the manifold

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Throttle check valve, clam cylinder piston side (section F)

(131.1)

Throttle check valve, Bucket cylinder piston side (section C)

(131.4)

Throttle check valve, Bucket cylinder piston side (section E)

(131.5)

Throttle check valve, Stick cylinder piston side (section H)

(131.6)

Throttle check valve, Stick cylinder piston side (section H)

(131.7)

Throttle check valve, Stick cylinder piston side (section K)

(131.8)

Throttle check valve, Stick cylinder piston side (section K)

(131.9)

Throttle check valve, Calm cylinder rod side (section L)

(131.11)

Throttle check valve, Bucket cylinder piston side (section N)

(131.12)

Throttle check valve, Bucket cylinder piston side (section N)

(132.1)

Throttle check valve, Boom cylinder piston side (section B)

(132.2)

Throttle check valve, Boom cylinder piston side (section B)

(132.3)

Throttle check valve, Boom cylinder piston side (section P)

(132.4)

Throttle check valve, Boom cylinder piston side (section P)

NOTE: The numbers (Fig.3-133) are component numbers for the hydraulic diagram. For further information about the SRV at the manifold, refer to the hydraulic diagram and the Service Manual.

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3.8.11.1 REMOVAL OF THE THROTTLE CHECK VALVES ON THE MANIFOLD Special tools:

n/a


Crane Oil drain pan Throttle check valve (long version): 31 kg Throttle check valve (short version): 28 kg

Dogman/rigger



z




z


z


z

Transfuse the oil from the return manifold into the main oil reservoir, refer to the Operation & Maintenance Manual, chapter 3, section "TRANSFUSION PROCEDURE". WARNING


z

Fig. 3-134

It is recommended to remove the front wall to avoid inclined hoist while using a crane, refer to section 3.3.3 on page 3-15.

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In the following steps a throttle check valve on the manifold is removed exemplarily. WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

z

Disconnect the flex hose (Fig. 3-135, Pos. 5) from the throttle check valve (Fig. 3-135, Pos. 1).

z

Remove the four bolts (Fig. 3-135, Pos. 2) and remove the pipe (Fig. 3-135, Pos. 3) from the throttle check valve (Fig. 3-135, Pos. 1).

NOTE: When the hydraulic lines are removed, the oil inside the piping and the valve will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-135 z

Remove the four bolts (Fig. 3-136, Pos. 5) attaching the throttle check valve (Fig. 3-136, Pos. 1) to the manifold (Fig. 3-136, Pos. 2).

z

Remove the throttle check valve (Fig. 3-136, Pos. 1) and the O-ring (Fig. 3-136, Pos. 3). Discard the O-ring.

NOTE: When the throttle check valve is removed, the oil inside the valve and the manifold will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

If required, remove the adaptor (Fig. 3-136, Pos. 4) from the throttle check valve. Fig. 3-136

z

If required, repeat the procedure to remove the other throttle check valves from the manifold.

z

If required, remove the built-in SRV (Fig. 3-132, Pos. 13) from the throttle check valve’s housing (Fig. 3-132, Pos. 11).

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3.8.11.2 REPLACEMENT OF THE THROTTLE CHECK VALVES ON THE MANIFOLD Special tools:

n/a


Crane Throttle check valve (long version): 31 kg Throttle check valve (short version): 28 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit a new O-ring (Fig. 3-136, Pos. 3) to the throttle check valve (Fig. 3-136, Pos. 1). z


NOTE: If the built-in SRV (Fig. 3-132, Pos. 13) has been removed from the housing (Fig. 3-132, Pos. 11) tighten the valve to the specified tightening torque. Tightening torque for the built-in SRV: 300 Nm z


z


z

Check and adjust the throttle check valve. Refer to the Service Manual.

z

Check and adjust the built-in SRV in the throttle check valves if required. Refer to the Service Manual.

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3.8.12 MANIFOLD 3.8.12.1 REMOVAL OF THE MANIFOLD Special tools:

n/a


Crane Oil drain pan Manifold incl. ACV and SRV: 1925 kg Manifold without ACV and SRV: 725 kg

Dogman/rigger



z




z


z


z


z

Remove the front roof plates, refer to section 3.3.3.1 on page 3-15.

Fig. 3-137

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z

Remove the grating (Fig. 3-138, Pos. 1).

z

Disconnect all hydraulic hoses (Fig. 3-138, Pos. 2) leading to the attachment, refer to section 5.1.7.1 on page 5-68.

z

Open the clamps (Fig. 3-138, Pos. 6) and remove all hydraulic piping (Fig. 3-138, Pos. 5) from the front of the manifold.

z

Disconnect all hydraulic lines (Fig. 3-138, Pos. 4) leading to the ACVs and SRVs.

z

Remove all hydraulic piping (Fig. 3-138, Pos. 7) leading to the main control valves from the manifold.

NOTE: When the hydraulic lines are removed, the oil inside the hydraulic lines will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Sling the manifold.

z

Remove four mounting bolts (Fig. 3-138, Pos. 3).

z

Remove the manifold using a crane.

Fig. 3-138

DANGER Risk of falling weights! Death or serious injury may result. When removing the manifold, make sure that nobody steps below the weight.

z

Remove the anti cavitation valves (ACV) from the manifold, refer to section 3.8.10.1 on page 3-127.

z

Remove the throttle check valves from the manifold, refer to section 3.8.11.1 on page 3-138.

z

Remove the SRV from the manifold, refer to section 3.8.9.1 on page 3-120.

z

Remove all other attached parts from the manifold.

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3.8.12.2 REPLACEMENT OF THE MANIFOLD Special tools:

n/a


Crane Manifold incl. ACVs and SRVs: 1925 kg Manifold without ACVs and SRVs: 725 kg

Dogman/rigger

Observe the safety hints for hydraulic hose installation, refer to section 2.2.6 on page 2-22. If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings to the SAE-flanges. z


z


z


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3.9

SLEW SYSTEM

3.9.1

SLEW GEAR

Slew system

Fig. 3-139 Slew gears, mounting positions overview The PC8000-6 is equipped with three slew gear assemblies. For further information, refer to the Service Manual. Multi disc brakes (Fig. 3-139, Pos. 3) are installed between the swing motors (Fig. 3-139, Pos. 2) and the gearboxes (Fig. 3-139, Pos. 4). These brakes are safety brakes, applied by spring force and released by hydraulic oil pressure. To operate the rotary motion, slew brake valves (Fig. 3-139, Pos. 1) are directly flanged to the swing motor heads. For further information, refer to the Service Manual.

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Slew system

Superstructure

Fig. 3-140 Slew gear assembly, overview

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Slew system


Slew brake valve

(2)

Intermediate plate

(3)

Swing motor

(4)

Cover plates

(5)

Slew parking brake

(6)

Slew gear

(7)

Superstructure platform

(8)

Bolt

(9)

O-ring

(10)

Bolt

(11)

Bolt

(12)

Protection cap

(13)

Bolt

(14)

Nut

NOTE: The machine can be equipped either with a slew gear of manufacturer "L&S" or of manufacturer "Siebenhaar". The removal and the replacement of the slew gear by different manufacturers are analogously the same. Refer to the data plate on each slew gear housing to find out the manufacturer of the slew gear.

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Superstructure

3.9.1.1 REMOVAL OF THE SLEW GEAR Special tools:

n/a


Crane Swivel hoist rings: 4 x M16 Swing motor with attached slew service brake valve: 330 kg Slew gear (Siebenhaar): 1700 kg Slew gear (L&S): 1880 kg

Dogman/rigger



z




z


z


z


Fig. 3-141 z

Depending on the mounting position of the slew gear, remove the front roof plates, refer to section 3.3.3.1 on page 3-15.

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z

Slew system

Remove the bleeder valves (Fig. 3-142, Pos. 1) Drain the gear oil from the slew gear (Fig. 3-142, Pos. 3 respectively Pos. 5) at the drain coupling (Fig. 3-142, Pos. 2), • approx 60 liters (Siebenhaar), • approx. 42 liters (L&S), refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL".

z

Remove the oil drain coupling (Fig. 3-142, Pos. 2) and if equipped also remove the union (Fig. 3-142, Pos. 4) from the slew gear (Fig. 3-142, Pos. 3 respectively Pos. 5).

Fig. 3-142 z

Remove the swing motor (Fig. 3-143, Pos. 2) from the slew gearbox (Fig. 3-143, Pos. 3), refer to section 3.9.2.1 on page 3-155.

NOTE: Leave the hydraulic hoses and the slew service brake valve (Fig. 3-143, Pos. 1) attached to the swing motor if possible. If not, disconnect the hydraulic lines.

Fig. 3-143 L&S slew gear as example

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Slew system

Superstructure

DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect the oil pressure line from the slew parking brake.

NOTE: When the hydraulic lines are disconnected, the oil inside the lines will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the cover plates (Fig. 3-144, Pos. 3) if equipped.

z

Remove the protection caps (Fig. 3-144, Pos. 1) from the bolt heads and remove the slew gear mounting bolts (Fig. 3-144, Pos. 2). Discard the bolts.

z

Disconnect the lubrication lines below the slew gear.

z

Insert swivel hoist rings (M16) displaced by 90° into the threads of the swing motor mounting bolts and attach a crane.

z

Remove the slew gear (Fig. 3-144, Pos. 4) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the slew gear, make sure that nobody steps below the weight.

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Slew system

3.9.1.2 REPLACEMENT OF THE SLEW GEAR Special tools:

Feeler gauge (customary)


Crane Swivel hoist rings: 4 x M16 Compound "KP2K", PN 324 969 40 Swing motor with attached slew service brake valve: 330 kg Slew gear (Siebenhaar): 1700 kg Slew gear (L&S): 1880 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. NOTE: The machine can be equipped either with a slew gear of manufacturer "Siebenhaar" or of manufacturer "L&S". Refer to the data plate on each slew gear housing to find out the manufacturer of the slew gear. Both slew gears are replaceable using a special modification kit. Refer to the PARTS & SERVICE NEWS No. "AH05535". NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. z


z

Install the new slew gear (Fig. 3-145, Pos. 4) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the slew gear, make sure that nobody steps below the weight.

z

Mount the slew gear (Fig. 3-145, Pos. 4) to the superstructure with new mounting bolts (Fig. 3-145, Pos. 2).

z

Check the tooth backlash between slew ring and slew pinion with a feeler gauge. Refer to the PARTS & SERVICE NEWS No. "AH00511".

NOTE: Use new slew gear mounting bolts (Fig. 3-145, Pos. 2) of grade 12.9. Apply compound "KP2K", PN 324 969 40 and tighten the bolts to the specified tightening torque.


Tightening torque for the slew gear mounting bolts: 1030 Nm

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Superstructure

z

Install the oil drain coupling (Fig. 3-146, Pos. 2) with the union (Fig. 3-146, Pos. 4), if equipped, at the new slew gear (Fig. 3-146, Pos. 3 respectively Pos. 5).

z

Clean the bleeder valves (Fig. 3-146, Pos. 1) with compressed air from inside to outside and reinstall at the new slew gear (Fig. 3-146, Pos. 3 respectively Pos. 5).

Fig. 3-146 z


Make sure to use the specified bolts and the tightening torque for the swing motor mounting bolts, refer to section 3.9.2.2 on page 3-158.

Fill specified gear oil into the slew gear, • approx. 60 liters (Siebenhaar), • approx. 42 liters (L&S). Fill specified oil into the motor adapter housing, • approx. 0.6 liters (L&S), • up to level gauge marking (Siebenhaar). Fill specified oil into the brake housing (Siebenhaar only), approx. 0.2 liters. NOTE: Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL". For the proper lubricants, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS".

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Slew system

3.9.2

Superstructure

SWING MOTOR

Fig. 3-147 Swing motor assembly (1)

Bolt

(12)

Bolt (only Siebenhaar)

(2)

Slew brake valve

(13)

Washer (only Siebenhaar)

(3)

O-ring

(14)

Expansion tank of the slew gear (only Siebenhaar)

(4)

Bolt

(15)

Sleeve (only Siebenhaar)

(5)

Intermediate plate

(6)

O-ring

(7)

Bolt

(8)

Washer

(9)

Swing motor

(10)

O-ring

(11)

Slew gear

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3.9.2.1 REMOVAL OF THE SWING MOTOR Special tools:

n/a


Crane Oil drain pan Swing motor: 120 kg

Dogman/rigger



z




z


z


z


Fig. 3-148 z

Depending on the mounting position of the slew gear, remove the front roof plates, refer to section 3.3.3.1 on page 3-15.

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Drain the gear oil from the motor adapter housing. Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL" z

Disconnect the leak oil hose, attached to the swing motor.

NOTE: When the hydraulic hose is disconnected, hydraulic oil from inside the hoses and the swing motor will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Fig. 3-149 Removal of the swing motor

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z

Slew system

Remove the four mounting bolts (Fig. 3-149, Pos. 1) and take the slew brake valve (Fig. 3-149, Pos. 2) off. Discard the O-ring (Fig. 3-149, Pos. 3). For further information regarding the slew brake valve, refer to section 3.9.4.1 on page 3-179.

NOTE: The hydraulic hoses remain connected to the slew brake valve. When the slew brake valve is removed, the oil inside the valve will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the mounting bolts (Fig. 3-149, Pos. 4) and take off the intermediate plate (Fig. 3-149, Pos. 5). Discard the O-ring (Fig. 3-149, Pos. 6).

z

Only slew gear "Siebenhaar": Remove the bolts (Fig. 3-149, Pos. 12), with washers (Fig. 3-149, Pos. 13), and the sleeves (Fig. 3-149, Pos. 15). Put the expansion tank (Fig. 3-149, Pos. 14) of the slew gear aside. Discard the bolts.

z

Remove the bolts (Fig. 3-149, Pos. 7) and the washers (Fig. 3-149, Pos. 8). Discard the bolts.

z

Sling the swing motor (Fig. 3-149, Pos. 9).

z

Pull the swing motor out of the slew gear (Fig. 3-149, Pos. 11) using a crane. Place the swing motor on the ground. DANGER

Risk of falling weights! Death or serious injury may result. When removing the swing motor, make sure that nobody steps below the weight.

z


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3.9.2.2 REPLACEMENT OF THE SWING MOTOR Special tools:



Crane Paste "Optimol White" PN 999 039 Compound "KP2K", PN 324 969 40 Swing motor: 120 kg

Dogman/rigger


Fig. 3-150 Installation of the swing motor

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NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings (Fig. 3-150, Pos. 3, Pos. 6, and Pos. 10). z

Apply "Optimol White" to the spline shaft of the motor.

z


NOTE: Use new swing motor mounting bolts (Fig. 3-150, Pos. 7 and 12) of grade 10.9. Apply compound "KP2K", PN 324 969 40 and tighten them to the specified tightening torque. Tightening torque for the swing motor mounting bolts: 265 Nm z


z

Add specified hydraulic oil up to the specified level. Fill specified oil into the motor adapter housing, • approx. 0.6 liters (L&S), • up to level gauge marking (Siebenhaar). Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL". For the proper lubricants, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS".

z

Check the adjustments of the swing motors. Refer to the Service Manual for further information.

z

Check the slew brake valve and adjust it if required. Refer to the Service Manual for further information.

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3.9.3

Slew system

SLEW PARKING BRAKE

NOTE: The machine can be equipped either with a slew parking brake of manufacturer "Siebenhaar" or of manufacturer "L&S". For the removal and the replacement, the "L&S" slew parking brake has to be disassembled/assembled. The "Siebenhaar" slew parking brake assembly can be exchanged completely.

Slew parking brake (L&S) (1)

Disc housing

(10)

Thrust washer

(2)

Thrust washer

(11)

Circlip

(3)

Inner discs

(12)

Drive shaft

(4)

Outer discs

(13)

Oil pressure port

(5)

Sinus spacer ring

(14)

Bolt

(6)

Piston

(15)

Bearing ring

(7)

Quad ring with back up ring

(16)

Rotary shaft seal

(8)

Quad ring with back up ring

(17)

Cylinder assembly

(9)

Springs

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General: Brake applied: The outer disks engaged to the housing by serration and the inner disks in serrated connection with the drive shaft are pressed together by the springs. This results in a fixed connection between housing and drive shaft due to the friction between the spring pressurized discs. Brake released: Oil pressure via the pilot port reaches the bottom of the piston and forces the piston upwards against the thrust washer and the spring force. This eliminates the spring force towards the disks so that the friction between the discs is released and the inner shaft can rotate. Only the brake of the L&S gear box uses an additional spacer ring (sinus ring) to keep the discs apart. It should reduce the friction in released condition. The minimum release pressure is 19 - 20 bar. In normal working conditions, the releasing pressure is about 60 bar. NOTE: The slew parking brake must only be applied with the superstructure at a complete standstill. Applying the parking brake with the superstructure still slewing may result in severe damage to the brake. WARNING z

Only use the slew parking brake in emergency situations to stop the rotating superstructure.

z

If the parking brake has been used for an emergency stop, it is necessary to shut down the excavator and to have the parking brake of each swing gear inspected and repaired if necessary. Contact your Komatsu dealer for repairing the brakes.

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3.9.3.1 REMOVAL/DISASSEMBLY OF THE SLEW PARKING BRAKE (L&S) Special tools:

n/a


Crane Swivel hoist rings: 2 x M16 Swing motor with attached slew service brake valve: 330 kg Bearing ring: 28.5 kg

Dogman/rigger

NOTE: The slew parking brake is attached to the slew gear with eight hexagon socket bolts. It is removed by disassembling it. z

Remove the swing motor from the slew gear, refer to section 3.9.2.1 on page 3-155. Leave the hydraulic hoses and the slew service brake valve attached to the swing motor.

z

Install swivel hoist rings (M16) displaced by 180° to the threads of the swing motor mounting bolts and attach a crane.

z

Remove the mounting bolts (Fig. 3-151, Pos. 1) at the swing motor flange.

z

Remove the inner snap ring (Fig. 3-151, Pos. 2).

z

Remove the bearing ring (Fig. 3-151, Pos. 3) from the slew gearbox using a crane.

Fig. 3-151

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Fig. 3-152 Slew parking brake (L&S) z

Check the rotary shaft seal (Fig. 3-152, Pos. 16) for wear and damage. Replace it if required.

z

Disconnect the pressure hose from the oil pressure port (Fig. 3-152, Pos. 13).

NOTE: When the pressure hose is removed, the oil inside the hose and the cylinder (Fig. 3-152, Pos. 17) will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. WARNING The piston (Fig. 3-152, Pos. 6) of the break assembly is spring loaded.

z

Remove the two socket head cap bolts (Fig. 3-152, Pos. 14) and relieve the spring load of the springs (Fig. 3-152, Pos. 9) on the piston (Fig. 3-152, Pos. 6).

z

Take off the cylinder assembly (Fig. 3-152, Pos. 17).

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z

Dismount 10 inner discs (Fig. 3-152, Pos. 3), 11 outer discs (Fig. 3-152, Pos. 4), and 10 sinus spacer rings (Fig. 3-152, Pos. 5) from the disc housing (Fig. 3-152, Pos. 1).

z

Remove the drive shaft (Fig. 3-152, Pos. 12).

z

Remove the thrust washer (Fig. 3-152, Pos. 2) from the disc housing (Fig. 3-152, Pos. 1).

z

Check the inner discs (Fig. 3-152, Pos. 3), the outer discs (Fig. 3-152, Pos. 4), the sinus spacer rings (Fig. 3-152, Pos. 5), and the thrust washer (Fig. 3-152, Pos. 2) for wear and damage. Replace if required.

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3.9.3.2 REPLACEMENT/ASSEMBLY OF THE SLEW PARKING BRAKE (L&S) Special tools:

n/a


Crane Paste "Optimol White" PN 999 039 Hydraulic power unit (60 bar) with fitting (M18 x 1.5) Swing motor with attached slew service brake valve: 330 kg Bearing ring: 28.5 kg

Dogman/rigger


Fig. 3-153 Slew parking brake (L&S)

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NOTE: Replace all O-rings. z

Install the thrust washer (Fig. 3-153, Pos. 2).

z

Install the drive shaft (Fig. 3-153, Pos. 12).

NOTE: Apply "Optimol White" to the spline shaft. z

Install new discs according to the following order: At first an outer disc (Fig. 3-153, Pos. 4), then an inner disc (Fig. 3-153, Pos. 3), and then a sinus spacer ring (Fig. 3-153, Pos. 5). Apply oil to the discs.

NOTE: Before reinstallation, apply pressure (max. 60 bar) to the cylinder assembly (Fig. 3-153, Pos. 17), otherwise the two socket head cap bolts (Fig. 3-153, Pos. 14) are prestressed (spring loaded). z

Install the cylinder assembly (Fig. 3-153, Pos. 17).

z


Make sure to use the specified bolts and torque for the swing motor mounting bolts, refer to section 3.9.2.2 on page 3-158.

Fill specified oil into the motor adapter housing, approx. 0.6 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL". For the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS". z


z

Check the slew parking brake for proper function. Refer to the Service Manual.

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3.9.3.3 REMOVAL OF THE SLEW PARKING BRAKE (SIEBENHAAR) Special tools:

n/a


Crane Swivel hoist rings: 2 x M16 Swing motor with attached slew service brake valve: 330 kg Slew parking brake assembly: 115 kg

Dogman/rigger


Remove the swing motor from the slew parking brake, refer to section 3.9.2.1 on page 3-155. Leave the hydraulic hoses and the slew service brake valve attached to the swing motor. Drain the oil of the brake housing, approx. 0.2 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL".

NOTE: After draining the oil of the brake housing, cap the openings with blind plugs to avoid contamination. DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect the pilot oil pressure line from the slew parking brake.

NOTE: When the pilot oil pressure line is disconnected, the oil inside the line will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

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z

Superstructure

Remove all hydraulic pipes (Fig. 3-154, Pos. 3) from the slew parking brake (Fig. 3-154, Pos. 2) and cap the openings with blind plugs to avoid contamination. DANGER

Danger of parts blasting off! Serious injury, permanent disfigurement and scarring, or death may result! The piston of the slew parking break assembly is spring loaded. It is necessary to release the brake manually (see following procedure) before removing the mounting bolts (Fig. 3-154, Pos. 1) attaching the complete slew parking brake (Fig. 3154, Pos. 2) to the slew gear box (Fig. 3-154, Pos. 4). Never open the brake by removing the flange mounting bolts (Fig. 3-155, Pos. 3) before the slew parking brake is manually released!

Fig. 3-154

Fig. 3-155 Slew parking brake (Siebenhaar), drawn released

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Releasing the slew parking brake manually: z

Insert two bolts (Fig. 3-156, Pos. 1) of suitable length with nuts (Fig. 3-156, Pos. 3) into the threaded borings (Fig. 3-155, Pos. 2) of the piston (Fig. 3-156, Pos. 2) opposed to each other.

z

Tighten each nut (Fig. 3-156, Pos. 3) alternately with a half turn, to withdraw the piston (Fig. 3-156, Pos. 2) to the flange (Fig. 3-156, Pos. 4).

NOTE: Avoid tilting the piston! z

Only remove the mounting bolts (Fig. 3-154 and 3-155, Pos. 1) attaching the complete slew parking brake (Fig. 3-154, Pos. 2) to the slew gearbox.

Fig. 3-156

DANGER Danger of parts blasting off! Serious injury, permanent disfigurement and scarring, or death may result! The piston of the slew parking break assembly is spring loaded. Never open the brake by removing the flange mounting bolts (Fig. 3-155, Pos. 3) before the slew parking brake is manually released!

z


z

Remove the slew parking brake (Fig. 3-154, Pos. 2) from the slew gearbox (Fig. 3-154, Pos. 4), using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the slew gear parking brake, make sure that nobody steps below the weight.

z


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3.9.3.4 REPLACEMENT OF THE SLEW PARKING BRAKE (SIEBENHAAR) Special tools:

n/a


Crane Paste "Optimol White" PN 999 039 Swivel hoist rings: 2 x M16 Swing motor with attached slew service brake valve: 330 kg Slew parking brake assembly: 115 kg

Dogman/rigger


Fig. 3-157 Slew parking brake (Siebenhaar), drawn released

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DANGER Danger of parts blasting off! Serious injury, permanent disfigurement and scarring, or death may result! The piston of the slew parking break assembly is spring loaded. Never open the brake by removing the flange mounting bolts (Fig. 3-157, Pos. 3) before the slew parking brake is manually released!


Apply paste "Optimol White" on the spline shaft at the adapter cover (Fig. 3-158, Pos. 4) of the gearbox.

z

Insert swivel hoist rings (M16) on the new pre-assembled slew parking brake, displaced by 180° into the threads of the swing motor mounting bolts and attach the brake assembly to a crane.

z

Insert a new O-Ring (Fig. 3-158, Pos. 3).

z

Centre the new pre-assembled slew parking brake (Fig. 3-158, Pos. 2) onto the adapter cover (Fig. 3-158, Pos. 4) of the gearbox. DANGER

Fig. 3-158

Risk of falling weights! Death or serious injury may result. When replacing the slew parking brake, make sure that nobody steps below the weight.

Releasing the slew parking brake manually: z

Insert two bolts (Fig. 3-159, Pos. 1) of suitable length with nuts (Fig. 3-159, Pos. 3) into the threaded borings (Fig. 3-157, Pos. 2) of the piston (Fig. 3-159, Pos. 2) opposed to each other.

z

Tighten each nut (Fig. 3-159, Pos. 3) alternately with a half turn, to withdraw the piston Fig. 3-159, Pos. 2) to the flange (Fig. 3-159, Pos. 4).

NOTE: Avoid tilting the piston! z

Turn the slew parking brake (Fig. 3-158, Pos. 2) until the bores in the slew parking brake are aligned to the threads in the adapter cover (Fig. 3-158, Pos. 4).

z

Insert new mounting bolts (Fig. 3-158, Pos. 1) and tighten them crosswise.

z

Remove the release bolts (Fig. 3-159, Pos. 1) with nuts alternately stepwise to prevent the piston from tilting.

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Fig. 3-159

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z

Superstructure


Make sure to use the specified bolts and torques for the swing motor mounting bolts, refer to section 3.9.2.2 on page 3-158.

Fill specified oil into the motor adapter housing, up to level gauge marking. Fill specified oil into the brake housing approx. 0.2 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "SWING GEARS AND MOTOR ADAPTER HOUSING - CHANGE OIL". For the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS". z


z

Check the slew parking brake for proper function. Refer to the Service Manual.

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3.9.4

Superstructure

DYNAMIC SLEW BRAKE

Fig. 3-160 Slew brake valve

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Pressure increasing valve

(2)

Check valve circuit A

(3)

Check valve circuit B

(4)

Anti-cavitation valve circuit B (check valve)

(5)

Anti cavitation valve circuit A (check valve)

(6)

Jet bore of main relief valve spool

(7)

Spring of main relief valve spool

(8)

Jet bore pilot relief valve

(9)

Valve cone of pilot relief valve

(10)

Spring of pilot relief valve

(11)

Intermediate pin

(12)

Control piston for pressure increase

(13)

Main relief valve spool

(X)

Pilot control port for pressure increase

(Y)

Leak oil, pilot valve drain

(T)

Return oil to tank / reservoir

(A)

Service line from main control valve block

(A’)

Service line to the motor

(B)

Service line from main control valve block

(B’)

Service line to the motor

(MA)

Check point circuit A

(MB)

Check point circuit B

Whenever a swing motion is carried out or the foot brake is used, pilot pressure is present at port X of the pressure increase valve (Fig. 3-160, Pos. 1). The pilot pressure preloads the relief valve. The oil for the hydraulic motor from the main control valve block feeds the service line port A or B depending of the slew direction left or right. The ports A and B are internally connected to the ports A’ and B’ and these ports in turn with the hydraulic motor. The operating pressure at either port A or B closes the anti-cavitation valves (Fig. 3-160, Pos. 4 and 5) and opens the check valves (Fig. 3-160, Pos. 2 and 3). That means the service lines are connected to the pressure increase valve by the check valves (Fig. 3-160, Pos. 2 and 3). Whenever the pressure is higher than the setting of the pressure increase valve, the valve opens and dumps oil into the return line T to the reservoir. If the superstructure is slewing by dynamical momentum, the motor is driven by the slew gear and acts as a pump. The pressure in the service lines to the motor changes.

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The low pressure return line becomes pressurized and the pressurized service line changes to suction line. The service line is closed at the main control valve block so the oil can only circulate through the brake valve block’s pressure increase valve.

Fig. 3-161 Pressure increase valve Whenever a swinging motion is carried out or the foot brake is used, pilot pressure is present at port X of the pressure increasing valve. The pilot pressure preloads the relief valve. By applying pilot pressure via the external port X to piston (Fig. 3-161, Pos. 12), the pretension of the spring (Fig. 3-161, Pos. 10) is increased by the amount of the piston stroke S which results in a higher pressure setting for the pilot valve. The system pressure is present at the main piston (Fig. 3-161, Pos. 13) and via the jet bore (Fig. 3-161, Pos. 6) in the chamber of the spring (Fig. 3-161, Pos. 7) as well. System pressure also is present at the pressure relief valve cone (Fig. 3-161, Pos. 9) via the jet bore (Fig. 3-161, Pos. 8). Due to the force balance, the piston (Fig. 3-161, Pos. 13) is kept in its position, supported by the spring (Fig. 3-161, Pos. 7). If the system pressure is higher than the setting of the valve (Fig. 3-161, Pos. 9) the valve opens a channel to the drain port Y. Due to the drop of pressure, the piston (Fig. 3-161, Pos. 13) is moved by the spring (Fig. 3-161, Pos. 7). The pressure line is connected to the return line T. Dampened opening and closing is obtained by the throttled volumetric change that is caused by the jet bores.

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3.9.4.1 REMOVAL OF THE SLEW BRAKE VALVE Special tools:

n/a


Crane Slew brake valve: 110 kg

Dogman/rigger



z




z


z


z


Fig. 3-162

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z

Disconnect the service hoses (Fig. 3-163, Pos. 2), the return hose (Fig. 3-163, Pos. 3), the leak oil hose (Fig. 3-163, Pos. 4), and the pilot hose (Fig. 3-163, Pos. 5) from the slew brake valve (Fig. 3-163, Pos. 6).

NOTE: When the hydraulic hoses are removed, hydraulic oil from inside the valve and the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Sling the slew brake valve (Fig. 3-163, Pos. 6).

z

Remove the four mounting bolts (Fig. 3-163, Pos. 1) and demount the slew brake valve (Fig. 3-163, Pos. 6) from the swing motor (Fig. 3-163, Pos. 7), using a crane.

Fig. 3-163

DANGER Risk of falling weights! Death or serious injury may result. When removing the slew brake valve, make sure that nobody steps below the weight.

z

Discard the O-ring from below the slew brake valve (Fig. 3-163, Pos. 6).

NOTE: When the slew brake valve is removed, hydraulic oil from inside the valve will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

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3.9.4.2 REPLACEMENT OF THE SLEW BRAKE VALVE Special tools:



n/a Slew brake valve: 110 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. Fit new O-rings below the slew brake valve and at the SAE-flanges. z


z


z


z

Check and adjust the slew brake valve. Refer to the Service Manual.

z

Check the dynamic slew brake for proper function. Refer to the Service Manual.

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3.9.5

Superstructure

SWING CIRCLE

Fig. 3-164 Swing circle

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Swing circle

(2)

Bolt

(3)

Bolt

(4)

Swing circle protection (partly shown)

(5)

Car body

(6)

Superstructure

The swing circle is the movable connection between the superstructure and the undercarriage. The swing circle bearing is connected to the central lubrication system. The outer ring gear is lubricated by an own lubrication system SLS which uses a special open gear lubricant. NOTE: For wear limits of the swing circle bearing, refer to PARTS & SERVICE NEWS No. "AH02513". For additional information, refer to PARTS & SERVICE NEWS No. "AH00511".

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3.9.5.1 REMOVAL OF THE SWING CIRCLE

Special tools:

Mounting cross, PN 329 179 40 Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 232 613 40 55 mm hexagon impact socket wrench, PN 232 267 40


2 x crane (2nd. crane for superstructure lifting) Swing circle: 16,300 kg

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and two cranes.

z




z

Remove the swing circle protection.

Fig. 3-165 z

Separate the superstructure from the undercarriage using one of the two procedures: z

For using the lifting procedure refer to section 3.15.1 on page 3-252.

z

For using the removal procedure refer to section 3.15.3 on page 3-256.

NOTE: When using the removal procedure, place the superstructure on appropriate supports high enough to handle the lifting device with mounting cross underneath the swing circle.

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DANGER Supports need to be substantial enough to carry total weight of the superstructure (without counterweight, fluids and attachment), total weight 298,000 kg.

z

Before removing swing circle, mark location of both slew rings to superstructure and the car body as well for further investigations.

z

Disconnect all slew ring bearing lubrication hoses (Fig. 3-166, Pos. 1) from the unions (Fig. 3-166, Pos. 3) at inner slew ring (Fig. 3-166, Pos. 2).

Fig. 3-166 z

Position the mounting cross, PN 329 179 40 underneath the swing circle.

z

Connect the the mounting cross to a crane.

NOTE: In order to avoid damage to the sling accessory, use edge protection at all sharp edges. The mounting cross is accessible from the centre of the machine (Fig. 3-167, arrow). CAUTION Move the sling accessory carefully between the pipe work/ hoses at the manifold to prevent the pipe work from being damaged or ripped off. Fig. 3-167

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z

Lift mounting cross (Fig. 3-168, Pos. 1) to place it under the swing circle (Fig. 3-168, Pos. 2).

z

Remove the mounting bolts of the inner slew ring to dismount the swing circle (Fig. 3-168, Pos. 2) from the superstructure (Fig. 3-168, Pos. 3).

Fig. 3-168

z

Lower the mounting cross with the swing circle resting on it to the ground.

NOTE: The guides (Fig. 3-169, Pos. 2) ensure that the swing circle (Fig. 3-169, Pos. 3) is aligned accurately with the superstructure (Fig. 3-169, Pos. 1) while it is removed and installed respectively. Do not remove the guides.

Fig. 3-169 z

Install four swivel hoist rings evenly distributed at the inner slew ring and remove the swing circle from the mounting cross using a crane. DANGER

Risk of falling weights! Death or serious injury result. When removing the swing circle, make sure that nobody steps below the weight.

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3.9.5.2 REPLACEMENT OF THE SWING CIRCLE

Special tools:

Mounting cross, PN 329 179 40 Measuring jaw, PN 274 703 40 8 x Measuring bolt, PN 909 004 40 or respectively 8 x Measuring bolt (cold weather), PN 898 287 40 Test block, PN 375 795 40 Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 232 613 40 55 mm hexagon impact socket wrench, PN 232 267 40


2 x crane (2nd. crane for superstructure lifting) Laser device for checking the level of bearing area Compound "KP2K", PN 324 969 40 Swing circle: 16,300 kg

Dogman/rigger


Check the wear of the swing circle pinions at the slew gears, refer to PARTS & SERVICE NEWS No. "AH05518".

z

Check the level of bearing area with a laser device before installing a new slew ring. Refer to the PARTS & SERVICE NEWS No. "AH00511".

z

Check the outer diameter of the new slew ring top surface and compare with the outer diameter of the factory machined surface of the superstructure. Refer to PARTS & SERVICE NEWS No. "AH00511". Remove the shoulder by machining if necessary. WARNING

z

Shocks to the swing circle (especially radial shocks) must be avoided.

z

Transport and store the new swing circle exclusively with transport star fitted.

z

It is strictly forbidden to hook up the new swing circle at the transport star.

z

Hang up and/or transport and store the swing circle only horizontally. If a special attachment is available, the transportation and storage in inclined position may be carried out.

z

Only hang swing circle at four swivel hoist rings evenly distributed in screw circle of the inner slew ring.

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Superstructure

NOTE: When replacing the swing circle, all fastening bolts must also be replaced. z

Install four swivel hoist rings evenly distributed at the inner slew ring and lift it using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the swing circle, make sure that nobody steps below the weight.

z

Place the swing circle (Fig. 3-170, Pos. 2) onto the mounting cross (Fig. 3-170, Pos. 1).

z

Centre the swing circle (Fig. 3-170, Pos. 2) on the mounting cross (Fig. 3-170, Pos. 1) with help of the transport star.

z

Position the mounting cross with the swing circle resting on it under the superstructure (Fig. 3-170, Pos. 3) and connect the mounting cross to a crane.

Fig. 3-170 NOTE: In order to avoid damage to the sling accessory, use edge protection at all sharp edges. The mounting cross is accessible from the centre of the machine (Fig. 3-171, arrow). CAUTION Move the sling accessory carefully between the pipe work/ hoses at the manifold to prevent the pipe work from being damaged or ripped off.

Fig. 3-171 z

Mating surfaces must be absolutely fat-free. Even the solvent must be rinsed away before assembling.

z

Check flatness of the mating surfaces.

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z

Prepare new bolts (Fig. 3-172, Pos. 3) and washers (Fig. 3-172, Pos. 4). Lubricate the threads and the head surface of the bolts with compound "KP2K", PN 324 969 40.

z

Align the "S-spots".

NOTE: The unhardened spot of race surfaces (changeover area between beginning and end of hardening process) is punch-marked with an "S" at the inner resp. outer side of each slew ring (Fig. 3-172, Pos. 1 and 2). These spots "S" must not be placed within the main load area of the swing circle. Hence, the unhardened spot "S" has to be turned in an angle of 90° to the main load area refer to Fig. 3-172. Fig. 3-172 z

Align the teeth of the outer slew ring with the lubrication pinions and the pinions of the slew gears.

z

Lift the swing circle (Fig. 3-173, Pos. 3) to approx. 10 mm below the superstructure platform (Fig. 3-173, Pos. 1) by means of the mounting cross.

z

Align the holes in the inner slew ring with the treads in the superstructure platform. The guides (Fig. 3-173, Pos. 2) centre the swing circle horizontally (observe the unhardened "S-spots").

NOTE: The guides ensure that the swing circle is aligned accurately into its mounting position. Do not remove the guides (Fig. 3-173, Pos. 2) after installation. z

Install bolts (Fig. 3-172, Pos. 3) and washers (Fig. 3-172, Pos. 4) to the inner slew ring.

z

Join the swing circle (Fig. 3-172, Pos. 5) on to the supporting surface at the superstructure platform (Fig. 3-172, Pos. 6) by tightening the bolts crosswise manually.

z

Remove the mounting cross.

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z

Superstructure

Connect all slew ring bearing lubrication hoses (Fig. 3-174, Pos. 1) to the unions (Fig. 3-166, Pos. 3) at the inner slew ring (Fig. 3-174, Pos. 2).

Fig. 3-174 z

Check the tooth backlash between slew ring and slew pinion with a feeler gauge. Refer to PARTS & SERVICE NEWS No. "AH00511". Tighten all bolts of the inner slew ring crosswise to the required torque, refer to PARTS & SERVICE NEWS No. "AH00511".

NOTE: The procedure of tightening has to be performed twice or three times, to ensure a setting of the bolts. Refer to PARTS & SERVICE NEWS No. "AH00511". z

After tightening all bolts at the slew ring the tooth back lash has to be checked once more at 4 points. Refer to PARTS & SERVICE NEWS No. "AH00511". If necessary adjust again.

z

Remount the superstructure onto the undercarriage, refer to section 3.15.2 on page 3-255, respectively refer to section 3.15.4 on page 3-261. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the superstructure, make sure that nobody steps below the weight.

z


z

Bleed air from the hydraulic system, refer to the Operation & Maintenance Manual, chapter 4, section "HYDRAULIC SYSTEM - CHANGE OIL, REPLACE SUCTION STRAINERS AND PULSATION DAMPER".

z


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Superstructure

3.10 LUBRICATION SYSTEM 3.10.1 SWING CIRCLE LUBRICATION PINION (DUMMY WHEEL)

Fig. 3-175 Slew ring lubrication 3 - 192

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Lubrication pump station (SLS) NOTE: A triple lubrication pump station may be installed instead.

(2)

Lubricant supply line from pump to injector

(3)

Injectors

(4)

End of line pressure switch

(5)

Lubricant feed line from injector to lubrication pinion

(6)

Lubrication pinion

(7)

Slew ring

(8)

Lubrication pinion

(9)

Lubricant outlet

(10)

Lubrication pinion centre shaft with distributing drillings

The swing circle lubrication system (SLS) lubricates the open gear of the outer slew ring with special open gear lubricant. The lubricant pump station (Fig. 3-175, Pos. 1) is identical with the central lubrication system (CLS), refer to section 3.10.2 on page 3-198. To apply the lubricant equably to the outer slew ring teeth (Fig. 3-175, Pos. 7), a special lubrication pinion (Fig. 3-175, Pos. 8) is mounted near each drive pinion of the slew gears. The lubrication pinion (Fig. 3-175, Pos. 8) distributes the lubricant from the injectors (Fig. 3-175, Pos. 3) evenly to the teeth. Normally two or more small SL1 injectors (Fig. 3-175, Pos. 3) are parallel connected to supply the required amount of lubricant to the lubrication pinion. NOTE: The pinion centre shaft (Fig. 3-175, Pos. 10) acts as a rotary joint and distributes lubricant through radial drillings only to the teeth, witch are in contact with the outer slew ring gear teeth. Outlet bores (Fig. 3-175, Pos. 9 on different position of the pinion gear distribute the lubricant equably to the outer slew ring teeth (Fig. 3-175, Pos. 7).

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3.10.1.1 REMOVAL OF THE LUBRICATION PINION ASSEMBLY Special tools:

n/a


Safety harness in conformity with EN 361 Mobile elevator working platform Pinion cover: 1.2 kg Lubrication pinion assembly: 15 kg

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and mobile working platform.

z

Park the machine on the prepared flat ground area with the lubrication pinion placed between the crawler carriers, so that the lubrication pinion can be accessed by a mobile working platform.



Before maintenance set main key switch S1 to OFF and the maintenance safety switch S58 (Fig. 3-176, Pos. 3) to -0position to prevent starting of the electric motors during the work. Fold up the flap (Fig. 3-176, Pos. 2) and secure this position by inserting a padlock into the holes (Fig. 3-176, Pos. 4) of the flap (Fig. 3-176, Pos. 2) and the safety switch (Fig. 3-176, Pos. 1). Assure that the system pressure of the lubrication system is relieved before maintenance. Fig. 3-176 z

Relieve the system pressure of the lubrication system by actuating the vent valve (Fig. 3-184, Pos. 2) by hand, refer to the PARTS & SERVICE NEWS No. "AH05546". WARNING

Always wear a safety harness when working at the lubrication pinion.

NOTE: A second person is required for the work at the lubrication pinion.

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Fig. 3-177 Lubrication pinion assembly, removal and replacement z

Remove the mounting bolts (Fig. 3-177, Pos. 6) with sleeves (Fig. 3-177, Pos. 7) and remove the pinion cover (Fig. 3-177, Pos. 1).

NOTE: A second person is required for this work. z

Disconnect the lubrication lines (Fig. 3-177, Pos. 4).

z

Remove the nuts (Fig. 3-177, Pos. 5) and take the lubrication pinion assembly (Fig. 3-177, Pos. 3) with connector plate (Fig. 3-177, Pos. 2) off the superstructure.

NOTE: A second person is required for this work.

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3.10.1.2 REPLACEMENT OF THE LUBRICATION PINION ASSEMBLY Special tools:

n/a


Safety harness in conformity with EN 361 Mobile elevator working platform Pinion cover: 1.2 kg Lubrication pinion assembly: 15 kg If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

WARNING Always wear a safety harness when working at the lubrication pinion.

z


NOTE: A second person is required for this work. z

After installation is complete, the swing circle lubrication system has to be activated manually, refer to the Operation & Maintenance Manual, chapter 3, section "SWING CIRCLE PINION LUBRICATION SYSTEM SLS”. Make sure that the end of line pressure switch B46 is pressurized and start a lubrication cycle manually with switch S26.

NOTE: There may be a time gap of up to 11 minutes until the next manually started cycle is carried out. Refer to the time table in the flowchart. z

Reset the lubrication cycle counter of the slew ring lubrication system. Refer to the Operation & Maintenance Manual, chapter 3, section "SWING CIRCLE PINION LUBRICATION SYSTEM SLS”.

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3.10.2 LUBRICATION PUMP STATION

Fig. 3-178 Lubrication pump station (old version)

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Coupling at the service arm for filling up the grease container (3) of the swing circle lubrication system (SLS)

(2)

Grease filter for swing circle pinion lubrication system (SLS)

(3)

Grease container of the swing circle pinion lubrication System (SLS)

(4)

Hydraulic motor with pump unit

(5)

Grease pressure gauge for SLS

(6)

Receiver panel at the service arm

(7)

Coupling at the service arm for filling the grease container of the central lubrication system (CLS)

(8)

Grease filter for central lubrication system

(9)

Grease container of the central lubrication system (CLS)

(10)

Hydraulic motor with pump unit

(11)

Grease pressure gauge for CLS

(12)

Mounting bolts of the grease pump station

The lubrication pump station includes two single lubrication pumps and a grease container for each lubrication pump. Each lubrication pump has its own lubrication system: –

One lubrication pump of the central lubrication system (CLS).

–

One lubrication pump of the swing circle pinion lubrication System (SLS).

–

The lubrication pump is a hydraulically driven seal-free differential piston pump. The pump pumps lubricant during the up and down stroke but sucks lubricant only during the up stroke. The scoop piston at the pump bottom supports the main pump with high viscosity lubricants. There is only one dynamic seal at the piston rod on top of the pump pipe.

The lubrication pump is divided in two main components, the pump drive’s hydraulic cylinder and the pump. The pump drive and only the pump outlet are outside on top of the lubricant container, the pump itself is mounted inside and reaches into the lubricant.

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Fig. 3-179 Lubrication pump station (actual version) 3 - 200

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Lubrication system


Grease container for the superstructure lubricating system, for swing connection bearing, and for boom cylinder foot bearings (CLS)

(2)

Grease container for the attachment lubrication system (CLS)

(3)

Grease container of the swing circle pinion lubrication System (SLS)

(4)

Grease filter for the grease containers of the CLS

(5)

Grease filter for the grease container SLS

(6)

Hydraulic motors with pump units

(7)

Grease pressure gauges

(8)

In-line high pressure grease filters

The lubrication pump station includes three single lubrication pumps and a grease container for each lubrication pump. Each lubrication pump has its own lubrication system: –

One lubrication pump of the attachment lubrication (CLS).

–

One lubrication pump of the superstructure lubricating system for swing connection bearing and boom cylinder foot (CLS).

–

One lubrication pump of the swing circle pinion lubrication System (SLS).

NOTE: The grease containers (Fig. 3-179, Pos. 1 and 2) are linked together by an opening in the upper part of the of the containers. This is for grease level compensation during refilling.

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Superstructure

3.10.2.1 REMOVAL OF THE LUBRICATION PUMP STATION Special tools:

n/a


Crane Double lubrication pump station: 412 kg Triple lubrication pump station: 618 kg

Dogman/rigger

NOTE: Remove the triple lubrication station analogously. z


z





Relieve the system pressure of the lubrication system by actuating the vent valve by hand, refer to the PARTS & SERVICE NEWS No. "AH05546".

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z

Disconnect all hydraulic and grease lines (Fig. 3-181, Pos. 1) from the front roof plate.

z

Disconnect the wire harnesses from the end of line pressure switches (B43 and B46). Clear the harnesses from the lubrication pump station.

z

Sling the lubrication pump station (Fig. 3-181, Pos. 3) at the lifting eyes (arrows).

z

Remove the bolts (Fig. 3-181, Pos. 2) and remove the lubrication pump station from the roof using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When removing the lubrication pump station, make sure that nobody steps below the weight.

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Fig. 3-181

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Lubrication system

Superstructure

3.10.2.2 REPLACEMENT OF THE LUBRICATION PUMP STATION Special tools:

n/a


Crane Double lubrication pump station: 412 kg Triple lubrication pump station: 618 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. NOTE: Replace the triple lubrication station analogously. z


z

if required, bleed the pump at the breather port (Fig. 3-182, Pos. 1).

NOTE: Make sure that the grease hoses are filled with grease. Therefore it may be necessary to carry out some lubrication cycles manually. z

Make sure that the end of line pressure switch of the resp. lubrication pump is pressurized, see following table.

z

Start a lubrication cycle manually with the resp. switch at the operator’s console, see following table. Fig. 3-182

Switch

Pressure switch

Lubrication system

S24

B43

CLS

S26

B46

SLS

S99

B174

Separate attachment lubrication pump (CLS) NOTE: Triple pump station only

NOTE: There may be a time gap of up to 11 minutes until the next manually started cycle is carried out. Refer to the time table in the flowchart. z

Adjust the lubrication pump speed and pressure. Refer to the Service Manual.

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3.10.2.3 REMOVAL OF THE LUBRICATION PUMP Special tools:

n/a


Crane Lubrication pump: 28 kg

Dogman/rigger

z


z





Relieve system pressure of the lubrication system by actuating the vent valve (Fig. 3-184, Pos. 1) by hand, refer to the PARTS & SERVICE NEWS No. "AH05546".

z

Disconnect the hydraulic lines (Fig. 3-184, Pos. 2) from the lubrication pump.

z

Disconnect the quick coupling from the grease feeding line (Fig. 3-184, Pos. 3).

Fig. 3-184

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z

Superstructure

Disconnect the grease feeding line (Fig. 3-185, Pos. 1) from the lubrication pump.

Fig. 3-185 z

Remove the bolt (Fig. 3-186, Pos. 1).

Fig. 3-186

z

Sling the lubrication pump (Fig. 3-187, Pos. 1) at the installed lifting eye (Fig. 3-187, arrow) and pull the lubrication pump out of the grease container.

Fig. 3-187

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3.10.2.4 REPLACEMENT OF THE LUBRICATING PUMP Special tools:

n/a


Crane Lubrication pump: 28 kg

Dogman/rigger



z

After replacement, bleed the pump at the breather port (Fig. 3-188, Pos. 1).

Fig. 3-188 z

Adjust the lubrication pump speed and pressure. Refer to the Service Manual.

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Superstructure

3.11 OPERATOR’S CAB

Fig. 3-189 Operator’s cab overview 3 - 208

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Operator’s cab

Legend for Fig. 3-189: A

Rear View of Operator’s Cab

(1)

Door handle

(2)

Door latch (with door fully opened)

(3)

Door locking pin, engages into the latch when the cab door is fully opened

(4)

Light switch for access area lighting

(5)

Light switch for interior cab lighting

(6)

Air conditioner door

(7)

Outside mirrors with integrated heaters, both mirrors are adjusted electrically via a control switch on the instrument panel

(8)

Main working lights

(9)

Adapter for warning beacon

B

Front View of Operator’s Cab

(10)

Release lever for the door lock (2 - 3)

(11)

Door opener push button

(12)

Lock lever

(13)

Control levers for working attachment

(14)

Operator’s seat

(15)

Upper windshield wiper

(16)

Lower windshield wiper

WARNING The operator’s cab is equipped with an integrated Falling Object Protective Structure (FOPS) that meets the requirements of ISO 3449. Any modifications on the steel structure of the cab are inadmissible. Repairs on the FOPS must only be carried out by specialists having the authorization for repair work on Falling Object Protective Structures and in accordance with the manufacturer’s repair instructions.

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Superstructure


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Operator’s cab

3.11.1 REMOVAL OF THE OPERATOR’S CAB Special tools:

n/a


Safety harness in conformity with EN 361 Crane Mobile elevator working platform Oil drain pan Operator’s cab: 3785 kg Dogman/rigger Air condition service specialist Electrician with permission to work on high voltage systems For further information about the needed blind plugs, refer to section 6.6 on page 6-14.

z


z





z

Perform the grounding procedure of the high voltage system, refer to section 2.3 on page 2-28. WARNING

Always wear a safety harness when working at the operator’s cab.

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Operator’s cab

z

Superstructure

Remove the grommet plate (Fig. 3-190, Pos. 1) inside the cab base.

If the machine is equipped with harness connectors: z

Disconnect all harness connectors at the back side of the grommet plate.

z

Disconnect all other harnesses leading to the operator’s cab from the X2C-board and pull it out of the grommet plate.

If the machine is not equipped with harness connectors: z

z

Disconnect all harnesses leading to the operator’s cab Fig. 3-190 from the X2C-board and remove the cable transfer elements.

Dismount the grommet plate (Fig. 3-191, Pos. 1) inside the cab base.

If machine is equipped with harness connectors: z

Disconnect all harness connectors of the manipulators at the back side of the grommet plate.

If machine is not equipped with harness connectors: z

Disconnect all harnesses leading to the operator’s cab from the X2-board and remove the cable transfer elements. Fig. 3-191

z

Remove the ground cable (Fig. 3-192, Pos. 1) in the cab base (Fig. 3-192, Pos. 2) from the left lower fixing bolt at the X2-board and pull it out of the grommet plate.

Fig. 3-192

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z

Remove the cover (Fig. 3-193, Pos. 1) inside the cab base.

z

Disconnect the hose (Fig. 3-193, Pos. 2) between cab support and operator’s cab from the other side of the cover.

Fig. 3-193 DANGER Danger of high pressure. Blindness, serious injury, permanent disfigurement, or scaring may result. The air conditioning system is pressurized. Make sure that the refrigerant is sucked from the system before any lines will be removed.

WARNING The air conditioning must be serviced by authorized service specialists only.

z

Aspirate the refrigerant from the air condition system.

z

Disconnect the refrigerant lines (Fig. 3-194, Pos. 2) from the air conditioning unit (Fig. 3-194, Pos. 2).

NOTE: Cap the openings with blind plugs to avoid contamination of the air conditioning system. z

Disconnect the condensate lines (Fig. 3-194, Pos. 3) from the air conditioning unit (Fig. 3-194, Pos. 2).

z

Clear all hoses from the operator’s cab.

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Fig. 3-194

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Operator’s cab

z

Superstructure

Sling the operator’s cab (Fig. 3-195, Pos. 2) at the lifting eye bolts (Fig. 3-195, Pos. 1) delivered with the cab.

Fig. 3-195

Fig. 3-196 Removal of the operator’s cab, overview

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Operator’s cab

z

Remove the hose (Fig. 3-196, Pos. 7) of the operator’s cab water supply.

z

Open the hose clips (Fig. 3-196, Pos. 5) and remove the water hoses (Fig. 3-196, Pos. 6).

z

Remove the gratings (Fig. 3-196, Pos. 8) from the cab support (Fig. 3-196, Pos. 9).

z

Remove the bolts (Fig. 3-196, Pos. 2) and resilient sleeves (Fig. 3-196, Pos. 3) from the viscous mounts (Fig. 3-196, Pos. 4).

z

Remove the operator’s cab (Fig. 3-196, Pos. 1) using a crane.

NOTE: Lift the operator´s cab slowly while using a second person inside the cab base to guide the harnesses through the grommet plates. DANGER Risk of falling weights! Death or serious injury may result. When removing the operator’s cab make sure that nobody steps below the weight.

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Operator’s cab

Superstructure

3.11.2 REPLACEMENT OF THE OPERATOR’S CAB Special tools:

n/a


Safety harness in conformity with EN 361 Crane Mobile elevator working platform Compound "KP2K", PN 324 969 40 Operator’s cab: 3785 kg Dogman/rigger Air condition service specialist Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

Fig. 3-197 Replacement of the operator’s cab, overview

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Operator’s cab

WARNING z


z

Ensure that no one stands between the cabin and the cab base during lowering.


z


NOTE: Use new bolts (Fig. 3-197, Pos. 2) of the grade 10.9 at the viscous mounts (Fig. 3-197, Pos. 4). Apply Compound "KP2K", PN 324 969 40 and tighten the bolts with the specified tightening torque. Tightening torque for the mounting bolts (Fig. 3-197, Pos. 2): 880 Nm NOTE: When lowering the operator’s cab have a second person inside the cab base to guide the harnesses through the grommet plates. z

Evacuate the air conditioning system and add refrigerant. WARNING

The air conditioning must be filled with refrigerant "R134a" by authorized service specialists only.

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Operator’s cab

Superstructure

3.11.3 VISCOUS CAB-MOUNTS 3.11.3.1 REMOVAL OF THE VISCOUS CAB-MOUNTS Special tools:

n/a


Safety harness in conformity with EN 361 Crane Mobile elevator working platform Operator’s cab: 3785 kg Viscous mount: 4 kg Absorber plate incl. 2 viscous mounts: 12 kg Absorber plate incl. 3 viscous mounts: 18 kg

Dogman/rigger

z


z





z

Sling the operator’s cab (Fig. 3-195, Pos. 2) at the lifting eye bolts (Fig. 3-195, Pos. 1) delivered with the cab.

Fig. 3-198

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Fig. 3-199 Removal of the cab-mounts, overview z

Remove the gratings (Fig. 3-199, Pos. 8) from the cab support (Fig. 3-199, Pos. 9).

z

Remove the bolts (Fig. 3-199, Pos. 2) and resilient sleeves (Fig. 3-199, Pos. 3) from the viscous mounts (Fig. 3-196, Pos. 4).

z

Raise the operator’s cab (Fig. 3-196, Pos. 1) only a few millimeters using a crane, just enough to clear the viscous mounts (Fig. 3-196, Pos. 4).

z

Remove the bolts (Fig. 3-199, Pos. 5) from the absorber plate (Fig. 3-199, Pos. 6) and remove the absorber plate with the viscous mounts.

z

Remove the bolts (Fig. 3-199, Pos. 7) and dismount the viscous mounts (Fig. 3-196, Pos. 4) from the absorber plate (Fig. 3-199, Pos. 6).

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Operator’s cab

Superstructure

3.11.3.2 REPLACEMENT OF THE VISCOUS CAB-MOUNTS Special tools:

n/a


Safety harness in conformity with EN 361 Crane Mobile elevator working platform Compound "KP2K", PN 324 969 40 Operator’s cab: 3785 kg Viscous mount: 4 kg Absorber plate incl. 2 viscous mounts: 12 kg Absorber plate incl. 3 viscous mounts: 18 kg

Dogman/rigger


Fig. 3-200 Replacement of the cab-mounts, overview

3 - 220

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Superstructure

Operator’s cab

WARNING Always wear a safety harness when working at the operator’s cab.

z


NOTE: Use new mounting bolts of the grade 10.9. Apply compound "KP2K", PN 324 969 40 to the bolts and tighten the bolts to the specified tightening torques. Tightening torque for the mounting bolts (Fig. 3-200, Pos. 7) at the cab mounts (Fig. 3-200, Pos. 4): 108 Nm Tightening torque for the mounting bolts (Fig. 3-200, Pos. 5) at the absorber plates (Fig. 3-200, Pos. 6): 880 Nm Tightening torque for the operator’s cab mounting bolts (Fig. 3-200, Pos. 2): 880 Nm

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Operator’s cab

Superstructure

3.11.4 FRONT WINDOW (WINDSCREEN) 3.11.4.1 REMOVAL OF THE FRONT WINDOW Special tools:

n/a


Suction lifters with hoist rings Safety harness in conformity with EN 361 Crane Mobile elevator working platform Front window: 112 kg

Dogman/rigger

z


z





z

Remove the wiper arms (Fig. 3-201, Pos. 1).

z

Use suction lifters with hoist rings at the front window (Fig. 3-201, Pos. 4) to sling the front window.

z

Remove the bolts (Fig. 3-201, Pos. 2). Hold the nuts (Fig. 3201, Pos. 3) from inside the cab.

z

Remove the front window (Fig. 3-201, Pos. 4) using a crane.

Fig. 3-201

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Operator’s cab

3.11.4.2 REPLACEMENT OF THE FRONT WINDOW Special tools:

n/a


Suction lifters with hoist rings Safety harness in conformity with EN 361 Crane Mobile elevator working platform Front window: 112 kg

Dogman/rigger


WARNING Always wear a safety harness when working at the operator’s cab.

z


NOTE: A different holes pattern is used since January 2007 for the frame of the front window. KOMATSU recommends to use front windows with new holes pattern in the frame, also for shovels, delivered before 2007. For further information refer to the PARTS & SERVICE NEWS No. "AH08504". z

Check the correct end position of the wiper arm(s) after installation of the front window.

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Operator’s cab

Superstructure

3.11.5 OPERATOR’S SEAT 3.11.5.1 REMOVAL OF THE OPERATOR’S SEAT Special tools:

n/a


Crane Operator’s seat: 62 kg

Dogman/rigger 2nd. person to handle the seat

z


z




z

Disconnect the wire harness connector (Fig. 3-202, Pos. 1) of the air suspension.

z

Remove both control lever carriers (Fig. 3-202, Pos. 2 and 8).

z

Remove all mounting bolts (Fig. 3-202, Pos. 6) from the cover plate (Fig. 3-202, Pos. 7) and remove the operator’s seat (Fig. 3-202, Pos. 9) with cover plate from the heating console (Fig. 3-202, Pos. 5).

z

Remove the cover plate (Fig. 3-202, Pos. 7) from the operator’s seat by removing all seat mounting bolts (Fig. 3-202, Pos. 4) with lock washers (Fig. 3-202, Pos. 3).

NOTE: A second person is required to carry the operator’s seat out of the operator’s cab. z

Sling the operator’s seat and lift it off the machine using a crane. Fig. 3-202

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3.11.5.2 REPLACEMENT OF THE OPERATOR’S SEAT Special tools:

n/a


Crane Operator’s seat: 62 kg

Dogman/rigger 2nd. person to handle the seat If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. z

Remove both control lever carriers from the new seat.

z


NOTE: A second person is required to carry the operator’s seat into the operator’s cab. z

Check the Seat’s functions after replacement.

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Operator’s cab

Superstructure

3.11.6 ECS 3.11.6.1 REMOVAL OF THE ECS TEXT DISPLAY Special tools:

n/a


n/a

z


z

Remove the keys from the battery main switches.

z

Open the operator’s console.

z

Disconnect the data cables (Fig. 3-203, Pos. 1 and 2) from the ECS text display (Fig. 3-203, Pos. 4).

z

Remove the wing nuts (Fig. 3-203, Pos. 3) and take the ECS text display (Fig. 3-203, Pos. 4) out of the operator’s console.

Fig. 3-203

3.11.6.2 REPLACEMENT OF THE ECS TEXT DISPLAY Special tools:

n/a


n/a

z


z

Set time, date and operating hours, refer to the Operation & Maintenance Manual, chapter 3, section "ELECTRONIC MONITORING AND CONTROL SYSTEM ECS".

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3.12 CAB BASE (MEDIUM VOLTAGE SWITCH CABINET) 3.12.1 REMOVAL OF THE CAB BASE Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 232 613 40 55 mm hexagon impact socket wrench, PN 232 267 40


Safety harness in conformity with EN 361 Mobile elevator working platform Crane 4x swivel hoist ring (M36) Support frame: 987 kg Cab base: 5410 kg Emergency ladder: 68 kg Platform: 135 kg Dogman/rigger Electrician with permission to work on high voltage systems

z

Prepare an area of flat ground large enough to accommodate the machine, boom, elevator working platform and crane.

z





z


Always wear a safety harness when working at the cab base.

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Superstructure

z

Remove the operator’s cab (Fig. 3-204, Pos. 1), refer to section 3.11.1 on page 3-211.

z

Remove the emergency ladder (Fig. 3-204, Pos. 2).

z

Remove the platform (Fig. 3-204, Pos. 3) with handlebar and gratings from the cab support using a crane.

NOTE: For safety reasons, the handrails at the cab support frame (Fig. 3-204, Pos. 4) remain mounted.

Fig. 3-204 z

Disconnect all wire harnesses leading to the cab base (Fig. 3-205, Pos. 1) inside the cab base.

z

Clear all wire harnesses running under the cab base from their cable channels.

z

Pull the harnesses out of the cable transfer elements at the bottom (Fig. 3-205, Pos. 2) and at the side (Fig. 3-205, Pos. 3) of the cab base.

z

If equipped with a cable clamp (Fig. 3-205, Pos. 4), clear the wire harnesses leading to the high voltage switch cabinet from the cab base by opening the cable clamp.

z

Disconnect the extinguishing agent hose of the fire suppression system between the cab base and the high voltage switch cabinet from the socket in the transfer element (Fig. 3-205, Pos. 3).

z

If equipped, disconnect the extinguishing agent hose of the fire suppression system between the cab base and the slip ring.

z

Clear the water and refrigerant hoses leading to the side of the cab base from the support frame (Fig. 3-206, Pos. 2).

z

Sling the support frame.

z

Remove the bolts (Fig. 3-206, Pos. 1) from within the cab base (Fig. 3-206, Pos. 3) and remove the support frame (Fig. 3-206, Pos. 2) using a crane.

Fig. 3-205

NOTE: The bolts are secured with Loctite 222.

Fig. 3-206

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z


Open the clamps and clear the water and refrigerant hoses from the cab base.

Fig. 3-207 z

Insert 4 swivel hoist rings (M36) and sling the cab base (Fig. 3-207, Pos. 1) at the hoist rings.

z

Remove the bolts (Fig. 3-207, Pos. 2) attaching the cab base to the superstructure platform.

z

Remove the cab base using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the cab base, make sure that nobody steps below the lifted cab base.

Fig. 3-208

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Superstructure

3.12.2 REPLACEMENT OF THE CAB BASE Special tools:



Safety harness in conformity with EN 361 Mobile elevator working platform Crane Compound "Epple 28", PN 592 199 40 Compound "Loctite 222", PN 414 299 40 Compound "KP2K", PN 324 969 40 Support frame: 987 kg Cab base: 5410 kg Emergency ladder: 68 kg Platform: 135 kg Dogman/rigger Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

WARNING Always wear a safety harness when working at the cab base.


z

Insert 4 swivel hoist rings (M36) and sling the cab base at the hoist rings.

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z


Align the cab base (Fig. 3-209, Pos. 1) with the superstructure using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the cab base, make sure that nobody steps below the lifted cab base.

z

Install the bolts (Fig. 3-209, Pos. 2) attaching the cab base to the superstructure platform.

Fig. 3-209 NOTE: Use new mounting bolts (Fig. 3-209, Pos. 2) of grade 10.9. Apply compound "KP2K", PN 324 969 40 and tighten the mounting bolts to the specified tightening torque. Tightening torque for the cab base mounting bolts (Fig. 3-209, Pos. 2): 3100 Nm

z

Lead the water and refrigerant hoses through the hose clamps at the side of the cab base.

Fig. 3-210

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Superstructure

z

Apply sealing compound "Epple 28" onto the whole contact surfaces (Fig. 3-211, arrows) of the cab base.

z

Install the support frame (Fig. 3-211, Pos. 2) using a crane.

z

Install bolts (Fig. 3-211, Pos. 1) attaching the support frame (Fig. 3-211, Pos. 2) to the cab base (Fig. 3-211, Pos. 3).

Fig. 3-211 NOTE: Use new mounting bolts (Fig. 3-211, Pos. 1) of grade 10.9. Apply compound "Loctite 222" on the threats of all bolts and tighten the mounting bolts to the specified tightening torque. Tightening torque for support frame mounting bolts (Fig. 3-211, Pos. 1): 265 Nm z


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3.12.3 PUMP CONTROLLER 3.12.3.1 REMOVAL OF THE PUMP CONTROLLER Special tools:

n/a


n/a


z



z


z

Remove the wiring harness connector X14 (Fig. 3-212, Pos. 2) from the electronic pump controller RC4 (Fig. 3-212, Pos. 3).

z

Remove four bolts and remove the pump controller RC4 from the wall of the cab base (Fig. 3-212, Pos. 1).

Fig. 3-212

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Superstructure

3.12.3.2 REPLACEMENT OF THE PUMP CONTROLLER Special tools:

n/a


n/a




z


z

Check and adjust the parameters of the pump controller. Refer to the Service Manual for further information.

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Access ladder

Superstructure

3.13 ACCESS LADDER

Fig. 3-213 Access ladder assembly

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Access ladder


Access ladder

(2)

Pin

(3)

Pin

(4)

Access ladder cylinder

(5)

Cotter pin

(6)

Washer

(7)

Union

(8)

Hydraulic hose

(9)

Hydraulic hose

(10)

Self-locking nut

(11)

Bearing

(12)

Dowel Screw

(13)

Left ladder bearing assembly

(14)

Right ladder bearing assembly

(15)

Self-locking nut

(16)

Hinged floor plate over the cylinder

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Access ladder

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Fig. 3-214 Access ladder removal

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3.13.1 REMOVAL OF THE ACCESS LADDER Special tools:

n/a


Safety harness in conformity with EN 361 Oil drain pan Crane Mobile elevator working platform Access ladder: 162 kg

Dogman/rigger

z


z




z

Isolate the machine according to local regulations with the access ladder (Fig. 3-214, Pos. 1) lowered to the ground.

NOTE: Relieve the remaining pressure for the ladder cylinder at the Minimess test point M37.1 and M37.2 on the control and filter plate at electric motor 2. WARNING z

Provide an adequate working platform for safe access to the access ladder bearing.

z

Always wear a safety harness when working at the access ladder assembly.

z

Secure the access ladder cylinder (Fig. 3-214, Pos. 4) in its position.

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Access ladder

Superstructure

Fig. 3-215 Access ladder removal

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Access ladder

CAUTION Assure that the pressure in the hydraulic system is completely relieved before removing the pin (Fig. 3-215, Pos. 2).

z

Remove the cotter pin (Fig. 3-215, Pos. 5) from the pin (Fig. 3-215, Pos. 2).

z

Clear the access ladder (Fig. 3-215, Pos. 1) by removing the pin (Fig. 3-215, Pos. 2) from the access ladder cylinder moving rod.

z

Sling the access ladder and remove the self locking nuts (Fig. 3-215, Pos. 10 and 15) from the ladder bearing assemblies (Fig. 3-215, Pos. 13 and 14).

z

Remove the dowel screws (Fig. 3-215, Pos. 12) to clear the ladder from the superstructure platform.

z

Remove the ladder. Rest it on the ground.

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Access ladder

Superstructure

Fig. 3-216 Access ladder replacement

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Access ladder

3.13.2 REPLACEMENT OF THE ACCESS LADDER Special tools:

n/a


Safety harness in conformity with EN 361 Crane Mobile elevator working platform Access ladder: 162 kg

Dogman/rigger


WARNING z


z


NOTE: Apply grease to the pin (Fig. 3-215, Pos. 2) at the access ladder cylinder moving rod. z


NOTE: Always use new self-locking nuts (Fig. 3-216, Pos. 10 and 15). Tightening procedure for the self-locking nuts (Fig. 3-216, Pos. 10 and 15): z

Screw on the nuts until they have contact with the ladder carrier frame.

z

Then tighten the nuts further by turning them through an angle of 45° (1/8 turn). Clamping torque of self locking nut (Fig. 3-216, Pos. 10): New nut: 106 Nm Clamping torque of Self locking nut (Fig. 3-216, Pos. 15): New nut: 200 Nm

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Access ladder

Superstructure

Fig. 3-217 Access ladder cylinder removal

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Access ladder

3.13.3 REMOVAL OF THE ACCESS LADDER CYLINDER Special tools:

n/a


Safety harness in conformity with EN 361 Oil drain pan Crane Mobile elevator working platform Access ladder cylinder: 23 kg

Dogman/rigger



z




z

Isolate the machine according to local regulations with the access ladder (Fig. 3-217, Pos. 1) lowered to the ground.

NOTE: Relieve the remaining pressure for the ladder cylinder at the Minimess test point M37.1 and M37.2 on the control and filter plate at electric motor 2. z

Remove floor plate fastening bolts and open the hinged floor plates (Fig. 3-217, Pos. 16). WARNING

z


z


z

Assure that the pressure in the hydraulic system is completely relieved before removing the pins (Fig. 3-217, Pos. 2 or 3) or disconnecting any hydraulic hoses.

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Access ladder

Superstructure

Fig. 3-218 Access ladder cylinder installation

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z

Access ladder

Remove the hydraulic hoses (Fig. 3-217, Pos. 8 and 9) with the union (Fig. 3-217, Pos. 7) from the access ladder cylinder (Fig. 3-217, Pos. 4).

NOTE: When the hydraulic hoses are removed, hydraulic oil from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Attach the access ladder cylinder (Fig. 3-218, Pos. 4) to a crane.

z

Remove the pins (Fig. 3-218, Pos. 2 and 3) and remove the access ladder cylinder (Fig. 3-218, Pos. 4) using a crane.

3.13.4 REPLACEMENT OF THE ACCESS LADDER CYLINDER Special tools:

n/a


Safety harness in conformity with EN 361 Oil drain pan Crane Mobile elevator working platform Access ladder cylinder: 23 kg

Dogman/rigger


WARNING z


z


z


NOTE: Apply grease to the pins (Fig. 3-218, Pos. 2 and 3). z


z


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Counterweight

Superstructure

3.14 COUNTERWEIGHT DANGER Risk of explosion! Blindness, serious injury, permanent disfigurement and scarring, or death may result. Do not weld, flame-cut, grind, or drill at the counterweight! Follow the instructions given in the PARTS & SERVICE NEWS No. "AH04518" for expelling the gases from the counterweight chambers!

The chambers of the counterweight are filled with a mixture of concrete, granulated ore and steel pellets. This mixture can create explosive gases which will accumulate in the chambers of the counterweight. Before any welding, flame-cutting, grinding, or drilling procedures are carried out on the counterweight, it is vital to expel these gases from the counterweight chambers. Failure to properly expel the gases from the counterweight chambers can result in an explosion with serious personal injury or death. Follow the instructions given in the PARTS & SERVICE NEWS No. "AH04518" for expelling the gases from the counterweight chambers.

3.14.1 REMOVAL OF THE COUNTERWEIGHT Special tools:



Safety harness in conformity with EN 361 Mobile elevator working platform Crane Counterweight: 54,000 kg

Dogman/rigger

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and a crane.

z

Park the machine on the prepared flat area and position the bucket on the ground.

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. 3 - 248

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z

Counterweight


Always wear a safety harness when working at the counterweight.

z

Remove the escape ladder (Fig. 3-219, Pos. 1), the hatch (Fig. 3-219, Pos. 2), and the covers (Fig. 3-219, Pos. 3).

z

Remove all additional equipment from the counterweight, if required.

Fig. 3-219 z

Remove the gratings (Fig. 3-220, Pos. 1) from the counterweight.

z

Remove all additional equipment from the counterweight, if required.

z

Remove the hand rails (Fig. 3-220, Pos. 2) from the counterweight.

Fig. 3-220 z

Sling the counterweight at the attached lifting eyes.

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Counterweight

Superstructure

Fig. 3-221 Counterweight WARNING Make sure that the maximum rope angles depending on the lifting situation (Fig. 3-221, Pos. 2 to 4) are not exceeded.

z

Remove the bolts (Fig. 3-221, Pos. 5) and the washers (Fig. 3-221 Pos. 6).

z

Remove the counterweight using the crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the counterweight, make sure that nobody steps below the lifted counterweight.

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Counterweight

3.14.2 REPLACEMENT OF THE COUNTERWEIGHT Special tools:



Safety harness in conformity with EN 361 Mobile elevator working platform Crane Compound "KP2K", PN 324 969 40 Counterweight: 54,000 kg

Dogman/rigger


WARNING Always wear a safety harness when working at the counterweight.

NOTE: Assure that the mounting surfaces are absolutely free of dirt, oil, fat, and paint before installation. z


Make sure that the maximum rope angles depending on the lifting situation (Fig. 3-221, Pos. 2 to 4) are not exceeded.

NOTE: Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts. Tighten the mounting bolts to the specified tightening torque. Tightening torque for the mounting bolts: 7500 Nm

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Superstructure lifting

Superstructure

3.15 SUPERSTRUCTURE LIFTING 3.15.1 LIFT THE SUPERSTRUCTURE (PLATFORM, PN 910 605 40 ONLY) Special tools:



Safety harness in conformity with EN 361 Mobile elevator working platform Additional tools and aid according to the PARTS & SERVICE NEWS No. "AH01516". Superstructure: 298,000 kg (special procedure)

Dogman/rigger Electrician with permission to work on high voltage systems For further information about the needed blind plugs, refer to section 6.6 on page 6-14.

DANGER The below procedure is suitable for superstructure platform 910 605 40 only. With any other superstructure platform contact the KOMATSU service concerning the procedure.

Fig. 3-222 Superstructure lifting 3 - 252

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z


z




z



z


z

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 3-223, Pos. 1) at the track tensioning valve block (Fig. 3-223, Pos. 2) inside the car body.

Fig. 3-223

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Superstructure

z


z


Fig. 3-224 WARNING Always wear a safety harness when working in height.

z


z

If equipped, remove the rotating direction sensors B98 and B99 from the swing circle protection.

z

Remove the slip ring unit, refer to section 3.17.1 on page 3-273.

Fig. 3-225 DANGER Information not up to date. Contact the KOMATSU service for important information concerning the next step.

z

Carry out the lifting procedure according to the PARTS & SERVICE NEWS No. "AH01516".

z

Move the undercarriage away from beneath the sperstructure.

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3.15.2 DUMP THE SUPERSTRUCTURE (PLATFORM, PN 910 605 40 ONLY)

Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 232 613 40 55 mm hexagon impact socket wrench, PN 232 267 40 Measuring jaw, PN 274 703 40 8 x Measuring bolt, PN 909 004 40 or respectively 8 x Measuring bolt (cold weather), PN 898 287 40 Test block, PN 375 795 40


Safety harness in conformity with EN 361 Mobile elevator working platform Compound "KP2K", PN 324 969 40 Additional tools and aid according to the PARTS & SERVICE NEWS No. "AH01516". Superstructure: 298,000 kg (special procedure)

Dogman/rigger Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. z

Move the undercarriage underneath the superstructure.

NOTE: Assure that the mounting surfaces are absolutely free of dirt, oil, fat, and paint before installation. WARNING Always wear a safety harness when working in height.


z

Carry out the dumping procedure according to the PARTS & SERVICE NEWS No. "AH01516".

z

Install the outer slew ring to the car body. Refer to the PARTS & SERVICE NEWS No. "AH00511" and "AH01516".

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Superstructure

3.15.3 REMOVE THE SUPERSTRUCTURE FROM THE UNDERCARRIAGE Special tools:



Safety harness in conformity with EN 361 Mobile elevator working platform 2 x crane Superstructure w.o. counterweight and attachment: 202,000 kg Dogman/rigger Crane operators trained in dual crane lift Electrician with permission to work on high voltage systems For further information about the needed blind plugs, refer to section 6.6 on page 6-14.

z


z




z



z


Always wear a safety harness when working in height.

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z



Fig. 3-226 z


z


Fig. 3-227 z


z

Remove the complete attachment, refer to section 5.1 on page 5-2.

z

Remove the counterweight from the superstructure, refer to section 3.14.1 on page 3-248.

z

Disconnect all hydraulic hoses between the superstructure and the rotary joint from the rotary joint, refer to section 4.3.5.1 on page 4-90.

z


z

If equipped, remove the rotating direction sensors B98 and B99 from the swing circle protection.

Fig. 3-228

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Superstructure

Fig. 3-229 Superstructure lifting

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z

Install the shackles (Fig. 3-229, Pos. 6) delivered with the machine to the flanges of the counterweight and attach both shackles to a crane.

z

Re-install the pins of both boom cylinders.

z

Attach the superstructure (Fig. 3-229, Pos. 4) by means of the boom cylinders pins to a second crane.

z

Remove all bolts (Fig. 3-229, Pos. 1) and washers (Fig. 3-229, Pos. 2) attaching the outer slew ring of the swing circle (Fig. 3-229, Pos. 3) to the undercarriage (Fig. 3-229, Pos. 5). WARNING

Before lifting the superstructure, make sure that the crane operators are trained in dual crane lift.

z

Lift off the superstructure using the two cranes and rest it on appropriate support on the ground. DANGER

Risk of falling weights! May result in death or serious injury When moving superstructure, make sure that all personnel are clear.

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Superstructure


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3.15.4 INSTALL THE SUPERSTRUCTURE ONTO THE UNDERCARRIAGE

Special tools:

Hydraulic torque wrench, PN 232 615 40 Electro-hydraulic pump set, PN 232 613 40 55 mm hexagon impact socket wrench, PN 232 267 40 Measuring jaw, PN 274 703 40 8 x Measuring bolt, PN 909 004 40 or respectively 8 x Measuring bolt (cold weather), PN 898 287 40 Test block, PN 375 795 40


Safety harness in conformity with EN 361 Mobile elevator working platform 2 x crane Compound "KP2K", PN 324 969 40 2 thread pins (M 36 x 500) Superstructure w.o. counterweight and attachment: 202,000 kg Dogman/rigger Crane operators trained in dual crane lift Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

WARNING Always wear a safety harness when working in height.


NOTE: Assure that the mounting surfaces are absolutely free of dirt, oil, fat, and paint before installation.

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Superstructure

Fig. 3-230 Superstructure lifting

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z

Clean the contact surfaces of the swing circle (Fig. 3-230, Pos. 3) and the undercarriage (Fig. 3-230, Pos. 5) very carefully and thoroughly.

z

Check the level of bearing area with a laser device before installing a new slew ring. Refer to PARTS & SERVICE NEWS No. "AH00511".

z

Remove the torque support lever of the rotary joint before installing the superstructure, refer to section 4.3.5.1 on page 4-90. WARNING

Before lifting the superstructure, make sure that the crane operators are trained in dual crane lift.

z

Attach the shackles (Fig. 3-229, Pos. 6) to one crane.

z

Attach the superstructure (Fig. 3-229, Pos. 4) by means of the boom cylinders pins to a second crane. DANGER

Risk of falling weights! May result in death or serious injury When moving superstructure, make sure that all personnel are clear.

NOTE: The unhardened spot of race surfaces (changeover area between beginning and ending of hardening process) is punch-marked with an "S" at the inner resp. outer side of each slew ring (Fig. 3-231, Pos. 1 and 2). Refer to PARTS & SERVICE NEWS No. "AH00511". z

Align the spots (Fig. 3-231, Pos. S) to each other.

z

Prepare new bolts, and washers. Lubricate the threads and the head surface of the bolts with compound "KP2K", PN 324 969 40.

Fig. 3-231 z

Align the superstructure to the undercarriage and lower the superstructure.

z

To simplify the alignment of the swing circle (Fig. 3-230, Pos. 3) to the undercarriage (Fig. 3-230, Pos. 5), install two thread pins (M 36 x 500) displaced by 180° at the outer slew ring (Fig. 3-231, Pos. 2).

z

Insert 4 bolts (Fig. 3-230, Pos. 1) with washers (Fig. 3-230, Pos. 2) displaced by 90° and lower the superstructure.

z

Remove the two thread pins from the outer slew ring.

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z

Superstructure

Install all remaining bolts and tight them manually. Tighten all bolts crosswise to the required torque, refer to PARTS & SERVICE NEWS No. "AH00511".

NOTE: If approx. 10 bolts (front and rear) are tightened the superstructure can be unhooked from the crane. z

Reinstall the torque support lever of the rotary joint,refer to section 4.3.5.2 on page 4-93. WARNING

Make sure to use the specified bolts and torque for the torque support lever mounting bolts, refer to section 4.3.5.2 on page 4-93.

z


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3.16 HIGH VOLTAGE SWITCH CABINET

Fig. 3-232 High voltage switch cabinet, overview (1)


(2)


(3)

Bolt

(4)

Resilient sleeve

(5)

Pin

(6)

Cable transfer element

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3.16.1 REMOVAL OF THE HIGH VOLTAGE SWITCH CABINET Special tools:



Safety harness in conformity with EN 361 Mobile elevator working platform 4 x Swivel hoist ring: M36 Crane High voltage switch cabinet: 7000 kg Platform assembly: 235 kg Emergency ladder: 68 kg Dogman/rigger Electrician with permission to work on high voltage systems

z


z





z


Always wear a safety harness when working at the high voltage switch cabinet.

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z


Remove the stairway (Fig. 3-233, Pos. 1).

NOTE: For safety reasons, the handrails (Fig. 3-233, Pos. 2) should remain mounted.

Fig. 3-233 z

Remove the operator’s cab (Fig. 3-234, Pos. 1), refer to section 3.11.1 on page 3-211.

z

Remove the emergency ladder (Fig. 3-234, Pos. 3) from the cab base.

z

Remove the cab support frame (Fig. 3-234, Pos. 2) from the cab base, refer to section 3.12.1 on page 3-227.

z

Remove the platform (Fig. 3-234, Pos. 4) with handrails and gratings from the high voltage switch cabinet using a crane.

z

Dismantle the upper part of the stairway (Fig. 3-234, Pos. 5) from the high voltage switch cabinet.

Fig. 3-234

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Superstructure

z

Open the hinged cover below the high voltage switch cabinet (Fig. 3-235, Pos. 1).

z

Disconnect the wire harnesses between he high voltage switch cabinet and the cab base inside the high voltage switch cabinet.

z

Pull the wire harnesses out of the cable transfer element (Fig. 3-235, Pos. 2) at the high voltage switch cabinet.

z

Disconnect the extinguishing agent hose of the fire suppression system between the cab base and the high voltage switch cabinet from the socket in the transfer element (Fig. 3-235, Pos. 2).

z

Disconnect the high voltage power supply cable between slip ring and high voltage switch cabinet from the load cut-off switch copper bars inside the high voltage switch cabinet. Fig. 3-235

z

Disconnect the high voltage motor power supply cables leading to the electric motors inside the high voltage switch cabinet.

z

Pull the disconnected cables out of the high voltage switch cabinet, into the front roof section next to the slew gear.

z

Open the brackets at the underside of the high voltage switch cabinet and clear all cable channels, wire harnesses, and hoses from the high voltage switch cabinet.

z

Remove the plates (Fig. 3-236, Pos. 1) at the threads (Fig. 3-236, Pos. 2).

z

Insert 4 swivel hoist rings (M36) into the threads at the high voltage switch cabinet.

z

Attach the high voltage switch cabinet to a crane.

Fig. 3-236

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PC8000-6E

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Superstructure

z


Remove the mounting bolts (Fig. 3-237, Pos. 2) and lift the high voltage switch cabinet (Fig. 3-237, Pos. 1) from the superstructure platform (Fig. 3-237, Pos. 3) using a crane. Discard the mounting bolts (Fig. 3-237, Pos. 2). DANGER

Risk of falling weights! Death or serious injury may result. When moving high voltage switch cabinet, make sure that nobody steps below the lifted high voltage switch cabinet.

Fig. 3-237 z

Dismantle the handrails and all other attached parts from the high voltage switch cabinet.

Version 2010/1

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3 - 269


Superstructure

3.16.2 REPLACEMENT OF THE HIGH VOLTAGE SWITCH CABINET Special tools:



Safety harness in conformity with EN 361 Mobile elevator working platform Crane Compound "KP2K", PN 324 969 40 High voltage switch cabinet: 7000 kg Platform assembly: 235 kg Emergency ladder: 68 kg Dogman/rigger Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

WARNING Always wear a safety harness when working at the high voltage switch cabinet.


z


NOTE: Use new mounting bolts (Fig. 3-238, Pos. 2) of grade 10.9 to attach the high voltage switch cabinet (Fig. 3-238, Pos. 1) to the superstructure platform (Fig. 3-238, Pos. 3). Apply compound "KP2K", PN 324 969 40 and tighten the bolts to the specified tightening torque. Tightening torque for the high voltage switch cabinet mounting bolts (Fig. 3-238, Pos. 2): 3100 Nm

Fig. 3-238

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Superstructure



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3 - 271

Slip ring unit

Superstructure

3.17 SLIP RING UNIT

Fig. 3-239 Slip ring unit, overview

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PC8000-6E

Version 2010/1

Superstructure

Slip ring unit


Slip ring unit

(2)

Carrier beam

(3)

Bolt

(4)

Washer

(5)

Nut

(6)

Cam

3.17.1 REMOVAL OF THE SLIP RING UNIT Special tools:

n/a


Crane Slip ring unit: 255 kg

Dogman/rigger Electrician with permission to work on high voltage systems

z


z





z


z

Remove the boom arc hoses over the slip ring unit, refer to section 5.1.7.1 on page 5-68.

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PC8000-6E

3 - 273

Slip ring unit

Superstructure

Fig. 3-240 Removal of the slip ring unit

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PC8000-6E

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Superstructure

Slip ring unit

z

Open the slip ring unit (Fig. 3-241, Pos. 1) and disconnect all high voltage power supply cables and wirering leading into the slip ring unit.

z

If equipped, disconnect the extinguishing agent hose (Fig. 3-241, Pos. 2) of the fire suppression system between from the slip ring unit.

z

Sling the slip ring unit at the installed hoist rings (Fig. 3-241, arrows).

Fig. 3-241 z

Remove the nuts (Fig. 3-240, Pos. 5), the washers (Fig. 3-240, Pos. 4) and the bolts (Fig. 3-240, Pos. 3) attaching the slip ring unit to the carrier beams (Fig. 3-240, Pos. 2).

z

Remove the slip ring unit using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving slip ring assembly, make sure that nobody steps below the lifted slip ring assembly.

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3 - 275

Slip ring unit

Superstructure

Fig. 3-242 Installation of the slip ring unit

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PC8000-6E

Version 2010/1

Superstructure

Slip ring unit

3.17.2 REPLACEMENT OF THE SLIP RING UNIT Special tools:

n/a


Crane Slip ring unit: 255 kg

Dogman/rigger Electrician with permission to work on high voltage systems If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.


z


NOTE: Make sure that the cam (Fig. 3-242, Pos. 6) fits properly in the slip ring unit (Fig. 3-242, Pos. 1) while mounting.

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3 - 277

Slip ring unit

Superstructure


3 - 278

PC8000-6E

Version 2010/1

Undercarriage

4 UNDERCARRIAGE

Version 2010/1

PC8000-6E

4 -1

Undercarriage overview

Undercarriage

4.1

UNDERCARRIAGE OVERVIEW

Fig. 4-1

PC8000-6E, undercarriage overview

4 -2

PC8000-6E

Version 2010/1

Undercarriage

Undercarriage overview


Car body

(2)

Crawler carrier

(3)

Carrier roller

(4)

Travel gear

(5)

Travel motors

(6)

Track tensioning valve block

(7)

High pressure accumulator

(8)

Rotary joint

(9)

Travel brake valve block (overspeed valve)

(10)

Sprocket

(11)

Low pressure accumulator

(12)

Track tensioning cylinder

(13)

Guide wheel

(14)

Track roller

(15)

Cable drum assembly

(16)

High voltage power supply cable

(17)

Track group

Version 2010/1

PC8000-6E

4 -3

Travel system

Undercarriage

4.2

TRAVEL SYSTEM

4.2.1

TRACK GROUP

4.2.1.1 CHANGING OF THE TRACK GROUP Special tools:

n/a


Personal Protective Equipment (PPE) Dozer Chain hoist Slide hammer Welding equipment Brass drift Track group 1900 mm: 56,000 kg Pin track group 1900 mm: 30 kg Track group 1500 mm: 50,000 kg Pin track group 1500 mm: 28 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. NOTE: Make sure that the wear of the track group was measured according to the PARTS & SERVICE NEWS No. "AH02521". z

Prepare an area of flat ground twice as large to accommodate the machine, the boom, and a dozer.

z




z

Remove the cover (Fig. 4-2, Pos. 1).

z

Relieve the pressure in the track tensioning system according to the PARTS & SERVICE NEWS "AH06530". Make sure that the slack in the track group is at the lower part of the guide wheel.

NOTE: The procedure in the PARTS & SERVICE NEWS "AH06530" prevent the track tensioning cylinders to get pressurized when moving the excavator.

Fig. 4-2 4 -4

PC8000-6E

Version 2010/1

Undercarriage

z

Travel system

Flame-cut the nuts (Fig. 4-3, Pos. 3) from the locking bolts (Fig. 4-3, Pos. 1). Remove the locking bolts (Fig. 4-3, Pos. 1), washers (Fig. 4-3, Pos. 2), and nuts (Fig. 4-3, Pos. 3) from one track shoe (Fig. 4-3, Pos. 5). WARNING

z

Ensure nothing flammable is in the working area during flame-cutting and welding work.

z

For welding follow the welding precautions given in the Operation & Maintenance Manual, chapter 4, section "WELD REPAIRS". Fig. 4-3

z

Weld a bolt to the pins (Fig. 4-3, Pos. 4) and attach a sliding hammer.

z

Pull out two pins (Fig. 4-3, Pos. 4) to open the track group using a sliding hammer.

NOTE: Open the track group at the guide wheel side for track group exchange. z

Sling the upper end of the track group using a chain and link it to a dozer in front of the excavator.

z

De-isolate the machine according to local regulations.

z

Switch S155 to Qmin.

NOTE: Use only one engine at Qmin. DANGER Danger of getting overrun or squished. Serious injury or death may result. Make sure nobody stays in driving direction of the excavator or the dozer. Make sure nobody stays next to the crawler carrier.

z

Fig. 4-4

Drive the excavator and the dozer backwards slowly and unroll the track group from the excavator (Fig. 4-4).

NOTE: Assure that excavator and dozer have the same speed. z

When the upper end of the track group runs off the sprocket, stop the excavator while driving the dozer backwards slowly to prevent the track from knocking over.

Version 2010/1

PC8000-6E

4 -5

Travel system

z

Undercarriage

Align the new track group on the ground behind the old track group.

NOTE: Observe the running direction of the new track group. Make sure that the new track group has the correct running direction as shown in Fig. 4-5. z

Remove the chain from the old track group.

z

Continue to drive the excavator backwards slowly on the new track group until the end of the of the track group is nearly reached.

z

Sling the end of the new track group at the sprocket using a chain and link it to a dozer in front of the excavator. DANGER

Danger of getting overrun or squished. Serious injury or death may result. Make sure nobody stays in driving direction of the excavator or the dozer. Make sure nobody stays next to the crawler carrier.

Fig. 4-5 z

Drive the excavator and the dozer forward slowly and pick up the track group with the sprocket.

z

Continue to drive the excavator and the dozer forward slowly to pull up the track group (Fig. 4-6).

NOTE: Assure that excavator and dozer have the same speed.

Fig. 4-6 z

Stop the excavator and the dozer, when the guide wheel reaches the end of the track group (approximately 3 track shoes away from the end of the track group).

z

Place the track group over the guide wheel as shown in Fig. 4-7.

z

Unchain the dozer.

z


Fig. 4-7 4 -6

PC8000-6E

Version 2010/1

Undercarriage

Travel system

z

Align the holes (Fig. 4-8, Pos. 3) in the two open track shoes (Fig. 4-8, Pos. 2) in front of the guide wheel (Fig. 4-8, Pos. 1) using a hoist.

z

Insert the pins (Fig. 4-9, Pos. 4) into the holes (Fig. 4-8, Pos. 3).

Fig. 4-8 z

Install the locking bolts (Fig. 4-9, Pos. 1), washers (Fig. 4-9, Pos. 2), and nuts (Fig. 4-9, Pos. 3) to the track shoes (Fig. 4-9, Pos. 5).

z

Weld the nuts (Fig. 4-9, Pos. 3) to the bolts (Fig. 4-9, Pos. 1). WARNING

z

Ensure nothing flammable is in the working area during welding work.

z

For welding follow the welding precautions given in the Operation & Maintenance Manual, chapter 4, section "WELD REPAIRS". Fig. 4-9

CAUTION The bolts (Fig. 4-10, Pos. 1) lock the pins (Fig. 4-10, Pos. 2). Therefore one side of the bolt’s head is hardened in order to prevent wear. This hardened side must face the pin. The hardened side (Fig. 4-10, arrow) of the bolt heads are marked.

Fig. 4-10

Version 2010/1

PC8000-6E

4 -7

Travel system

Undercarriage

z

Perform the procedure given in the PARTS & SERVICE NEWS "AH06530" in reverse order.

z

Switch S155 to back normal condition.

z

Install the cover (Fig. 4-11, Pos. 1).

Fig. 4-11

4 -8

PC8000-6E

Version 2010/1

Undercarriage

4.2.2

Travel system

SPROCKET

4.2.2.1 REMOVAL OF THE SPROCKET ASSEMBLY Special tools:

n/a


Personal Protective Equipment (PPE) Hydraulic torque wrench, PN 232 614 40 Electro-hydraulic pump aggregate, PN 232 613 40 2 x Crane Dozer Pulling bolts M30 Sprocket assembly: 6164 kg Sprocket assembly oversize: 6357 kg Hollow shaft: 790 kg Drive shaft: 1140 kg

Dogman/rigger

NOTE: KOMATSU recommends to change the flange bearings (Fig. 4-12, Pos. 1 + 3) and the O-rings (Fig. 4-12, Pos. 4 to 7) when changing the sprocket. Therefore the travel gear has to be removed, refer to section 4.2.11.1 on page 4-58. The removal and installation procedure of the inner flange bearing (Fig. 4-12, Pos. 10) is analogously to the removal and installation procedure of the outer flange bearing (Fig. 4-12, Pos. 9) including the tightening torques. Only for removal of the sprocket (Fig. 4-12, Pos. 2) it is not necessary to remove the travel gear (Fig. 4-12, Pos. 4). Subsequently, the removal of the sprocket without removing the travel gear is described.

Fig. 4-12 WARNING Ensure appropriate (PPE) Personal Protective Equipment is used during the task. There maybe sharp edges on the worn sprocket that is being removed.

Version 2010/1

PC8000-6E

4 -9

Travel system

Undercarriage

z

Prepare an area of flat ground twice as large to accommodate the machine, the boom, and two cranes.

z

Park the machine on the prepared flat ground area with the attachment placed at the final drive end of the machine, counterweight above guide wheels.



z


Fig. 4-13

Drain oil of the final drive housing, approx. 250 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL". z

Check the wear of the sprocket hub, refer to PARTS & SERVICE NEWS No. "AH00515".

NOTE: Make sure that the sprocket runs free after opening the track group and it has no contact to the ground or the track group. For example drive the excavator with the track rollers at the respective crawler frame side onto a knoll.

4 - 10

PC8000-6E

Version 2010/1

Undercarriage

Travel system

WARNING Before beginning the work, block the track group to prevent the track shoes against falling down (refer to Fig. 4-14).

z

Open the track group at the sprocket end (Fig. 4-14, Pos. 1), refer to section 4.2.1.1 on page 4-4.

Fig. 4-14 z

Sling the upper end of the track group using a chain and link it to a dozer behind the excavator.

z

De-isolate the machine according to local regulations. DANGER

Danger of getting overrun or squished. Serious injury or death may result. Make sure nobody stays in driving direction of the excavator or the dozer. Make sure nobody stays next to the crawler carrier. Fig. 4-15 z

Drive the excavator and the dozer forwards slowly and unroll the track group from the excavator (refer to Fig. 4-15).

NOTE: Assure that excavator and dozer have the same speed. z

When the upper end of the track group is over the carrier roll next to the sprocket, stop the excavator and the dozer.

z


z

Fasten the track group to the carrier roll to hold it in position.

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. z

Sling sprocket (refer to Fig. 4-16) using a crane.

NOTE: The travel parking brakes must be released to allow the sprocket to turn slightly and find the centre of gravity.

Fig. 4-16

Version 2010/1

PC8000-6E

4 - 11

Travel system

Undercarriage

Fig. 4-17 Removal of the sprocket z

Remove the bolts (Fig. 4-17, Pos. 11) and the cover (Fig. 4-17, Pos. 10).

NOTE: When the cover is removed, oil may flow out. Catch it in an oil pan. z


NOTE: Observe the mounting position of the drive shaft (Fig. 4-17, Pos. 6). The splines at the drive shaft have different lengths. z

Pull the drive shaft out of the hollow shaft (Fig. 4-17, Pos. 5). WARNING

Sling the drive shaft as soon as possible and support it using the second crane to prevent the shaft from falling.

DANGER Risk of falling weights! Death or serious injury may result. When lifting the drive shaft, make sure that nobody steps below the weight.

4 - 12

PC8000-6E

Version 2010/1

Undercarriage

Travel system

CAUTION Make sure that the hollow shaft (Fig. 4-17, Pos. 5) is not weight loaded before removing the flange bearing (Fig. 4-17, Pos. 8).

z

Remove mounting bolts (Fig. 4-17, Pos. 1) and extract the flange bearing (Fig. 4-17, Pos. 8) including the bush (Fig. 4-17, Pos. 7) from the crawler carrier using pulling bolts.

z

Extract the hollow shaft (Fig. 4-17, Pos. 5) from the sprocket (Fig. 4-17, Pos. 3) and remove it using a crane. WARNING

Sling the drive shaft as soon as possible and support it using a crane to prevent the shaft from falling.

DANGER Risk of falling weights! Death or serious injury may result. When lifting the hollow shaft, make sure that nobody steps below the weight.

z

Lift the sprocket assembly out of the crawler carrier. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the sprocket assembly, make sure that nobody steps below the weight.

z

Discard the dual-cone seals (Fig. 4-17, Pos. 2 and Pos. 4).

NOTE: Dual-cone seals are mounted in the sprocket hub as well as in the inner and outer flange bearing. For further information refer to PARTS & SERVICE NEWS No. "AH05511". z

If required, remove the sprocket from the hub, refer to PARTS & SERVICE NEWS No. "AH00514".

Version 2010/1

PC8000-6E

4 - 13

Travel system

Undercarriage

4.2.2.2 REPLACEMENT OF THE SPROCKET ASSEMBLY Special tools:

Assembly tool for dual-cone seals: locally made


Personal Protective Equipment (PPE) Hydraulic torque wrench PN 232 615 40 Electro-hydraulic pump aggregate PN 232 613 40 2 x Crane Dozer Compound "KP2K", PN 324 969 40 Paste "Optimol White", PN 999 039 Sprocket assembly: 6164 kg Sprocket assembly oversize: 6357 kg Hollow shaft: 790 kg Drive shaft: 1140 kg

Dogman/rigger


Fig. 4-18 Replacement of the sprocket z

If required, install the sprocket to the hub, refer to PARTS & SERVICE NEWS No. "AH00514".

4 - 14

PC8000-6E

Version 2010/1

Undercarriage

Travel system

NOTE: For mounting the dual-cone seals (Fig. 4-18, Pos. 2 and Pos. 4), an assembly tool has to be manufactured, refer to PARTS & SERVICE NEWS No. "AH05511". z

Mount new dual-cone seals (Fig. 4-18, Pos. 2 and Pos. 4) into the flange bearing, on the gear side and into the flange bearing (Fig. 4-18, Pos. 8) on the opposite side. Refer to PARTS & SERVICE NEWS No. "AH05511".

z

Mount new dual-cone seals (Fig. 4-18, Pos. 2 and Pos. 4) into the sprocket hub, refer to PARTS & SERVICE NEWS No. "AH05511". CAUTION

Before reassembling the sprocket, the axial play has to be determined, if necessary adjust the axial play, refer to PARTS & SERVICE NEWS No. "AH00514".

NOTE: Observe the mounting position of the drive shaft (Fig. 4-18, Pos. 6) when installing it. The splines at the drive shaft have different lengths. The longer splines must point to the gear box. z

Apply paste "Optimol White" on the splines of the drive shaft (Fig. 4-18, Pos. 6), the hollow shaft (Fig. 4-18, Pos. 5), and the splines of the planet carrier inside the travel gearbox.

z


NOTE: Use a new O-ring (Fig. 4-18, Pos. 9). Apply compound "KP2K", PN 324 969 40 on the sleeve of the flange bearing (Fig. 4-18, Pos. 8) and to the flange bearing bolts (Fig. 4-18, Pos. 1). Tighten the bolts to the specified tightening torque. Tightening torque for flange bearing mounting bolts (Fig. 4-18, Pos. 1): 1250 Nm Tightening torque for cover mounting bolts (Fig. 4-18, Pos. 11): 179 Nm Refill oil in the final drive housing, approx. 250 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL".

Version 2010/1

PC8000-6E

4 - 15

Travel system

4.2.3

Undercarriage

GUIDE WHEELS (IDLERS)

4.2.3.1 REMOVAL OF THE GUIDE WHEEL ASSEMBLY Special tools:

n/a


Crane Guide wheel assembly: 4938 kg

Dogman/rigger

z


z




z


z

Relieve the pressure in the track tensioning system according to the PARTS & SERVICE NEWS "AH06530".

NOTE: If other work is carried out simultaneously, which includes motors running, the procedure in the PARTS & SERVICE NEWS "AH06530" prevent the track tensioning cylinders to get pressurized and therefore falling out due to the missing end stop.

Fig. 4-19 z

Remove the track group from the guide wheel, refer to section 4.2.1.1 on page 4-4.

4 - 16

PC8000-6E

Version 2010/1

Undercarriage

z

Travel system

Remove bolts (Fig. 4-20, Pos. 1) and remove the stop plates (Fig. 4-20, Pos. 2) from both sides of the guide wheel assembly (Fig. 4-20, Pos. 3).

Fig. 4-20 z

Sling guide wheel assembly (Fig. 4-21) and pull the guide wheel assembly out of the crawler carrier.

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. WARNING Ensure to keep hands away for the component sliding surfaces during removal.

Fig. 4-21 z

Remove the plates (Fig. 4-22, Pos. 1) from the guide wheel assembly.

Fig. 4-22

Version 2010/1

PC8000-6E

4 - 17

Travel system

Undercarriage

4.2.3.2 REPLACEMENT OF THE GUIDE WHEEL ASSEMBLY Special tools:

n/a


Crane Guide wheel assembly: 4938 kg

Dogman/rigger



NOTE: Observe the mounting position of the sliding blocks (Fig. 4-23, Pos. 3): Assure that the oil plug (Fig. 4-23, Pos. 2) at the guide wheel (Fig. 4-23, Pos. 1) is facing the inner side of the excavator.

Fig. 4-23

z

Perform the procedure given in the PARTS & SERVICE NEWS "AH06530" in reverse order.

z

Install the cover (Fig. 4-24, Pos. 1).

Fig. 4-24

4 - 18

PC8000-6E

Version 2010/1

Undercarriage

4.2.4

Travel system

TRACK TENSIONING ACCUMULATORS

The hydraulic track tensioning system automatically maintains the correct track tension. The pilot oil pressure of the travel brake release circuit is used to pressurize the four adjusting cylinders. The resulting force moves the guide wheels toward the front, until the correct track tension is obtained. External forces acting upon the guide wheels are absorbed through the pressure accumulators (Fig. 4-25, Pos. 1 and 2). Two different types of pressure accumulators are installed: Four high pressure (150 bar) bladder accumulators (Fig. 4-25, Pos. 1) in the car body and a low pressure (31 bar) diaphragm type accumulators (Fig. 4-25, Pos. 2) in each crawler carriers.

Fig. 4-25

4.2.4.1 REMOVAL OF THE LOW PRESSURE ACCUMULATORS Special tools:

n/a


Oil drain pan Low pressure accumulator: 12 kg For further information about the needed blind plugs, refer to section 6.6 on page 6-14.

z


z


Fig. 4-26

Version 2010/1

PC8000-6E

4 - 19

Travel system

z

Undercarriage

Remove the cover (Fig. 4-27, Pos. 1). WARNING


Fig. 4-27 DANGER Danger of hydraulic pressure! Blindness, serious injury, permanent disfigurement, or scaring may result. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic line will be removed.

z

Disconnect the pressure hose (Fig. 4-28, Pos. 1).

NOTE: When the pressure hose is removed, hydraulic oil from inside the piping and the pressure accumulator will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove four bolts (Fig. 4-28, Pos. 4) and remove the pressure accumulator (Fig. 4-28, Pos. 3).

z

Remove union (Fig. 4-28, Pos. 2).

Fig. 4-28

4 - 20

PC8000-6E

Version 2010/1

Undercarriage

Travel system

4.2.4.2 REPLACEMENT OF THE LOW PRESSURE ACCUMULATORS Special tools:

Testing and refilling device, PN 761 520 73


n/a Low pressure accumulator: 12 kg If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

z


z

Fill the pressure accumulator with nitrogen gas (N2). Refer to PARTS & SERVICE NEWS No. "AH01531". DANGER

Danger of explosion! Blindness, serious injury, permanent disfigurement, scaring, or death may result. Only fill pressure accumulators with nitrogen gas (N2). Do not use any other gases due to explosion hazard!

z

Bleed the track tensioning system. Refer to the Operation & Maintenance Manual, chapter 4, section "CRAWLER TRACK - INSPECTION".

z


z

Check the track tensioning system and adjust if required. Refer to the Service Manual for further information.

z

For adjusting the pressure increasing valve and further information relating the pressure increasing valve refer to the PARTS & SERVICE NEWS No. "AH06544".

Version 2010/1

PC8000-6E

4 - 21

Travel system

Undercarriage

4.2.4.3 REMOVAL OF THE HIGH PRESSURE ACCUMULATORS Special tools:

n/a


n/a High pressure accumulator: 23 kg For further information about the needed blind plugs, refer to section 6.6 on page 6-14.

z


z

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 4-29, Pos. 1) at the track tensioning valve block (Fig. 4-29, Pos. 2) inside the car body. WARNING



z

Disconnect the pressure hose assembly (Fig. 4-30, Pos. 1).

NOTE: When the pressure hose is removed, hydraulic oil from inside the piping and the pressure accumulator will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Open two clamp clips (Fig. 4-30, Pos. 2) and remove the pressure accumulator (Fig. 4-30, Pos. 3).

z

Remove the socket (Fig. 4-30, Pos. 4) from the pressure accumulator (Fig. 4-30, Pos. 3).

Fig. 4-30

NOTE: The same type of assembly is installed at the other side of the car body for the second crawler carrier.

4 - 22

PC8000-6E

Version 2010/1

Undercarriage

Travel system

4.2.4.4 REPLACEMENT OF THE HIGH PRESSURE ACCUMULATORS Special tools:

Testing and refilling device, PN 761 520 73


n/a High pressure accumulator: 23 kg If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

z


z

Fill the pressure accumulator with nitrogen gas (N2). Refer to PARTS & SERVICE NEWS No. "AH01531". DANGER

Danger of explosion! Blindness, serious injury, permanent disfigurement, scaring, or death may result. Only fill pressure accumulators with nitrogen gas (N2). Do not use any other gases due to explosion hazard!

z


z


z


z


Version 2010/1

PC8000-6E

4 - 23

Travel system

4.2.5

Undercarriage

TRACK TENSIONING VALVE BLOCK

4.2.5.1 REMOVAL OF THE TRACK TENSIONING VALVE BLOCK Special tools:

n/a


Chain host Oil drain pan Track tensioning valve block: 46 kg For further information about the needed blind plugs, refer to section 6.6 on page 6-14.

z


z




The track tensioning valve block is located between the high pressure accumulators in the front in direction of travel inside the car body.

4 - 24

PC8000-6E

Version 2010/1

Undercarriage

z

Travel system

Disconnect all piping (Fig. 4-32, Pos. 2) from the track tensioning valve block (Fig. 4-32, Pos. 1).

NOTE: When the piping is removed, hydraulic oil from inside the piping and the track tensioning valve block will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Find an appropriate suspension point for the chain hoist and sling the track tensioning valve block (Fig. 4-32, Pos. 1).

z

Remove four mounting bolts and let down the track tensioning valve block (Fig. 4-32, Pos. 1) using the chain hoist.

Fig. 4-32 z

If required: z

Remove the pressure increasing valve (Fig. 4-33, Pos. 1) from the track tensioning valve block.

z

Remove the check valves (Fig. 4-33, Pos. 2) from the track tensioning valve block. NOTE:Two different types of check valves are installed at the valve block. Do not mix up.

z

Remove the unions (Fig. 4-33, Pos. 3) from the track tensioning valve block. Fig. 4-33

Version 2010/1

PC8000-6E

4 - 25

Travel system

Undercarriage

4.2.5.2 REPLACEMENT OF THE TRACK TENSIONING VALVE BLOCK Special tools:

n/a


Chain host Track tensioning valve block: 46 kg Observe the safety hints for hydraulic hose installation, refer to section 2.2.6 on page 2-22. If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

z


z


z


z


z


4 - 26

PC8000-6E

Version 2010/1

Undercarriage

4.2.6

Travel system

TRACK TENSIONING CYLINDERS

4.2.6.1 REMOVAL OF THE TRACK TENSIONING CYLINDERS Special tools:

n/a


Crane Oil drain pan Track tension cylinder: 570 kg

Dogman/rigger



z




z

Remove the guide wheel assembly, refer to section 4.2.3.1 on page 4-16.

z


Fig. 4-34

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PC8000-6E

4 - 27

Travel system

Undercarriage



z

Disconnect the pressure hoses from the track tension cylinder.

NOTE: When the pressure hoses are removed, hydraulic oil from inside the piping and the track tension cylinder will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Sling the track tension cylinders (Fig. 4-35, Pos. 1) at the retracting device (Fig. 4-35, arrow) and pull the cylinders out of their guidance in the crawler carrier (Fig. 4-35, Pos. 2).

Fig. 4-35

4 - 28

PC8000-6E

Version 2010/1

Undercarriage

Travel system

4.2.6.2 REPLACEMENT OF THE TRACK TENSIONING CYLINDERS Special tools:

n/a


Crane Track tension cylinder: 570 kg

Dogman/rigger



z


z


z


z


Version 2010/1

PC8000-6E

4 - 29

Travel system

Undercarriage


4 - 30

PC8000-6E

Version 2010/1

Undercarriage

4.2.7

Travel system

SUBSTITUTE THE HYDRAULIC HOSES OF THE TRACK TENSIONING SYSTEM

Special tools:

n/a


Oil drain pan Hydraulic hose: 2...15 kg (depending on length) Observe the safety hints for hydraulic hose installation, refer to section 2.2.6 on page 2-22. If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. For further information about the needed blind plugs, refer to section 6.6 on page 6-14

z


z


z


z

Relieve the pressure in the track tensioning system by opening the ball cock (Fig. 4-36, Pos. 1) at the track tensioning valve block (Fig. 4-36, Pos. 2) inside the car body. WARNING



Version 2010/1

PC8000-6E

4 - 31

Travel system

Undercarriage

Fig. 4-37 Hydraulic hoses of the track tensioning system NOTE: All hose clamps A are installed inside the car body. All hose clamps B are installed inside the crawler carrier.

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PC8000-6E

Version 2010/1

Undercarriage

Travel system

4.2.7.1 SUBSTITUTE THE HYDRAULIC HOSES INSIDE THE CAR BODY z

Open the respective hose clamps (Fig. 4-37, A) to clear the hydraulic hoses (Fig. 4-37, Pos. 2 to 4) from the car body.

z

Disconnect both ends of the hydraulic hoses (Fig. 4-37, Pos. 1 to 5) and remove the hydraulic hoses.

NOTE: When a hose is disconnected, hydraulic oil from inside the piping or the hose will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Install a new hydraulic hose in reverse order to removal.

z

Carry out the subsequent work, refer to section 4.2.7.4 on page 4-36.

4.2.7.2 SUBSTITUTE THE HYDRAULIC HOSE BETWEEN CAR BODY AND CRAWLER FRAME z

Disconnect both ends of the hydraulic hose (Fig. 4-37, Pos. 6).


Pull the hydraulic hose out completely.

z

Insert a new hydraulic hose from inside the car body.

z

Bolted undercarriage only: Slide the hydraulic hose through the hose (Fig. 4-38, Pos. 1 and Fig. 4-37, Pos. 10) between car body and crawler carrier.

Fig. 4-38 z

Connect both ends of the hydraulic hose (Fig. 4-37, Pos. 6).

z


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PC8000-6E

4 - 33

Travel system

Undercarriage

Fig. 4-39 Hydraulic hoses of the track tensioning system NOTE: All hose clamps A are installed inside the car body. All hose clamps B are installed inside the crawler carrier.

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PC8000-6E

Version 2010/1

Undercarriage

Travel system

4.2.7.3 SUBSTITUTE THE HYDRAULIC HOSES INSIDE THE CRAWLER FRAME z


Fig. 4-40 z


Fig. 4-41 z

Open the respective hose clamps (Fig. 4-37, B) to clear the hydraulic hoses (Fig. 4-37, Pos. 8 and 9) from the crawler frame.

z

Disconnect both ends of the hydraulic hoses (Fig. 4-37, Pos. 7 to 9) and remove the hydraulic hoses.


Install a new hydraulic hose in reverse order to removal.

z


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PC8000-6E

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Travel system

Undercarriage

4.2.7.4 SUBSEQUENT WORK z


z


z


z


z

Reinstall the cover(s) (Fig. 4-42, Pos. 1, 2).

Fig. 4-42

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PC8000-6E

Version 2010/1

Undercarriage

4.2.8

Travel system

TRAVEL BRAKE VALVE BLOCK (OVERSPEED VALVE)

Fig. 4-43 Location of the travel brake valve blocks (1)

Travel brake valve block

(2)

Travel motor

(3)

Hydraulic hoses

The travel brake valve blocks (Fig. 4-43, Pos. 1) are located in the car body. Two travel brake valve blocks are installed, one valve block for the two travel motors of each crawler track. At one side the travel brake valve blocks are connected to the travel motors with hydraulic hoses (Fig. 4-43, Pos. 3) and at the other side to the rotary joint (Fig. 4-43, Pos. 2) with hydraulic pipes.

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PC8000-6E

4 - 37

Travel system

Undercarriage

Fig. 4-44 Travel brake valve block 4 - 38

PC8000-6E

Version 2010/1

Undercarriage

Travel system

Task: Travel brake valves control the oil flow from the hydraulic motors to the hydraulic oil reservoir depending on the operating pressure. This braking action prevents the motors from over speeding. Function: The spring force keeps the spool in the lowest flow position. restricted by an internal restrictor. With increasing operating pressure the opening for the return oil flow becomes larger. On its way to the hydraulic motor the oil flows from port A to port A1 respectively from port B to port B1, depending on the selected travel motion (refer to Fig. 4-44). Example: Operating pressure at port A moves the spool (Fig. 4-44, Pos. 1) against the force of the spring (Fig. 4-44, Pos. 2) and opens the way for the return oil from port B1 to port B. The check valve (Fig. 4-44, Pos. 3) prevents a direct oil flow from port B1 to port B. If the operating pressure decreases to an amount so that the spring force overcomes the force of the spool, the oil flow to the tank becomes restricted again, resulting in braking of the machine.

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PC8000-6E

4 - 39

Travel system

Undercarriage

4.2.8.1 REMOVAL OF THE TRAVEL BRAKE VALVE BLOCK Special tools:

n/a


Chain hoist Oil drain pan Travel brake valve block: 80 kg For further information about the needed blind plugs, refer to section 6.6 on page 6-14.

z


z




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PC8000-6E

Version 2010/1

Undercarriage

Travel system

z

Disconnect the pressure hoses (Fig. 4-45, Pos. 2) to the rotary joint from the travel brake valve block (Fig. 4-45, Pos. 4).

z

Disconnect the hydraulic lines (Fig. 4-45, Pos. 1) to the travel motors from the travel brake valve block (Fig. 4-45, Pos. 4).

z

Disconnect the leakage oil line from the travel brake valve block (Fig. 4-45, Pos. 4).

NOTE: When the hydraulic lines are disconnected, hydraulic oil from inside the piping and the travel brake valve block will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Discard the O-rings (Fig. 4-45, Pos. 5).

z

Sling the travel brake valve block (Fig. 4-45, Pos. 4) at the installed hoist rings.

z

Remove the mounting bolts (Fig. 4-45, Pos. 3) and lift off the travel brake valve block (Fig. 4-45, Pos. 4) using a chain hoist.

z

Remove the relief valve (Fig. 4-46, Pos. 1) from the travel brake valve block (Fig. 4-46, Pos. 2).

Fig. 4-45

Fig. 4-46

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PC8000-6E

4 - 41

Travel system

Undercarriage

4.2.8.2 REPLACEMENT OF THE TRAVEL BRAKE VALVE BLOCK Special tools:

n/a


Chain hoist Travel brake valve block: 80 kg If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

z


NOTE: Tighten the relief valve (Fig. 4-46, Pos. 1) to the specified tightening torque. Tightening torque for relief valve (Fig. 4-46, Pos. 1): 300 Nm z


z


z

Check the travel system and adjust if required. Refer to the Service Manual for further information.

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PC8000-6E

Version 2010/1

Undercarriage

4.2.9

Travel system

TRAVEL MOTOR

The travel motor is an axial piston unit with fixed displacement. The drive speed is proportional to the consumption capacity. The output torque increases with the pressure drop between high and low pressure side.

4.2.9.1 REMOVAL OF THE TRAVEL MOTORS Special tools:

n/a


Crane Oil drain pan Travel motor: 161 kg each

Dogman/rigger



z




z

Isolate the machine according to local regulations. Drain oil of the motor adapter housing, approx. 0.5 liters each. Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL".

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PC8000-6E

4 - 43

Travel system

Undercarriage



z

Remove the pressure lines (Fig. 4-47, Pos. 2) and the leak oil hoses (Fig. 4-47, Pos. 5) from the travel motor (Fig. 4-47, Pos. 3).

NOTE: When the hoses are removed, hydraulic oil from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Discard the O-rings of the SAE-flanges.

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. z

Sling the travel motor (Fig. 4-47, Pos. 3) and remove the mounting bolts (Fig. 4-47, Pos. 4). Discard the bolts.

z

Remove the travel motor (Fig. 4-47, Pos. 3) by pulling it out of the motor adapter housing of the travel gearbox using a crane.

Fig. 4-47

DANGER Risk of falling weights! Death or serious injury may result. When lifting the travel motor, make sure that nobody steps below the weight.

4 - 44

PC8000-6E

Version 2010/1

Undercarriage

Travel system

4.2.9.2 REPLACEMENT OF THE TRAVEL MOTORS Special tools:

n/a


Crane Paste "Optimol White", PN 999 039 Travel motor: 161 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. z

Apply "Optimol White" at the spline shaft of the travel motor before attaching the travel motor to the motor adapter housing.

z


NOTE: Use new mounting bolts (Fig. 4-47, Pos. 4) of grade 8.8 and tighten to the specified tightening torque. Tightening torque for travel motor mounting bolts: 360 Nm z

Add specified hydraulic oil up to the specified level. Refill oil of the motor adapter housing, approx. 0.5 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL".

Version 2010/1

PC8000-6E

4 - 45

Travel system

Undercarriage

4.2.10 TRAVEL PARKING BRAKE

Fig. 4-48 Travel parking brake assembly

4 - 46

PC8000-6E

Version 2010/1

Undercarriage

Travel system


Bolt

(2)

Snap ring

(3)

Control pressure port to release the brake

(4)

Oil filler plug

(5)

Outer disc carrier

(6)

Intermediate flange

(7)

Drive shaft

(8)

Inner disc carrier

(9)

Bolt

(10)

Oil drain plug

(11)

Inner and outer discs

(12

Quad rings

(13)

Bolt

(14)

Piston

(15)

Springs

(16)

Oil level plug

(17)

Retainer

Brake applied: The outer discs (Fig. 4-48, Pos. 11) engaged to the outer disc carrier (Fig. 4-48, Pos. 5) by serration and the inner discs (Fig. 4-48, Pos. 11) in serration connection with the inner disc carrier (Fig. 4-48, Pos. 8) are pressed together by the springs (Fig. 4-48, Pos. 15). This results in a fixed connection between outer disc carrier (Fig. 4-48, Pos. 5) and drive shaft (Fig. 4-48, Pos. 7). Brake released: Oil pressure via the control pressure port (Fig. 4-48, Pos. 3) forces the piston (Fig. 4-48, Pos. 14) against the spring towards the retainer (Fig. 4-48, Pos. 17). This function eliminates the spring force onto the discs, thus the brake is released. NOTE: The release pressure is 21...23 bar, the maximum permissible pressure is 50 bar.

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PC8000-6E

4 - 47

Travel system

Undercarriage

4.2.10.1 REMOVAL OF THE TRAVEL PARKING BRAKE Special tools:

n/a


Crane Oil drain pan Travel parking brake assembly: 44 kg Inner disc carrier: 3.5 kg

Dogman/rigger



z


NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to a location with appropriate ground condition. z


z


z

Place wedges at front and rear side of both crawlers and lower the bucket onto the ground. Drain oil of the brake housing, approx. 0.2 liters. Refer to the PART & SERVICE NEWS No. "AH06512".

4 - 48

PC8000-6E

Version 2010/1

Undercarriage

z

Travel system

Remove the driving performance meter (Fig. 4-49, Pos. 1) if attached at the travel parking brake (Fig. 4-49, Pos. 2).

Fig. 4-49



z

Fig. 4-50

Disconnect the hydraulic control pressure lines (Fig. 4-50, Pos. 1) from the travel parking brakes.

NOTE: When the hydraulic lines are removed, hydraulic oil from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Attach the travel parking brake assembly to a crane.

Version 2010/1

PC8000-6E

4 - 49

Travel system

Undercarriage

Fig. 4-51 Removal of the travel parking brake

4 - 50

PC8000-6E

Version 2010/1

Undercarriage

Travel system

z

Remove the mounting bolts (Fig. 4-51, Pos. 1).

z

Remove the travel parking brake assembly from the travel gearbox (Fig. 4-51, Pos. 4) and lift it off. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the travel parking brake, make sure that nobody steps below the weight.

NOTE: When the travel parking brake is removed, a rest of hydraulic oil from inside the brake will flow out. Catch it in an oil pan to avoid contamination. z

Remove the snap ring (Fig. 4-51, Pos. 2) and pull the inner disc carrier (Fig. 4-51, Pos. 3) off the drive shaft.

NOTE: The inner disc carrier is used for the alignment of the discs when installing the travel parking brake.

4.2.10.2 REPLACEMENT OF THE TRAVEL PARKING BRAKE Special tools:

n/a


Crane 2 x Threaded pin M12 x 250 mm (grade 8.8) 2 x Nut M12 (grade 8.0) 2 x Threaded pin M10 x 100 mm (grade 8.8) 2 x Nut M10 (grade 8.0) Paste "Optimol White", PN 999 039 Paste "Loctite 574", PN 255 239 40 Travel parking brake assembly: 44 kg Inner disc carrier: 3.5 kg Retainer with cover: 8.7 kg

Dogman/rigger


DANGER For safety reasons, KOMATSU does not permit to install the travel parking brake with pressure applied to the control pressure port to release the brake.

NOTE: For the following procedures the brake is considered to be pre-assembled.

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PC8000-6E

4 - 51

Travel system

Undercarriage

DANGER Risk of retainer (Fig. 4-52, Pos. 1) blasting off! Death or serious injury may result. Do not apply any pressure to the control pressure port (Fig. 4-52, Pos. 2) of the travel parking brake during the installation process.

z

Clean the mating surfaces of the travel parking brake (Fig. 4-52, Pos. A) and the travel gearbox (Fig. 4-52, Pos. B) from old sealing agent.

z

Measure the protrusion (Fig. 4-52, "a") at the intermediate flange and the protrusion (Fig. 4-52, "b") at the travel gearbox.

NOTE: The flange surface (Fig. 4-52, Pos. A) of the intermediate flange must rest plain against the flange surface (Fig. 4-52, Pos. B) of the gearbox.

Fig. 4-52

Machine the intermediate flange if required.

WARNING The retainer (Fig. 4-53, Pos. 1) is spring loaded, so do not remove the bolts (Fig. 4-53, Pos. 4) as long as the retainer is not bolted together with at least two mounting bolts (Fig. 4-53, Pos. 2) with nuts (Fig. 4-53, Pos. 2), displaced by 180° to prevent the retainer from blasting off.

z

After the travel parking brake is secured by mounting bolts (Fig. 4-53, Pos. 2) and nuts (Fig. 4-53, Pos. 3), remove the retainer mounting bolts (Fig. 4-53, Pos. 4).

Fig. 4-53

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PC8000-6E

Version 2010/1

Undercarriage

Travel system

z

Replace the two retainer mounting bolts by threaded pins (Fig. 4-54, Pos. 5) M10 x 100 mm of grade 8.8.

z

Install nuts (Fig. 4-54, Pos. 4) of the grade 8.0 with appropriate large diameter washers and tighten the nuts hand-tight.

z

Remove the mounting bolts (Fig. 4-54, Pos. 1).

z

Apply "Optimol White" at the outer spline shaft of the inner disc carrier (Fig. 4-54, Pos. 3) and insert the inner disc carrier into the discs (Fig. 4-54, Pos. 2). If it is not possible to insert the inner disc carrier, carry out the following two steps: z

Untighten the two nuts (Fig. 4-54, Pos. 4) alternately stepwise to release the brake, until it is possible to insert the inner disc carrier (Fig. 4-54, Pos. 3) into the discs (Fig. 4-54, Pos. 2).

z

Retighten the two nuts alternately stepwise, with the inner disc carrier inside the discs to lock the brake again.

Fig. 4-54

NOTE: Ensure that the inner disc carrier (Fig. 4-54, Pos. 3) slides smoothly into the discs (Fig. 4-54, Pos. 2). z

Remove the inner disc carrier (Fig. 4-54, Pos. 3) and reinstall it onto the drive shaft. Reinstall the snap ring (Fig. 4-51, Pos. 2).

NOTE: Ensure that the mating surfaces of the travel parking brake and of the travel gearbox are clean and free of paint and old sealing agent before reinstalling. z

Apply "Loctite 574" at the mating surface of the travel gearbox.

Version 2010/1

PC8000-6E

4 - 53

Travel system

z

Undercarriage

Attach the travel parking brake assembly to a crane and align it to the installed inner disc carrier. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the travel parking brake, make sure that nobody steps below the weight.

z

Push the travel parking brake assembly onto the inner disc carrier (Fig. 4-55, Pos. 4).

NOTE: Make sure that the pilot oil plug (Fig. 4-55, Pos. 2) is on top of the brake. z

If possible (when the bores for the mounting bolts are aligned with the threads in the travel gearbox (Fig. 4-55, Pos. 3)), insert two threaded pins M12 x 250 mm (Fig. 4-55, Pos. 1) of the grade 8.8 displaced by 180° into the threads in the travel gearbox.

z

Carry out the following two steps only, if the bores in the travel parking brake are not aligned to the threads in the travel gearbox and release the brake: z

z

Untighten the two nuts (Fig. 4-55, Pos. 5) fixing the retainer, alternately stepwise until it is possible to align bores for the mounting bolts with the threads in the travel gearbox.

Fig. 4-55

Insert two threaded pins M12 x 250 mm (Fig. 4-55, Pos. 1) of the grade 8.8 displaced by 180° into the threads in the travel gearbox.

z

Remove the nuts (Fig. 4-55, Pos. 5) (alternately stepwise if the brake was not released) and washers.

z

Remove the retainer (Fig. 4-55, Pos. 8) and the two threaded pins (Fig. 4-55, Pos. 6) fixed in the outer disc carrier. CAUTION

Be careful! Springs (Fig. 4-55, Pos. 7) are no longer fixed, and can fall out of the piston.

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PC8000-6E

Version 2010/1

Undercarriage

Travel system

z

Clean the mating surfaces of retainer (Fig. 4-56, Pos. 5) and outer disc carrier (Fig. 4-56, Pos. 3) from sealing agent.

z

Apply "Loctite 574" at the mating surface of the retainer and install the retainer with oil level plug (Fig. 4-56, Pos. 4) downward.

z

Tighten the two nuts (Fig. 4-56, Pos. 2) alternately stepwise until the mounting bolts of the travel parking brake can be inserted.

NOTE: Always use new mounting bolts. z

Pretighten the mounting bolts hand-tight.

z

Remove the threaded pins (Fig. 4-56, Pos. 1).

Fig. 4-56 z

Insert the last two mounting bolts (Fig. 4-57, Pos. 1).

z

Tighten all mounting bolts to the specified tightening torque. Tightening torque for the mounting bolts (Fig. 4-57, Pos. 1) of the travel parking brake: 85 Nm

z

Insert the two retainer mounting bolts (Fig. 4-57, Pos. 2).

NOTE: Use new retainer mounting bolts (socket head) and tighten them to the specified tightening torque. Tightening torque for the retainer mounting bolts (Fig. 4-57, Pos. 2): 49 Nm z

Connect the hydraulic control pressure hose at the travel parking brake.

Version 2010/1

PC8000-6E

Fig. 4-57

4 - 55

Travel system

z

Undercarriage

If required, reinstall the driving performance meter (Fig. 4-58, Pos. 1) to the travel parking brake (Fig. 4-58, Pos. 2).

Fig. 4-58 z

Add specified hydraulic oil up to the specified level. Fill engine oil (SAE 10) or hydraulic oil (HLP 22 or HLP 33, ISO 51524T.2 and T3) in the travel parking brake, approx. 0.2 liters. Refer to PART & SERVICE NEWS No. "AH06512"

NOTE: Filling of the brake housing has to be done with the engine stopped and the brakes applied to prevent overfilling. z

Perform a function check of the travel parking brake. Refer to the Service Manual.

4 - 56

PC8000-6E

Version 2010/1

Undercarriage

Travel system

4.2.11 TRAVEL GEARBOX

Fig. 4-59 Travel gearbox (1)

Crawler carrier

(2)

O-ring

(3)

Travel gearbox

(4)

Mounting bolt

(5)

Nut

(6)

Travel motor

(7)

Travel parking brake

Version 2010/1

PC8000-6E

4 - 57

Travel system

Undercarriage

4.2.11.1 REMOVAL OF THE TRAVEL GEARBOX Special tools:

n/a


Hydraulic torque wrench PN 232 614 40 Electro-hydraulic pump aggregate PN 232 613 40 Crane Chain hoist Oil drain pan Travel gearbox: 7350 kg

Dogman/rigger



z



Place wedges at front and rear side of both crawlers and lower the bucket onto the ground.

z


z

Isolate the machine according to local regulations. Drain oil of the final drive housing, approx. 250 liters. Drain oil of the travel gear housing, approx. 390 liters. Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL".

z

If required, remove the drive performance meter from the travel parking brake.

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PC8000-6E

Version 2010/1

Undercarriage

Travel system



z

Disconnect the hydraulic lines (Fig. 4-60, Pos. 1) from the travel parking brakes.

z

Disconnect all breather hoses from the travel motor adapter housings, the travel gearbox, and from the final drive housing.

z

Disconnect the hydraulic pressure hoses and the leak oil hoses from the travel motors.

NOTE: When the hydraulic lines are removed, hydraulic oil from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

z

Fig. 4-60

Sling the travel gearbox (Fig. 4-61, Pos. 1).

Fig. 4-61

Version 2010/1

PC8000-6E

4 - 59

Travel system

Undercarriage

z

Remove the nuts (Fig. 4-62, Pos. 3) and the mounting bolts (Fig. 4-62, Pos. 2). Discard the bolts and the nuts.

z

Extract the travel gearbox (Fig. 4-62, Pos. 6) from the crawler carrier (Fig. 4-62, Pos. 1) using a crane. Discard the O-ring (Fig. 4-62, Pos. 7). DANGER

Risk of falling weights! Death or serious injury may result. When lifting the travel gearbox, make sure that nobody steps below the weight.

z

If required, remove the travel parking brake (Fig. 4-62, Pos. 5) from the travel gearbox, refer to section 4.2.10.1 on page 4-48.

z

If required, remove the travel motors (Fig. 4-62, Pos. 4) from the travel gearbox, refer to section 4.2.9.1 on page 4-43.

4 - 60

PC8000-6E

Fig. 4-62

Version 2010/1

Undercarriage

Travel system

4.2.11.2 REPLACEMENT OF THE TRAVEL GEARBOX Special tools:

n/a


Hydraulic hand pump (pressure min. 25 bar max. 35 bar) Hydraulic torque wrench PN 232 614 40 Electro-hydraulic pump aggregate PN 232 613 40 Crane Paste "Optimol White" PN 999 039 Compound "KP2K", PN 324 969 40 Travel gearbox: 7350 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. NOTE: Ensure that the mating surfaces are clean and free of paint before assembly. z

If required, install the travel parking brake at the travel gearbox, refer to section 4.2.10.2 on page 4-51.

z

If required, install the travel motors at the travel gearbox, refer to section 4.2.9.2 on page 4-45.

z

Sling the travel gearbox (Fig. 4-63, Pos. 1). DANGER

Risk of falling weights! Death or serious injury may result. When lifting the travel gearbox, make sure that nobody steps below the weight.

z

Insert a new O-ring (Fig. 4-64, Pos. 2).

z

Apply "Optimol White" at the drive shaft.

z

Connect a hydraulic hand pump (pressure min. 25 bar max. 35 bar) to the pressure port of the installed travel parking brake (Fig. 4-64, Pos. 5). Loosen the brake by means of the hydraulic hand pump.

z

Open the hydraulic ports of the travel motors (Fig. 4-64, Pos. 4).

z

Align the travel gearbox (Fig. 4-64, Pos. 6) to the drive shaft and flange it to the crawler carrier (Fig. 4-64, Pos. 1).

z

Insert new mounting bolts (Fig. 4-64, Pos. 2) of grade 10.9 and new nuts (Fig. 4-64, Pos. 3). Apply compound "KP2K", PN 324 969 40 on the bolts.

Version 2010/1

PC8000-6E

Fig. 4-63

Fig. 4-64

4 - 61

Travel system

Undercarriage

NOTE: Remove the cover (Fig. 4-65, Pos. 1) of one travel parking brake to turn the gear drive manually while aligning the travel gearbox or use the opening of the drive performance meter.

Fig. 4-65 z

Tighten the mounting bolts to the specified tightening torque. Tightening torque for travel gearbox mounting bolts (Fig. 4-64, Pos. 2): 4950 Nm

z

Carry out further installation in reverse order to removal. Refill oil of the final drive housing, approx. 250 liters. Refill oil of the travel gear housing, approx. 390 liters. Refill oil of the motor adapter housing, approx. 0.5 liters each. Refer to the Operation & Maintenance Manual, chapter 4, section "TRAVEL GEARS, MOTOR ADAPTER HOUSINGS AND FINAL DRIVES CHANGE OIL".

NOTE: Be sure to fill in the correct oil as specified, refer to section 6.2 on page 6-3. CAUTION The travel parking brakes are dry multiple disk brakes. DO NOT fill the housings with oil.

z


4 - 62

PC8000-6E

Version 2010/1

Undercarriage

Travel system

4.2.12 CARRIER ROLLER 4.2.12.1 REMOVAL OF THE CARRIER ROLLER ASSEMBLY Special tools:

n/a


Hydraulic jack 30 tonnes Forklift (as the most economical device) Chain hoist Carrier roller assembly: 294 kg

z

Prepare an area of flat ground large enough to accommodate the machine, boom, and forklift.

z




z


Fig. 4-66 z

Push up track shoe assembly (Fig. 4-67, Pos. 3) at the carrier roller assembly to be removed (Fig. 4-67, Pos. 1) using hydraulic jack (Fig. 4-67, Pos. 2). In addition to the hydraulic jack, secure the track shoe assembly using appropriate supports.

Fig. 4-67

Version 2010/1

PC8000-6E

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Travel system

Undercarriage

Pinned crawler carrier only: z

Sling the carrier roller assembly (Fig. 4-68, Pos. 1) at both sides and connect the slings to the forks (Fig. 4-68, Pos. 2) of a forklift.

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges.

Fig. 4-68 Pinned crawler carrier z

Remove the carrier roller assembly mounting bolts (Fig. 4-69, Pos. 1) and lift off the carrier roller assembly (Fig. 4-69, Pos. 2) using the forklift. DANGER

Risk of falling weights! May result in death or serious injury When lifting the carrier roller, make sure that nobody steps below the weight.

Fig. 4-69 Pinned crawler carrier

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Undercarriage

Travel system

Bolted crawler carrier only: z

Shove the forks (Fig. 4-70, Pos. 1) together that far, that the carrier roller (Fig. 4-70, Pos. 2) can rest on the forks. WARNING

z

If the forks can not be locked in that position, use a chain hoist at the forks to prevent them from sliding apart.

z

Make sure that nobody is in the danger zone while lifting the carrier roller assembly from the pedestal. Fig. 4-70 Bolted crawler carrier

z

Remove the carrier roller assembly mounting bolts (Fig. 4-71, Pos. 1) and lift the carrier roller assembly (Fig. 4-71, Pos. 2) off the crawler carrier (Fig. 4-71, Pos. 3) using the forklift. DANGER

Risk of falling weights! May result in death or serious injury When lifting the carrier roller, make sure that nobody steps below the weight.

Fig. 4-71 Bolted crawler carrier

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Travel system

Undercarriage

4.2.12.2 REPLACEMENT OF THE CARRIER ROLLER ASSEMBLY Special tools:

n/a


Forklift (as the most economical device) Chain hoist Compound "KP2K", PN 324 969 40 Carrier roller assembly (with mounting pins): 294 kg If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

DANGER Danger of crush or pinch injuries to hands and fingers! Exercise extreme care when aligning the carrier roller assembly to the crawler carrier.

z


NOTE: Observe the mounting position of the carrier roller assembly (Fig. 4-70 and 4-71, Pos. 2). The oil plug must face the outside of the excavator. z

Check the oil level in the carrier roller. The following positions of the oil level and filler plug have been defined for checking the oil level in the carrier rollers: z

9.00 o'clock or 3.00 o'clock position, equal to 90° angle from TOP position of the plug to left or to the right = MINIMUM oil level.

z

9.30 o'clock or 2.30 o'clock position, equal to 75° angle from TOP position of the plug to left or to the right = MAXIMUM oil level (factory filling).

z

For information about the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS".

NOTE: Use new mounting bolts of the grade 10.9. Apply compound "KP2K", PN 324 969 40 and tighten the bolts to the specified tightening torque. Tightening torque for the carrier roller mounting bolts (bolted type / pinned type): 1770 Nm

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Undercarriage

Travel system

4.2.13 TRACK ROLLER 4.2.13.1 REMOVAL OF THE TRACK ROLLER ASSEMBLY Special tools:

Safety unit for changing track rollers, PN 921 142 40 Tool for changing track rollers (optional, P&S-news in development)


Crane Forklift (optional, instead of the tool for changing track rollers) Track roller assembly: 925 kg

Dogman/rigger

z


z




Fig. 4-72 z

Jack up the machine with the work equipment.

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Travel system

Undercarriage

z

Support two track rollers with the safety unit for changing track rollers, PN 921 142 40 (Fig. 4-73, Pos. 1).

z

Lower the machine and place the work equipment on the ground.

z


z

Support the track roller assembly (Fig. 4-73, Pos. 2) from the bottom side using a forklift. Alternatively the changing tool for track rollers can be used, refer to Fig. 4-75.

z

Remove the track roller mounting bolts (Fig. 4-73, Pos. 3). Fig. 4-73 Use of the safety unit

NOTE: The track roller mounting bolts (Fig. 4-74, Pos. 1) are secured with lever-nuts (Fig. 4-74, Pos. 2) inside the crawler frame. When the bolts are removed, the nuts may slip away from their mounting position. z

Remove the track roller assembly using the forklift or the special tool. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the track roller, make sure that nobody steps below the weight.

Fig. 4-74 Changing tool for track rollers: NOTE: Make sure that both sides of the tool are balanced (e.g. with the new track roller assembly). NOTE: A PARTS & SERVICE NEWS for this tool is under development. Contact the KOMATSU service for further information.

Fig. 4-75 Optional use of the special tool

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Undercarriage

Travel system

4.2.13.2 REPLACEMENT OF THE TRACK ROLLER ASSEMBLY Special tools:

Safety unit for changing track rollers, PN 921 142 40 Tool for changing track rollers (P&S-news in development)


Crane Compound "KP2K", PN 324 969 40 Track roller assembly: 925 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. NOTE: Observe the mounting position of the track rollers. The oil plug must face the outside of the excavator. z

z

Check the oil level in the track roller. The following positions of the oil level and filler plug have been defined for checking the oil level in the track rollers: z

9.00 o'clock or 3.00 o'clock position, equal to 90° angle from TOP position of the plug to left or to the right = MINIMUM oil level.

z

9.30 o'clock or 2.30 o'clock position, equal to 75° angle from TOP position of the plug to left or to the right = MAXIMUM oil level (factory filling).

z

For information about the proper lubricant, refer to the Operation & Maintenance Manual, chapter 4, section "FLUIDS AND LUBRICANTS".

Carry out installation in reverse order to removal. z

When inserting the track roller mounting bolts (Fig. 4-76, Pos. 1), hold the lever-nuts (Fig. 4-76, Pos. 2) inside the crawler frame by hand for the first convolutions.

NOTE: Use new track roller mounting bolts of the grade 10.9. Apply compound "KP2K", PN 324 969 40 and tighten the bolts to the specified tightening torque.

Tightening torque for the track roller mounting bolts (Fig. 4-76, Pos. 1): 1770 Nm

Fig. 4-76

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Car body

Undercarriage

4.3

CAR BODY

4.3.1

REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH MOUNTING PINS)

Special tools:

n/a


2 x Crane Dozer Oil drain pan Car body: 55,000 kg Crawler carrier assembly: 46,000 kg each (without track group) Dogman/rigger Crane operators trained in dual crane lift For further information about the needed blind plugs, refer to section 6.6 on page 6-14.

NOTE: At first the wear of the bushes in the car body should be checked, refer to the PARTS & SERVICE NEWS No. "AH08508". z

Remove the track groups from both crawler carriers, refer to section 4.2.1.1 on page 4-4.

NOTE: Remove both track groups simultaneously. This can be done using the same dozer. z

Remove the travel gear boxes from both crawler carriers, refer to section 4.2.11.1 on page 4-58.

z

Lift the superstructure, refer to section 3.15.1 on page 3-252.

z

Attach the dozer to the car body (Fig. 4-77, Pos. 2) by means of a chain (Fig. 4-77, Pos. 1).

z

Move the car body below the lifted superstructure using the dozer.

NOTE: Move the car body over the unrolled track group.

Fig. 4-77

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z

Car body

Remove the pressure hoses (Fig. 4-78, Pos. 1) of the track tensioning leading to the shut-off cocks (Fig. 4-78, Pos. 2) and pull it out of the crawler carriers, refer to section 4.2.7.2 on page 4-33.

NOTE: When the pressure hoses are removed, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hose (Fig. 4-78, Pos. 3) between crawler carrier and car body. Fig. 4-78

z

Attach one crawler carrier to two cranes and lift it up (Fig. 4-79).

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. WARNING Before lifting, make sure that the crane operators are trained in dual crane lift.

Fig. 4-79 z

Rest the car body on appropriate supports (also see Fig. 4-80). CAUTION

Supports need to be substantial enough to carry total weight of both crawler carrier assembly (46,000 kg) and car body (55,000 kg).

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Car body

Undercarriage

Fig. 4-80 Crawler carrier removal z

Remove all bolts (Fig. 4-80, Pos. 6) and the retainer plates (Fig. 4-80, Pos. 7).

z

Remove the nuts (Fig. 4-80, Pos. 2), the inner retainer plates (Fig. 4-80, Pos. 3), and the thread pins (Fig. 4-80, Pos. 4) only if required (changing to a replacement car body).

z

Pull out the four mounting pins (Fig. 4-80, Pos. 5) just enough to clear the crawler carrier (Fig. 4-80, Pos. 1) from the car body as shown in (Fig. 4-80).

z

Remove the crawler carrier (Fig. 4-80, Pos. 1) using two cranes. WARNING

Before lifting the crawler carrier, make sure that the crane operators are trained in dual crane lift.

DANGER Risk of falling weights! Death or serious injury may result. When lifting the crawler carrier, make sure that nobody steps below the weight.

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Car body

z

Attach the car body to two cranes (Fig. 4-81).

z

Clear the other crawler carrier from the car body using the same procedure as before.

z

Remove the car body using two cranes. WARNING

Before lifting the car body, make sure that the crane operators are trained in dual crane lift.

DANGER Risk of falling weights! Death or serious injury may result. When lifting the car body, make sure that nobody steps below the weight.

z

Fig. 4-81

Carry out the following steps only if required: z

Remove the rotary joint from the car body, refer to section 4.3.5.1 on page 4-90.

z

Remove the high pressure accumulators from the car body, refer to section 4.2.4.3 on page 4-22.

z

Remove the track tensioning valve from the car body, refer to section 4.2.5.1 on page 4-24.

z

Remove the travel brake valve blocks from the car body, refer to section 4.2.8.1 on page 4-40.

z

Remove all hydraulic hoses from the car body, refer to section 4.2.7 on page 4-31.

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Car body

4.3.2

Undercarriage

REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH MOUNTING PINS)

Special tools:

Water level gauge


AL-Compound, PN 509 623 98 2 x Crane Dozer Car body: 55,000 kg Crawler carrier assembly: 46,000 kg each (without track group) Dogman/rigger Crane operators trained in dual crane lift If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.


Carry out the following five steps only if required: z

Install all hydraulic hoses into the new car body, refer to section 4.2.7 on page 4-31.

z

Install the rotary joint in the new car body, refer to section 4.3.5.2 on page 4-93.

z

Install the high pressure accumulators in the new car body, refer to section 4.2.4.4 on page 4-23.

z

Install the track tensioning valve in the new car body, refer to section 4.2.5.2 on page 4-26.

z

Install the travel brake valve blocks in the new car body, refer to section 4.2.8.2 on page 4-42.

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Car body

z

If required, install new inner bushings (Fig. 4-82, Pos. 5) and new outer bushings (Fig. 4-82, Pos. 7) in the new car body.

z

Install the thread pins (Fig. 4-82, Pos. 4) and the inner retainer plates (Fig. 4-82, Pos. 3) with nuts (Fig. 4-82, Pos. 2) and washers at the four borings for the pins on the car body.

z

Attach the car body (Fig. 4-82, Pos. 1) to two cranes and lift it up. WARNING

Before lifting the car body, make sure that the crane operators are trained in dual crane lift.

DANGER

Fig. 4-82

Risk of falling weights! Death or serious injury may result. When lifting the car body, make sure that nobody steps below the weight.

z

Align the car body over the crawler carrier (Fig. 4-82, Pos. 10) and let it down.

NOTE: The oil supply lines to the travel motors must be aligned in the direction of the travel motors. Insert the hydraulic lines for track tensioning into the crawler carrier before installing it. z

Align the upper borings first and insert the mounting pins (Fig. 4-82, Pos. 6).

NOTE: Lubricate pins (Fig. 4-82, Pos. 6) with AL-Compound, PN 509 623 98. z

Align the lower borings and insert the mounting pins.

z

Install the retainer plates (Fig. 4-82, Pos. 9) at the mounting pins and secure the retainer plates with the mounting bolts (Fig. 4-82, Pos. 8) inclusive washers.

z

Tighten the mounting bolts to the specified tightening torque. Tightening torque for mounting bolts (Fig. 4-82, Pos. 8): 360 Nm

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Car body

z

Undercarriage

For easier mounting of the second crawler carrier, support left side of the car body with appropriate supports of approx. 1500 mm hight and lower the car body on the supports. CAUTION

Supports need to be substantial enough to carry total weight of one crawler carrier assembly (46,000 kg) and the car body (55,000 kg).

NOTE: Assure that the track groups are parallel and the distance "A" between track groups is: 4750 mm for track width 1900 5150 mm for track width 1500

Fig. 4-83

Fig. 4-84 Assembly of the car body z

Install the thread pins (Fig. 4-84, Pos. 4) and the inner retainer plates (Fig. 4-84, Pos. 3) with nuts (Fig. 4-84, Pos. 2) and washers at the four borings for the pins on the car body.

z

Attach the second crawler carrier (Fig. 4-84, Pos. 1) to two cranes, lift it up and align it to the car body.

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Car body

NOTE: In order to avoid damage to the lifting devices, use edge protection at all sharp edges. WARNING Before lifting the crawler carrier, make sure that the crane operators are trained in dual crane lift.

DANGER Risk of falling weights! Death or serious injury may result. When lifting the car body, make sure that nobody steps below the weight.

z

Align the lower borings first and insert the mounting pins (Fig. 4-84, Pos. 5).

NOTE: Lubricate pins (Fig. 4-84, Pos. 5) with AL-compound, PN 509 623 98. z

Align the lower borings and insert the mounting pins.

z

Install the retainer plates (Fig. 4-84, Pos. 7) at the mounting pins and secure the retainer plates with the mounting bolts (Fig. 4-84, Pos. 6) inclusive washers.Tighten the mounting bolts to the specified tightening torque.

Tightening torque for mounting bolts: 360 Nm

z

Lift the undercarriage as far as it is necessary to remove the supports.

z

Rest the undercarriage to the ground.

z


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Car body

4.3.3

Undercarriage

REMOVAL OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH BOLTED CONNECTION)

Special tools:

Hydraulic torque wrench, PN 793 374 73 + PN 793 376 73 Electro-hydraulic pump set, PN 795 922 73


2 x Crane Dozer Car body: 59,000 kg Crawler carrier assembly: 55,000 kg each (without track group) Dogman/rigger Crane operators trained in dual crane lift For further information about the needed blind plugs, refer to section 6.6 on page 6-14.

z

Remove the track groups from both crawler carriers, refer to section 4.2.1.1 on page 4-4.

NOTE: Remove both track groups simultaneously. This can be done using the same dozer. z

Remove the travel gear boxes from both crawler carriers, refer to section 4.2.11.1 on page 4-58.

z

Lift the superstructure, refer to section 3.15.1 on page 3-252.

z

Attach the dozer to the car body (Fig. 4-77, Pos. 2) by means of a chain (Fig. 4-77, Pos. 1).

z

Move the car body below the lifted superstructure using the dozer.

NOTE: Move the car body over the unrolled track group.

Fig. 4-85

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z

Car body

Disconnect the pressure hoses (Fig. 4-86, Pos. 1) for the track tensioning from the shut-off cocks (Fig. 4-86, Pos. 2).

NOTE: When the pressure hoses are removed, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hoses from both crawler carriers.

Fig. 4-86

z

Attach one crawler carrier (Fig. 4-87, Pos. 1) to two cranes at the installed lifting eyes (Fig. 4-87, Pos. 2) and lift it up. WARNING

Before lifting, make sure that the crane operators are trained in dual crane lift.

z

Support the car body with appropriate supports so that all of the track rollers are clear of the track roller path. CAUTION

Supports need to be substantial enough to carry total weight of one crawler carrier assembly (46,000 kg) and the car body (55,000 kg).

Fig. 4-87

NOTE: Place supports between the cross-ties (Fig. 4-88, Pos. 1) in a manner that the mounting bolts can be removed.

Fig. 4-88

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Undercarriage

Fig. 4-89 Crawler carrier mounting bolts z

Remove all 244 mounting bolts (Fig. 4-89, Pos. M48) and the two measuring bolts (Fig. 4-89, Pos. 1) attaching the crawler carrier to the car body using the hydraulic torque wrench PN 793 374 73 + PN 793 376 73. Discard the bolts.

NOTE: The mounting bolts marked with "S" have to be removed from inside the car body. For hints using the torque wrench refer to section 6.3.1 on page 6-4 and refer to chapter 9 "Supplier’s documentation", "AVANTI HYTORQUE". z

Remove the crawler carrier using the two cranes. WARNING

Before lifting the crawler carrier, make sure that the crane operators are trained in dual crane lift.

DANGER Risk of falling weights! Death or serious injury may result. When lifting the crawler carrier, make sure that nobody steps below the weight.

z

Remove the car body from the other crawler carrier accordingly to “Removal of the car body and the crawler carriers (type with mounting pins)” on page 70.

NOTE: Clear the second crawler carrier from the car body using the procedure on this page.

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Undercarriage

4.3.4

Car body

REPLACEMENT OF THE CAR BODY AND THE CRAWLER CARRIERS (TYPE WITH BOLTED CONNECTION)

Special tools:



2 x Crane Dozer Compound "KP2K", PN 324 969 40 Car body: 59,000 kg Crawler carrier assembly: 55,000 kg each (without track group) Dogman/rigger Crane operators trained in dual crane lift If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 2.3 on page 2-30.


Carry out installation in reverse order to removal and accordingly to “Replacement of the car body and the crawler carriers (type with mounting pins)” on page 74. When mounting the crawler carrier to the car body, tighten the mounting bolts to the specified tightening torques as follows:

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Car body

Undercarriage

Fig. 4-90 Crawler carrier mounting bolts z

Insert 244 new bolts (Fig. 4-90, Pos. M48) and two measuring bolts (Fig. 4-90, Pos. 1) with a resilient sleeves.

NOTE: Lubricate all bolts (Fig. 4-90, Pos. M48) with compound "KP2K", PN 324 969 40. Clean bottom and top surface of the resilient sleeves and contact areas completely free of paint. Insert the two measuring bolts (Fig. 4-90, Pos. 7) into the upper corners. The measuring bolts are part of the measuring device, PN 928 476 40. The mounting bolts marked with "S" have to be installed from inside the car body. z

Pretighten the mounting bolts using the hydraulic torque wrench PN 793 374 73 + PN 793 376 73.

NOTE: For hints using the torque wrench refer to section 6.3.1 on page 6-4 and refer to chapter 9 "Supplier’s documentation", "AVANTI HYTORQUE". Pretightening torque for crawler carrier mounting bolts: 2100 Nm z

Determine the torque and tighten the crawler carrier mounting bolts to the determined torque, refer to section 4.3.4.1 on page 4-84.

NOTE: Check the torque of the crawler carrier mounting bolts after 1000 operating hours, refer to section 4.3.4.1 on page 4-84.

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Car body


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Car body

Undercarriage

4.3.4.1 TIGHTENING TORQUE FOR THE CRAWLER CARRIER MOUNTING BOLTS Special tools:

Hydraulic torque wrench, PN 793 374 73 + PN 793 376 73 Electro-hydraulic pump set, PN 795 922 73 Measuring device, PN 928 476 40

Fig. 4-91 Tightening torque for the crawler carrier mounting bolts 4 - 84

PC8000-6E

Version 2010/1

Undercarriage

Car body

The required tightening torque for all fastening bolts has to be determined with the 4 measuring bolts (Fig. 4-91, Pos. 7), which dimension is analogous to the fastening bolts (Fig. 4-91, Pos. M48). The required axial tension force of the bolts depends on the elongation of the fastening bolts. NOTE: The tightening torque must be determined at the first assembly of the excavator at the operation site, for the first inspection, and after 1000 operation hours, or after replacing either crawler carrier or car body. The required measuring device, PN 928 476 40 is delivered with the excavator. To determine the tightening torque, 4 specially prepared measuring bolts are supplied besides the normal fastening bolts. The measuring bolts can be recognized by the machined area at the end of the bolt. The measuring device (Fig. 4-91, Pos. 1 - 6) is composed of the following items and will be delivered with each new machine. Refer to Fig. 4-91: Pos.

Part name

Part number

Qty.

(1)

Angle bar

928 475 40

1

(2)

Dial gauge

092 706 40

1

(3)

Screw M5x16

502 515 98

1

(4)

Feeler

477 172 40

1

(5)

Bolt M10x25

307 777 99

2

(6)

Washer

517 122 98

2

(7)

Measuring bolt (installed)

933 613 40

4

WARNING Pre-condition: Crawler carrier is assembled and bolts tightened to 2100 Nm

z

Loosen all 4 measuring bolts (Fig. 4-91, Pos. 7). Do not lubricate the measuring bolts again.

z

Tighten the 4 measuring bolts (Fig. 4-91, Pos. 7) to 150 Nm.

z

Install the measuring device (Fig. 4-91, Pos. 1 - 6).

z

Set the dial gauge (Fig. 4-91, Pos. 2) to zero.

z

Install the special hydraulic torque wrench, PN 793 374 73 + PN 793 376 73, refer to section 6.4.2 on page 6-13.

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Car body

Undercarriage

Fig. 4-92 Tightening torque for the crawler carrier mounting bolts

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Version 2010/1

Undercarriage

Car body

z

Adjust the pressure at the hydraulic torque wrench to 2100 Nm and tighten the measuring bolt (Fig. 4-92, Pos. 7).

z

List the pressure and the changed bolt length in a table.

z

Increase the pressure in steps of 10 bar until the measuring bolts have the required elongation of 1.22 mm.

z

List the corresponding hydraulic pressure in a table.

z

Repeat this procedure for all 4 measuring bolts.

z

Add all 4 determined hydraulic pressures and then divide by 4 to obtain an average value.

z

Loosen one mounting bolt (Fig. 4-92, Pos. M48) and tighten the bolt with the calculated average pressure. CAUTION

Do not lubricate the bolts again. Do not loosen more than one bolt at a time.

z

Repeat this procedure step by step for all the other bolts.

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Car body

4.3.5

Undercarriage

ROTARY JOINT

Fig. 4-93 Rotary joint

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Car body


Rotary joint

(2)

Torque support lever

(3)

Resilient sleeve

(4)

Mounting bolt

(5)

Car body

(6)

Support plate

(7)

Center of the rotary joint (hollow-bore)

(8)

Cam at the superstructure

Ports: A-D

Service lines

F

Grease

L

Leak (case drain) oil

ST

Control oil (pilot oil)

K1 / K2

Return oil to tank

The rotary distributor (rotary joint) permits a hydraulic connection between the superstructure and the undercarriage. That means there is an unrestricted hydraulic connection installed between the rotating and stationary part which allows free rotation in both slew directions. During operation the superstructure and the undercarriage rotate towards each other. The travel motors must be supplied with hydraulic oil in each position in which the superstructure is slewed against the undercarriage. The rotary joint is hollow-bored, so the main power cable to the slip ring runs through the center of the rotary joint.

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Car body

Undercarriage

4.3.5.1 REMOVAL OF THE ROTARY JOINT Special tools:

n/a


Crane Rotary joint: 261 kg

Dogman/rigger


Prepare an area of flat ground large enough to accommodate the machine, boom, and a crane.

z




z


z


Fig. 4-94

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Version 2010/1

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z

Car body

Close the hand wheel (Fig. 4-95, Pos. 1) of the main gate valve between suction oil reservoir and main oil reservoir.

Fig. 4-95 DANGER Hazardous Voltage! Risk of electric shocks. Death or serious burns may result. Any work on the high voltage system has to be carried out by authorized electricians having the permission to work on high voltage systems only.

z


z


z

Pull the high voltage power supply cable out of the rotary joint and the support plate. WARNING


z

Mark and disconnect all hydraulic hoses and pipes from the rotary joint. Discard the O-rings of the SAE–flange connections, refer to Fig. 4-93.

NOTE: When the hydraulic lines are removed, hydraulic oil from inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Disconnect the lines of the central lubrication system from the rotary joint.

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Car body

z

Undercarriage

Sling the rotary joint.

NOTE: The rotary joint is accessible from above, from between the pipe work at the manifold at the centre of the machine (Fig. 4-96, arrow). CAUTION Move the sling carefully between the pipe work/hoses at the manifold to prevent the pipe work from being damaged or ripped off.

Fig. 4-96 z

Remove the mounting bolts (Fig. 4-97, Pos. 1) and remove the torque support lever (Fig. 4-97, Pos. 2) from the rotary joint (Fig. 4-97, Pos. 3).

z

Remove mounting bolts (Fig. 4-97, Pos. 4) and lift the rotary joint (Fig. 4-97, Pos. 3) off the support plate (Fig. 4-97, Pos. 5) in the car body using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the rotary joint, make sure that nobody steps below the weight.

Fig. 4-97

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Car body

4.3.5.2 REPLACEMENT OF THE ROTARY JOINT Special tools:

n/a


Crane Compound "KP2K", PN 324 969 40 Rotary joint: 261 kg

Dogman/rigger


z

Place the new rotary joint (Fig. 4-98, Pos. 3) at the support plate (Fig. 4-98, Pos. 5) using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When lifting the rotary joint, make sure that nobody steps below the weight.

NOTE: Insert new mounting bolts (Fig. 4-98, Pos. 4) of grade 10.9. Apply compound "KP2K", PN 324 969 40 and tighten the bolts to the specific tightening torque. Tightening torque for rotary joint mounting bolts (Fig. 4-98, Pos. 4): 265 Nm z

Install the torque support lever to the new rotary joint (Fig. 4-98, Pos. 3). Make sure that the torque support lever fits into the cam at the superstructure.

Fig. 4-98

NOTE: Use new mounting bolts (Fig. 4-98, Pos. 1) of grade 10.9. Apply compound "KP2K", PN 324 969 40 and tighten the bolts to the specified tightening torque. Tightening torque for torque support lever mounting bolts (Fig. 4-98, Pos. 1): 265 Nm z

Lead the high voltage power supply cable through the support plate (Fig. 4-98, Pos. 5) and the center of the rotary joint (Fig. 4-98, Pos. 3).

z


z


z


Version 2010/1

PC8000-6E

4 - 93

Cable drum assembly

4.4

Undercarriage

CABLE DRUM ASSEMBLY

Fig. 4-99 Cable drum, overview (1)

Mounting flange

(2)

Connection box

(3)

Cable drum brake motor

(4)

Power cable guiding tube

(5)

Carrier

(6)

Cable guide mechanism

(7)

Cable drum

(8)

Brake motor resistor

(9)

Maintenance access ladder

4 - 94

PC8000-6E

Version 2010/1

Undercarriage

4.4.1

Cable drum assembly

REMOVAL OF THE CABLE DRUM ASSEMBLY

Special tools:

n/a


Crane 2 x Chain hoist (carrying capacity: 5000 kg, each) Cable drum assembly (empty): 10,000 kg

Dogman/rigger

z


z



Turn the superstructure 45 degrees to the right, i.e. in the position where the corner with the hydraulic cooler is located above the centre of the cable drum.

z

Unroll the high voltage power supply cable from the cable drum til the end using the manual switch of the unit.

z



z


z

Disconnect the high voltage power supply cable at the power station.

z

If the electric supply has been switched off from the power plant, loosen the brake of the drum motor, refer to the Operation & Maintenance Manual of the cable drum assembly.

z

Open the man hole of the cable drum.

z

Disconnect the high voltage power supply cable coming from the power station inside the drum, and pull the cable out of the drum.

Version 2010/1

PC8000-6E

4 - 95

Cable drum assembly

Undercarriage

z

Disconnect all cables and wires leading from the car body (Fig. 4-100, Pos. 1) to the cable drum assembly, and put them down on the machine.

z

Sling the cable drum assembly at the carrier (Fig. 4-100, Pos. 2) using a crane and two chain hoists (for balancing).

z

Remove the mounting bolts (Fig. 4-100, Pos. 3) and resilient sleeves (Fig. 4-100, Pos. 4) at the flanges (Fig. 4-100, Pos. 5). DANGER

Risk of falling weights! Death or serious injury may result. When removing the mounting bolts, make sure that nobody steps below the cable drum assembly.

z

Move the cable drum assembly away from the machine carefully, and put it down on the ground. Fig. 4-100 DANGER

Risk of falling weights! Death or serious injury may result. When lifting the cable drum assembly, make sure that nobody steps below the weight.

4 - 96

PC8000-6E

Version 2010/1

Undercarriage

4.4.2

Cable drum assembly

REPLACEMENT OF THE CABLE DRUM ASSEMBLY

Special tools:

n/a


Crane 2 x Chain hoist Cable drum assembly (empty): 10,000 kg

Dogman/rigger



NOTE: Ensure that the mating surfaces are free of grease and rust, and that the surfaces are plane. z

Sling the cable drum assembly (Fig. 4-101, Pos. 2) using a crane and two chain hoists (for balancing).

z

Bring the cable drum assembly into mounting position at the car body (Fig. 4-100, Pos. 1). DANGER

Risk of falling weights! Death or serious injury may result. When lifting the cable drum assembly, make sure that nobody steps below the weight.

z

Install the mounting bolts (Fig. 4-100, Pos. 3) with resilient sleeves (Fig. 4-100, Pos. 4) at the mounting flanges (Fig. 4-100, Pos. 5).

NOTE: Always use new mounting bolts of grade 10.9. Apply compound "KP2K", PN 324 969 40 on heads and threads of the bolts and tighten them to the specified tightening torque: Fig. 4-101 Tightening torques for the cable drum assembly mounting bolts: 880 Nm

Version 2010/1

PC8000-6E

4 - 97

Cable drum assembly

Undercarriage

z

Reconnect all cables and wires leading from the machine to the cable drum and the connection box of the cable drum assembly.

z

Open the manhole of the cable drum.

z

Reconnect the high voltage power supply cable from the power station inside the cable drum.

z

Change the dryer pack according to the Operation & Maintenance Manual of the cable drum assembly.

z

Clean the inside of the cable drum.

NOTE: Dirt, water, oil or other contamination is not permissible inside the cable drum. z

Carry out further installation in reverse order to removal

NOTE: For the initial operation of the cable drum assembly, refer to the Operation & Maintenance Manual of the cable drum assembly, delivered with the machine.

4 - 98

PC8000-6E

Version 2010/1

Attachment

5 ATTACHMENT

Version 2010/1

PC8000-6E

5 -1

Face Shovel (FSA)

Attachment

5.1

FACE SHOVEL (FSA)

5.1.1

FSA OVERVIEW

Fig. 5-1

Face shovel attachment, overview

(1)

Lip with installed ground engaging tools (GET)

(2)

Bull clam bucket (clam)

(3)

Bull clam bucket (wall)

(4)

Stick

(5)

Boom

(6)

Boom cylinder

(7)

Stick cylinder

(8)

Bucket cylinder

5 -2

PC8000-6E

Version 2010/1

Attachment

5.1.2

Face Shovel (FSA)

USING THE INSTALLATION TOOLS FOR HYDRAULIC CYLINDERS

Designated use: Each hydraulic cylinder has a groove (Fig. 5-2, arrow) at each end of the cylinder body (Fig. 5-2, Pos. 1). Clamp the installation tool (Fig. 5-2, Pos. 2) on the hydraulic cylinder using the groove.

Fig. 5-2 The tools are designed to handle the attachment’s hydraulic cylinders vertically in combination with a forklift. Thereby, the forks of the forklift are inserted between the cylinder body and the scorpers (Fig. 5-3, Pos. 2). The tools’ extensions (Fig. 5-3, Pos. 1) rest on the forks of the forklift. This is the tools’ main direction of stress, indicated by "F". DANGER Use the installation tools in the proper way shown only! Cylinders may only be handled vertically when using these tools. Misuse may result in death, serious injury, or damage to the tools.

Version 2010/1

PC8000-6E

Fig. 5-3

5 -3

Face Shovel (FSA)

5.1.3

Attachment

BOOM

5.1.3.1 REMOVAL OF THE BOOM

Fig. 5-4

Boom removal

(1)

Boom

(2)

Stripper

(3)

Bush

(4)

Pin boom/superstructure

(5)

Cover

(6)

Bolt

(7)

Pin boom cylinder/superstructure

(8)

Chain hoist

(9)


5 -4

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

Special tools:

n/a


Safety harness in conformity with EN 361 Mobile elevator working platform 2 x Crane 4 x Chain hoist Oil drain pan Boom with attached stick and boom cylinders: 71,020 kg Pin boom/superstructure: 339 kg Pin boom cylinder/superstructure: 243 kg Dogman/rigger Crane operators trained in dual crane lift For further information about the needed blind plugs, refer to section 6.6 on page 6-14.

WARNING z

Always wear a safety harness when working at the attachment.

z


z


z

Park the machine on the prepared flat area and position the bucket on the ground with the stick and the bucket cylinders in vertical position (Fig. 5-5).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-5 z


z


z

Remove the stick, refer to section 5.1.4 on page 5-22.

NOTE: Leave the stick cylinders retracted and fixed to the boom. Secure them under the boom using chain hoists.

Version 2010/1

PC8000-6E

5 -5

Face Shovel (FSA)

Fig. 5-6

Attachment

Boom removal

z

For safety reasons tie the piston rods to the stick cylinder bodies with a wire rope.

z


z

Fully retract the boom cylinders.

z


z


z

Fix the boom cylinders at the boom (Fig. 5-6, Pos. 1) using chain hoists (Fig. 5-6, Pos. 8).

5 -6

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


z

Disconnect the boom arc hoses incl. grease feeding lines from the boom, refer to section 5.1.7.1 on page 5-68.


Disconnect all electric wires from the boom.

z

Remove the bolts (Fig. 5-6, Pos. 6) and the covers (Fig. 5-6, Pos. 5) securing the pins (Fig. 5-6, Pos. 4 and 7).

z

Attach the front part of the boom to a crane.

z

Remove the pins (Fig. 5-6, Pos. 7) attaching the boom cylinders to the superstructure. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

z

Lift the boom’s front side.

z

For safety reasons tie the piston rods to the boom cylinder body with a wire rope.

z

Attach the rear part of the boom to another crane.

z

Remove the pins (Fig. 5-6, Pos. 4) attaching the boom to the superstructure. WARNING


Version 2010/1

PC8000-6E

5 -7

Face Shovel (FSA)

z

Attachment

Remove the boom with attached stick cylinders and boom cylinders using two cranes, refer to Fig. 5-6. Place it on appropriate supports. WARNING

Make sure that the crane operators are trained in dual crane lift.

DANGER Risk of falling weights! Death or serious injury may result. When moving the boom, make sure that nobody steps below the lifted boom.

z

Carry out the next steps with the boom placed on the ground: z

Remove the pins of the boom cylinders, refer to section 5.1.3.3 on page 5-14 and remove the boom cylinders from the boom.

z

Remove the pins of the stick cylinders, refer to section 5.1.4.3 on page 5-30 and remove the stick cylinders from the boom.

z

Remove all provided parts and the hydraulic piping from the boom.

5 -8

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

5.1.3.2 REPLACEMENT OF THE BOOM Special tools:

n/a


Safety harness in conformity with EN 361 2 x Crane 4 x Chain hoist Mobile elevator working platform Boom with attached stick and boom cylinders: 71,020 kg Pin boom/superstructure: 339 kg Pin boom cylinder/superstructure: 243 kg Dogman/rigger Crane operators trained in dual crane lift If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals. Apply the appropriate grease on every bush and pin on assembly! z

Install new bushes (Fig. 5-7, Pos. 2) into the boom (Fig. 5-7, Pos. 1) if required, and insert new seals (Fig. 5-7, Pos. 3) into the bushes. CAUTION

There is a tolerance gap between bush and seal so that the seal can move freely within the groove. In order to avoid damage to the seals stick the seals into the grooves of the bushes with grease and center the seals in their mounting position.

Fig. 5-7

Version 2010/1

PC8000-6E

5 -9

Face Shovel (FSA)

Fig. 5-8 z

Attachment

FSA boom installation

Install all provided parts and the hydraulic piping to the boom.

NOTE: For safety reasons tie the piston rods to the cylinder bodies with wire ropes. z

Install the boom cylinders to the boom in reverse order to removal, refer to section 5.1.3.4 on page 5-19.

z

Install the stick cylinders to the boom in reverse order to removal, refer to section 5.1.4.4 on page 5-35.

NOTE: Make sure that the hydraulic hoses are already connected to the cylinders at this state. z

Fix the cylinders at the boom using chain hoists (Fig. 5-8, Pos. 8).

5 - 10

PC8000-6E

Version 2010/1

Attachment

z

Face Shovel (FSA)

Install new bushes (Fig. 5-8, Pos. 3), if required and insert new seals (Fig. 5-8, Pos. 2) into the bushes. CAUTION


z

Attach the boom to two cranes. WARNING

Before lifting the boom, make sure that the crane operators are trained in dual crane lift.

z

Lift the boom (Fig. 5-8, Pos. 1) with the boom and stick cylinders attached using two cranes.

NOTE: Lift the front part of the boom higher than the back part. DANGER Risk of falling weights! Death or serious injury may result. When moving the boom, make sure that nobody steps below the lifted boom.

z

Align the boom (Fig. 5-8, Pos. 1) with the superstructure. DANGER

Never put hands into the holes when aligning the boom to the superstructure.

z

Insert both pins (Fig. 5-8, Pos. 4) connecting the boom to the superstructure.

z

Detach the rear crane.

z

Install the covers (Fig. 5-8, Pos. 5), and bolts (Fig. 5-8, Pos. 6) to secure the pins (Fig. 5-8, Pos. 4).

z

Connect the boom arc hoses incl. the grease feeding lines to the boom, refer to section 5.1.7.1 on page 5-68.

z


z

Switch S155 to Qmin and retract the boom cylinders fully.

NOTE: Use only one engine at Qmin.

Version 2010/1

PC8000-6E

5 - 11

Face Shovel (FSA)

Fig. 5-9

Attachment

FSA boom installation

z

Remove the wire ropes from the boom cylinders.

z


z


z

Align the boom cylinders to superstructure. Move the boom up and down using the crane. Use the chain hoist (Fig. 5-9, Pos. 8) to align the boom cylinders to the superstructure. DANGER

Never put hands into the holes when aligning the boom to the superstructure.

5 - 12

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

z

Insert the pins (Fig. 5-9, Pos. 7) connecting the boom cylinders to the superstructure.

z

Lower the boom completely and detach the front crane.

z

Install the covers (Fig. 5-9, Pos. 5) and the bolts (Fig. 5-9, Pos. 6) to secure the pin (Fig. 5-9, Pos. 7).

z

Connect the electric wires to the boom.

z


z

Perform the bleeding procedure for the boom cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


z


z


z

Check for leaks and the cylinders operation.

z

Check the hydraulic oil level again and add oil if required.

Version 2010/1

PC8000-6E

5 - 13

Face Shovel (FSA)

Attachment

5.1.3.3 REMOVAL OF THE BOOM CYLINDERS

Fig. 5-10 Boom cylinder, removal and installation

5 - 14

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


Boom cylinder

(2)

Boom

(3)

Catch

(4)

Pin

(5)

Cover

(6)

Bolt

(7)

Seal

(8)

Bush

(9)

Seal

(10)

Bush

(11)

O-ring

(12)

Hydraulic hose

(13)

Bolt

(14)

Cover

(15)

Bush

(16)

Pin

(17)


(18)

Stripper

(19)

Bolt

(20)

Bush

Special tools:

Installation tool, PN 934 606 40


Safety harness in conformity with EN 361 Crane Chain hoist Forklift 10 t Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Boom cylinder: 7500 kg Pin boom cylinder/superstructure: 243 kg Pin boom cylinder/boom: 255 kg

Dogman/rigger


Version 2010/1

PC8000-6E

5 - 15

Face Shovel (FSA)

Attachment

NOTE: At first the wear of the bushes in the hydraulic cylinder should be checked, refer to the PARTS & SERVICE NEWS No. "AH08508". WARNING z


z


z


z

Park the machine on the prepared flat area with the superstructure turned by 90° and position the bucket on the ground as shown (Fig. 5-11).



z


z

Disconnect the grease feeding line (Fig. 5-12, Pos. 1) from the cover (Fig. 5-12, Pos. 2) of the boom cylinder pin at the union (Fig. 5-12, Pos. 3).

z

Disconnect the grease feeding lines from the boom cylinder(s) to be removed.

Fig. 5-11

Fig. 5-12

5 - 16

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

z

Sling the lower end of the boom cylinder (Fig. 5-13, Pos. 1) and fix it to the boom (Fig. 5-13, Pos. 2) using a chain hoist (Fig. 5-13, Pos. 6).

z

Remove the bolts (Fig. 5-13, Pos. 3) and the covers (Fig. 5-13, Pos. 4) securing the pin (Fig. 5-13, Pos. 5).

z

Remove the pin (Fig. 5-13, Pos. 5) attaching the boom cylinder to the superstructure. WARNING


Fig. 5-13 z


z


NOTE: Use only one engine at Qmin. z

For safety reasons tie the piston rod to the boom cylinder body with a wire rope.

z


z




Version 2010/1

PC8000-6E

5 - 17

Face Shovel (FSA)

z

Attachment

Disconnect the hydraulic hoses from the boom cylinder, refer to section 5.1.7.2 on page 5-72.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping and the hoses will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Lower the boom cylinder using the chain hoist until the cylinder is in vertical position.

z

Install the installation tool, PN 934 606 40 at the boom cylinders upper side, refer to section 5.1.2 on page 5-3.

z

Hold the boom cylinder by means of the installation tool using the forklift.

z


z

Remove the pin (Fig. 5-14, Pos. 4) with the catches (Fig. 5-14, Pos. 5).

z

Check the bushes (Fig. 5-14, Pos. 3) and replace if required. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling. Fig. 5-14 z

Remove the boom cylinder with the forklift.

NOTE: Use a crane to lift the cylinder from the forklift. DANGER Risk of falling weights! Death or serious injury may result. When moving the boom cylinder, make sure that nobody steps below the lifted cylinder.

z

If required, remove the pipe work, the connecting blocks, and the seals from the removed cylinder(s). Discard the seals and fit caps to the cylinder(s) openings to avoid environmental contamination.

5 - 18

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

5.1.3.4 REPLACEMENT OF THE BOOM CYLINDERS Special tools:



Safety harness in conformity with EN 361 Chain hoist Crane Fork lift 10 t Mobile elevator working platform (telescopic or articulated boom lift) Boom cylinder: 7500 kg Pin boom cylinder/superstructure: 243 kg Pin boom cylinder/boom: 255 kg

Dogman/rigger


WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals. Apply the appropriate grease on every bush and pin on assembly! z

Insert new bushes (Fig. 5-15, Pos. 3) into the boom cylinder (Fig. 5-15, Pos. 1) if required, refer to the PARTS & SERVICE NEWS No. "AH06545".

z

If required, install the pipe work, the connecting blocks, and the seals at the cylinder(s).

z

Insert new seals (Fig. 5-15, Pos. 2) into the bushes (Fig. 5-15, Pos. 3) of the boom cylinder (Fig. 5-15, Pos. 1). CAUTION


z

Fig. 5-15

For safety reasons tie the piston rod to the boom cylinder body with a wire rope.

Version 2010/1

PC8000-6E

5 - 19

Face Shovel (FSA)

Attachment

z

Install the installation tool, PN 934 606 40 at the upper end of the new boom cylinder, refer to section 5.1.2 on page 5-3.

z

Place the boom cylinder on the forklift in a vertical position so that the cylinder is supported by means of the installation tool. DANGER

Risk of falling weights! Death or serious injury may result. When moving the boom cylinder, make sure that nobody steps below the lifted boom.

z

Align the upper end of the boom cylinder with the boom using the forklift. DANGER

Never put hands into the holes when aligning the boom cylinder to the boom.

z

Insert the pin (Fig. 5-16, Pos. 4) with the catches (Fig. 5-16, Pos. 5).

z

Install the cover (Fig. 5-16, Pos. 2), and the bolts (Fig. 5-16, Pos. 1).

z

Remove the installation tool from the boom cylinder.

Fig. 5-16 z

Sling the piston rod side of the boom cylinder (Fig. 5-17, Pos. 1) and fix it to the boom (Fig. 5-17, Pos. 2) using a chain hoist (Fig. 5-17, Pos. 6).

z

Hoist the boom cylinder to a position in which the hydraulic hoses can be connected.

z

Connect the hydraulic lines to the boom cylinder, refer to section 5.1.7.2 on page 5-72.

NOTE: Always use new O-rings at the SAE–flange connections. z


z



Remove the wire ropes from the boom cylinders.

5 - 20

PC8000-6E

Fig. 5-17

Version 2010/1

Attachment

z

Face Shovel (FSA)

Extend and retract the boom cylinder (Fig. 5-17, Pos. 1) slowly at Qmin 2...3 times as far as possible to partly bleed the cylinder. WARNING

The air in the cylinder will result in slightly jerky movements of the cylinder.

z

Operate the boom cylinder slowly at Qmin and use the chain hoist to align the boom cylinders to the superstructure. DANGER

Never put hands into the holes when aligning the boom cylinder to the superstructure.

z

Insert the pin (Fig. 5-17, Pos. 5).

z


z


z

Install the covers (Fig. 5-17, Pos. 4), and the bolts (Fig. 5-17, Pos. 3) to secure the pin (Fig. 5-17, Pos. 5).

z


z


z

Perform the bleeding procedure for the boom cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


z


Version 2010/1

PC8000-6E

5 - 21

Face Shovel (FSA)

5.1.4

Attachment

STICK

5.1.4.1 REMOVAL OF THE STICK

Fig. 5-18 Stick, removal and installation

5 - 22

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


Boom

(2)

Stick

(3)

Bush

(4)

Seal ring

(5)

Catch

(6)

Pin

(7)

Ring

(8)

Cover

(9)

Bolt

(10)

Seal

(11)

Ring (welded to the stick)

(12)

Flange bush

(13)

Bush

(14)

Pin

(15)

Shackle

(16)

Bolt

(17)

Bush

Special tools:

n/a


Safety harness in conformity with EN 361 Crane 2 x Chain hoist Mobile elevator working platform (telescopic or articulated boom lift) Stick: 25,170 kg Pin stick/boom: 373 kg Pin stick cylinder/stick: 98 kg

Dogman/rigger


WARNING z


z


Version 2010/1

PC8000-6E

5 - 23

Face Shovel (FSA)

Attachment

z


z




z

Remove the bull clam bucket, refer to section 5.1.5.1 on page 5-40.

z

Hook up both stick cylinders (Fig. 5-20, Pos. 1) using chain hoists (Fig. 5-20, Pos. 2).

z

Remove the bolts (Fig. 5-20, Pos. 7) and the shackles (Fig. 5-20, Pos. 4) securing the pins (Fig. 5-20, Pos. 3) from the stick cylinders.

z

Remove the pins (Fig. 5-20, Pos. 3) from both cylinders.

Fig. 5-19

WARNING Sling the pin as soon as possible and support it using a crane to prevent the pin from falling.

z

Remove the seals (Fig. 5-20, Pos. 5) from the bushes (Fig. 5-20, Pos. 6) in the stick. Discard the seals.

z

Check the bushes (Fig. 5-20, Pos. 6) in the stick and replace them if required.

z


z

Switch S155 to Qmin and retract the stick cylinders (Fig. 5-20, Pos. 1) fully.

Fig. 5-20



z


5 - 24

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


z

Disconnect all hydraulic hoses and the grease feeding line from the stick leading to the boom, refer to section 5.1.7.3 on page 5-76.

z

Disconnect all electric wires from the stick.

z

Sling the stick (Fig. 5-21, Pos. 1) and lift it using a crane.

z

Remove the bolts (Fig. 5-21, Pos. 2) and the covers (Fig. 5-21, Pos. 3).

z

Remove the pins (Fig. 5-21, Pos. 4) with the catches (Fig. 5-21, Pos. 5). WARNING

Sling the pins as soon as possible and support them using a crane to prevent the pins from falling.

z

Remove the stick and rest it on the ground using a crane. Place it on appropriate supports. Fig. 5-21

DANGER Risk of falling weights! Death or serious injury may result. When moving the stick, make sure that nobody steps below the lifted stick.

z

Remove all provided parts and the hydraulic piping from the stick (Fig. 5-21, Pos. 1).

Version 2010/1

PC8000-6E

5 - 25

Face Shovel (FSA)

Attachment

5.1.4.2 REPLACEMENT OF THE STICK Special tools:

n/a


Safety harness in conformity with EN 361 Crane 2 x Chain hoist Mobile elevator working platform (telescopic or articulated boom lift) Stick: 25,170 kg Pin stick/boom: 373 kg Pin stick cylinder/stick: 98 kg

Dogman/rigger


WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Put the appropriate grease in every bush on assembly! z

Check the bushes (Fig. 5-22, Pos. 2) at the boom side of the stick (Fig. 5-22, Pos. 1) and replace if required.

z

Insert new seals (Fig. 5-22, Pos. 3) into the grooves of the bushes (Fig. 5-22, Pos. 2). CAUTION

There is a tolerance gap between bush and seal so that the seal can move freely within the groove. In order to avoid damage to the seals stick the seals into the grooves of the bushes with grease and center the seals in their mounting position. Fig. 5-22

5 - 26

PC8000-6E

Version 2010/1

Attachment

z

Face Shovel (FSA)

Check the bushes (Fig. 5-23, Pos. 1) at the boom (Fig. 5-23, Pos. 2) and replace if required.

Fig. 5-23 z

Install all provided parts and hydraulic piping to the stick (Fig. 5-24, Pos. 1).

z

Sling the stick (Fig. 5-24, Pos. 1) and align it to the boom using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the stick, make sure that nobody steps below the lifted stick.

DANGER Never put hands into the holes when aligning the stick to the boom.

z

Install the pins (Fig. 5-24, Pos. 4) attaching the stick (Fig. 5-24, Pos. 1) to the boom.

z

Install the catches (Fig. 5-24, Pos. 5), the covers (Fig. 5-24, Pos. 3), and the bolts (Fig. 5-24, Pos. 2) to secure the pins (Fig. 5-24, Pos. 4).

Version 2010/1

PC8000-6E

Fig. 5-24

5 - 27

Face Shovel (FSA)

Attachment

z

Bring the stick to the position shown in Fig. 5-25 using the crane.

z

Install new seals (Fig. 5-25, Pos. 5) into the bushes (Fig. 5-25, Pos. 6) in the stick. CAUTION


z


z

Switch S155 to Qmin and extend the stick cylinders to align the stick cylinders with the stick horizontally. Use the chain hoists (Fig. 5-25, Pos. 2) to align the stick cylinders with the stick vertically.

Fig. 5-25

NOTE: Use only one engine at Qmin. DANGER Never put hands into the holes when aligning the stick cylinders to the stick.

z

Install the pins (Fig. 5-26, Pos. 3).

z


z

Install the shackle (Fig. 5-26, Pos. 4) and the bolts (Fig. 5-26, Pos. 7) to secure the pins (Fig. 5-26, Pos. 3).

z


z


z


z


z


5 - 28

PC8000-6E

Fig. 5-26

Version 2010/1

Attachment

Face Shovel (FSA)


Version 2010/1

PC8000-6E

5 - 29

Face Shovel (FSA)

Attachment

5.1.4.3 REMOVAL OF THE STICK CYLINDERS

Fig. 5-27 Stick cylinder, removal and installation

5 - 30

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


Stick cylinder

(2)

Boom

(3)

Stick

(4)

Seal

(5)

O-ring

(6)

Connecting block

(7)

Pipe

(8)

Pin

(9)

Seal

(10)

Bush

(11)

Bolt

(12)

Shackle

(13)

Pin

(14)

Catch

(15)

Bolt

(16)

Cover

(17)

Ring

Special tools:

n/a


Safety harness in conformity with EN 361 2 x Chain hoist Crane Mobile elevator working platform (telescopic or articulated boom lift) Forklift 6 t Oil drain pan Stick cylinder: 4007 kg each Pin stick cylinder/boom: 225 kg Pin stick cylinder/stick: 98 kg

Dogman/rigger


WARNING Always wear a safety harness when working at the attachment.

Version 2010/1

PC8000-6E

5 - 31

Face Shovel (FSA)

Attachment

WARNING Most of the following operations require the use of men safety cages on elevator working platforms.

NOTE: At first the wear of the bushes in the hydraulic cylinders should be checked, refer to the PARTS & SERVICE NEWS No. "AH08508". z


z




z


z

Remove the grease feeding lines from the stick cylinder(s) to be removed.

z

Secure the stick cylinder (Fig. 5-29, Pos. 1) to be removed under the boom using one chain hoist at each side of the cylinder.

z

Remove the pin connecting the stick cylinder piston rod to the stick, refer to section 5.1.4.1 on page 5-22. WARNING

Sling the pin as soon as possible and support it using a crane to prevent the pin from falling when it is pulled out completely. Fig. 5-29 z


z

Switch S155 to Qmin and retract the stick cylinders (Fig. 5-29, Pos. 1) fully.


For safety reasons tie the piston rod to the cylinder body with a wire rope.

5 - 32

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

z


z




z

Disconnect the hydraulic hoses from the stick cylinder, refer to section 5.1.7.4 on page 5-82.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping and the hoses will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the bolts (Fig. 5-30, Pos. 1), the cover (Fig. 5-30, Pos. 2), the ring (Fig. 5-30, Pos. 3), and the catches (Fig. 5-30, Pos. 5), securing the pin (Fig. 5-30, Pos. 4).

z

Pull out the pin (Fig. 5-30, Pos. 4) connecting the stick cylinder to the boom.

NOTE: Pull out the pin just far enough to clear the left stick cylinder if only this cylinder needs to be removed. Only pull out the pin completely, if both cylinders need to be removed. WARNING Sling the pin as soon as possible and support it using a crane to prevent the pin from falling when it is pulled out completely. Fig. 5-30 z

Check the bushes (Fig. 5-30, Pos. 6) in the boom and replace the bushes if required.

Version 2010/1

PC8000-6E

5 - 33

Face Shovel (FSA)

z

Attachment

Lower the stick cylinder in horizontal position using the chain hoists simultaneously. Use the Forklift to take over the stick cylinder. DANGER

Risk of falling weights! Death or serious injury may result. When moving the stick cylinder, make sure that nobody steps below the lifted cylinder.

z

If required, remove the pipe work, the connecting blocks, and the seals from the removed cylinder(s). Discard the seals and fit caps to the cylinder(s) openings to avoid environmental contamination.

5 - 34

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

5.1.4.4 REPLACEMENT OF THE STICK CYLINDERS Special tools:

n/a


Safety harness in conformity with EN 361 2 x Chain hoist Crane Forklift 6 t Mobile elevator working platform (telescopic or articulated boom lift) Stick cylinder: 4007 kg each Pin stick cylinder/boom: 225 kg Pin stick cylinder/stick: 98 kg

Dogman/rigger


WARNING z


z


NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Apply the appropriate grease on every bush and pin on assembly! z

Install new bushes (Fig. 5-31, Pos. 3) into the stick cylinder (Fig. 5-31, Pos. 1) if required, refer to the PARTS & SERVICE NEWS No. "AH06545".

z

Insert new seals (Fig. 5-31, Pos. 2) into the bushes. CAUTION

There is a tolerance gap between bush and seal so that the seal can move freely within the groove. In order to avoid damage to the seals stick the seals into the grooves of the bushes with grease and center the seals in their mounting position. Fig. 5-31 z

If required, install the pipe work, the connecting blocks, and the seals at the cylinder(s).

z

For safety reasons tie the piston rod to the cylinder body with a wire rope.

Version 2010/1

PC8000-6E

5 - 35

Face Shovel (FSA)

z

Attachment

Lift the stick cylinder beneath the boom using a forklift. WARNING

Risk of falling weights! Death or serious injury may result. When moving the stick cylinder, make sure that nobody steps below the lifted cylinder.

z

Hook up two chain hoists to the underside of the boom.

z

Connect the two chain hoists to the stick cylinder bodies using one chain hoist at each side of the cylinder.

z

Pull up the stick cylinder using the chain hoists and align the stick cylinder to the boom. DANGER

Never put hands into the holes when aligning the stick cylinders to the boom.

z

Insert the pin (Fig. 5-32, Pos. 4).

NOTE: Insert the pin just far enough to hold right stick cylinder if this or both cylinders were removed. Insert the pin completely if the left stick cylinder is in mounting position. z

Install the catches (Fig. 5-32, Pos. 5), the ring (Fig. 5-32, Pos. 3), the cover (Fig. 5-32, Pos. 2), and the bolts (Fig. 5-32, Pos. 1) to secure the pin (Fig. 5-32, Pos. 4).

Fig. 5-32

5 - 36

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

z

Connect the hydraulic hoses to the stick cylinder (Fig. 5-33, Pos. 1), refer to section 5.1.7.4 on page 5-82.

z


z

Switch S155 to Qmin and retract the stick cylinder (Fig. 5-33, Pos. 1) fully.


Remove the wire ropes from the stick cylinder (Fig. 5-33, Pos. 1).

z

Extend and retract the stick cylinder (Fig. 5-33, Pos. 1) slowly at Qmin 2...3 times as far as possible to partly bleed the cylinder.

Fig. 5-33

WARNING The air in the cylinder will result in slightly jerky movements of the cylinder.

z

Operate the stick cylinder slowly at Qmin and use the chain hoist to align the stick cylinder to the stick. DANGER

Never put hands into the holes when aligning the stick cylinder to the stick.

z

Install the pin connecting the stick cylinder to the stick, refer to section 5.1.4.2 on page 5-26.

z


z


z


z


z

Perform the bleeding procedure for the stick cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


z


Version 2010/1

PC8000-6E

5 - 37

Face Shovel (FSA)

5.1.5

Attachment

BULL CLAM BUCKET

Fig. 5-34 Bull clam bucket, removal and installation

5 - 38

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


Bull clam bucket

(2)

Bush

(3)

Ring (welded to the bucket)

(4)

Pin

(5)

Axle stirrup

(6)

Catch (welded to the bucket)

(7)

Shackle

(8)

Bolt

(9)

Bush

(10)

Pin

(11)

Axle stirrup

(12)

Catch (welded to the bucket)

(13)

Shackle

(14)

Bolt

(15)

Bucket cylinder

(16)

Seal

(17

Stick

(18)

Seal fixing ring

(19)

Seal

Version 2010/1

PC8000-6E

5 - 39

Face Shovel (FSA)

Attachment

5.1.5.1 REMOVAL OF THE BULL CLAM BUCKET Special tools:

n/a


Crane Oil drain pan Bucket: 63,316 kg Pin bucket cylinder/bucket: 238 kg Pin bucket/stick: 365 kg

Dogman/rigger


z


z




z


z

Disconnect the grease feeding lines leading to the bucket.

z

Remove the cover plate (Fig. 5-36, Pos. 2) from inside the bucket (Fig. 5-36, Pos. 1) to gain access to the assembly opening.

Fig. 5-36

5 - 40

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)



z

Disconnect the hydraulic hoses from the clam cylinder distributor blocks, refer to section 5.1.7.6 on page 5-92.


Remove the seal fixing rings (Fig. 5-37, Pos. 1) from the pin (Fig. 5-37, Pos. 4) located on both sides of the bucket cylinder respectively the stick (Fig. 5-37, Pos. 3).

NOTE: Always use new seals (Fig. 5-37, Pos. 2).

Fig. 5-37

Version 2010/1

PC8000-6E

5 - 41

Face Shovel (FSA)

Attachment

Fig. 5-38 Bull clam bucket removal z

Sling the bucket cylinders (Fig. 5-38, Pos. 15) to prevent them from swinging when the pins (Fig. 5-38, Pos. 10) are removed.

z

Remove the bolts (Fig. 5-38, Pos. 14) with washers and the shackle (Fig. 5-38, Pos. 13).

5 - 42

PC8000-6E

Version 2010/1

Attachment

z

Face Shovel (FSA)

Push the pin (Fig. 5-38, Pos. 10) inwards just enough to remove the axle stirrups (Fig. 5-38, Pos. 11) from the catches (Fig. 5-38, Pos. 12).

NOTE: The catches (Fig. 5-38, Pos. 12) are welded to the bucket (Fig. 5-38, Pos. 1). z

Remove the pin (Fig. 5-38, Pos. 10) to clear the bucket cylinder (Fig. 5-38, Pos. 15). Remove the seals (Fig. 5-38, Pos. 16) when removing the pin. WARNING


z

Remove the bolts (Fig. 5-38, Pos. 8) with washers and the shackle (Fig. 5-38, Pos. 7).

z

Push the pins (Fig. 5-38, Pos. 4) inwards just enough to remove the axle stirrups (Fig. 5-38, Pos. 5) from the catches (Fig. 5-38, Pos. 6).

NOTE: The catches are welded to the bucket. Use the assembly opening (refer to Fig. 5-36) to push the pin. z

Push the pins (Fig. 5-39, Pos. 1) out of the inner pin bearing (Fig. 5-39, Pos. 2) outwards until the stick is cleared from the bucket. Remove the seals (Fig. 5-37, Pos. 2) when removing the pin.

NOTE: When the stick is cleared, the pins can remain in the outer pin bearings (Fig. 5-39, Pos. 3).

Fig. 5-39 z

Check the bushes (Fig. 5-38, Pos. 2 and 9) for wear or damage and replace if required.

z


z

Lift the boom, and move the excavator away.

z


Version 2010/1

PC8000-6E

5 - 43

Face Shovel (FSA)

Attachment

5.1.5.2 REPLACEMENT OF THE BULL CLAM BUCKET

Fig. 5-40 Bull clam bucket replacement

5 - 44

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

Special tools:

n/a


n/a Bucket: 63,316 kg Pin bucket cylinder/bucket: 238 kg Pin bucket/stick: 365 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Insert new bushes into the stick (Fig. 5-40, Pos. 17) if required! Apply the appropriate grease on every bush and pin on assembly! z

Attach the seals (Fig. 5-40, Pos. 16 and 19) to the flange of the steel bushes (Fig. 5-40, Pos. 2 and 9) installed in the bucket (Fig. 5-40, Pos. 1).

NOTE: During the installation of the stick resp. the cylinder, there is not enough space to insert the seals. z


z

Perform the bleeding procedure for the clam cylinder. Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


z


z


Version 2010/1

PC8000-6E

5 - 45

Face Shovel (FSA)

Attachment

5.1.5.3 REMOVAL OF THE BUCKET CYLINDERS

Fig. 5-41 Bucket cylinders, removal and installation

5 - 46

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


Bucket cylinder

(2)

Stick

(3)

Boom

(4)

Axle stirrup

(5)

Pin

(6)

Ring

(7)

Cover

(8)

Bolt

(9)

Bull clam bucket

(10)

Bush

(11)

Seal fixing ring

(12)

Seal

(13)

Catch

(14)

Shackle

(15)

O-ring

(16)

SAE–flange

(17)

Flange

(18)

Bush

Version 2010/1

PC8000-6E

5 - 47

Face Shovel (FSA)

Attachment

Special tools:



Safety harness in conformity with EN 361 Crane Forklift 8 t Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Bucket cylinder: 5358 kg Pin bucket cylinder/boom: 209 kg Pin bucket cylinder/bucket: 238 kg

Dogman/rigger


WARNING z


z


NOTE: At first the wear of the bushes in the hydraulic cylinder should be checked, refer to the PARTS & SERVICE NEWS No. "AH08508". z


z

Park the machine on the prepared flat area with the superstructure turned by 90° and position the bucket on the ground as shown (Fig. 5-42), bucket cylinders in vertical position.



z


z

Disconnect the grease feeding lines from the bucket cylinder(s) to be removed.

z

Install the installation tool, PN 923 828 40 at the piston rod side of the bucket cylinder, refer to section 5.1.2 on page 5-3.

z

Support the bucket cylinder by means of the installation tool using the forks of a forklift.

5 - 48

PC8000-6E

Fig. 5-42

Version 2010/1

Attachment

Face Shovel (FSA)

z

Remove the bolts (Fig. 5-43, Pos. 1), the cover (Fig. 5-43, Pos. 2), and the ring (Fig. 5-43, Pos. 3).

z

Remove the pin (Fig. 5-43, Pos. 4) with the catches (Fig. 5-43, Pos. 5) to clear the bucket cylinder from the boom. WARNING


Fig. 5-43 z


z

Switch S155 to Qmin and retract the bucket cylinder (Fig. 5-20, Pos. 1) fully.


For safety reasons tie the piston rod to the bucket cylinder body with a wire rope.

z


z




z

Disconnect the hydraulic hoses from the bucket cylinder, refer to section 5.1.7.5 on page 5-86.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping and the hoses will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination.

Version 2010/1

PC8000-6E

5 - 49

Face Shovel (FSA)

z

Attachment

Remove the seal fixing rings (Fig. 5-44, Pos. 1) from the pin (Fig. 5-44, Pos. 4) located on both sides of the bucket cylinder (Fig. 5-44, Pos. 3).

NOTE: Always use new seals (Fig. 5-44, Pos. 2).

Fig. 5-44 z

Remove the bolts (Fig. 5-45, Pos. 5) and the shackle (Fig. 5-45, Pos. 4) securing the pin (Fig. 5-45, Pos. 1).

z

Pull out the pin (Fig. 5-45, Pos. 1). Thereby remove the axle stirrups (Fig. 5-45, Pos. 2) from the catches (Fig. 5-45, Pos. 3).

NOTE: The catches are welded to the bucket.

Fig. 5-45 z

Remove the bucket cylinder using the forklift.

NOTE: Use a crane to lift the cylinder from the forklift. WARNING Risk of falling weights! Death or serious injury may result. When moving the bucket cylinder, make sure that nobody steps below the lifted cylinder.

5 - 50

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

5.1.5.4 REPLACEMENT OF THE BUCKET CYLINDERS Special tools:



Safety harness in conformity with EN 361 Crane Forklift 8 t Mobile elevator working platform (telescopic or articulated boom lift) Bucket cylinder: 5358 kg Pin bucket cylinder/boom: 209 kg Pin bucket cylinder/bucket: 238 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Apply the appropriate grease on every bush and pin on assembly!. z

z

Check the following bushes and replace them if required: z

Bushes in the boom (Fig. 5-41, Pos. 18).

z

Bushes in the bucket cylinder (Fig. 5-46, Pos. 1) and in the bucket (Fig. 5-41, Pos. 10). For replacement of the cylinders bushes refer to the PARTS & SERVICE NEWS No. "AH06545".

Insert new seals (Fig. 5-46, Pos. 2) into the bushes in the piston rod. CAUTION


z

Fig. 5-46

Attach the seals (Fig. 5-46, Pos. 3) to the flange of the steel bushes installed in the bucket.

NOTE: During the installation of the cylinder, there is not enough space to insert the seals.

Version 2010/1

PC8000-6E

5 - 51

Face Shovel (FSA)

Attachment

WARNING z


z


z

Install the installation tool, PN 923 828 40 at the piston rod side of the new bucket cylinder.

z

Sling the bucket cylinder to a crane at the piston rod side, using the installation tool as a stop for the wire rope. WARNING

Do not sling the wire rope to the installation tool.

z

Lift the bucket cylinder until it is in upright position.

z

Take over the bucket cylinder with a forklift, supporting the cylinder at the installation tool with the forks of the forklift. DANGER

Risk of falling weights! Death or serious injury may result. When moving the bucket cylinder, make sure that nobody steps below the lifted cylinder.

z

Align the bucket cylinder with the bucket using the forklift. DANGER

Never put hands into the holes when aligning the bucket cylinder to the bucket.

NOTE: Install the bucket cylinder so that the hydraulic ports at the piston rod point outward and the hydraulic ports at cylinder point to the superstructure, refer to Fig. 5-49.

5 - 52

PC8000-6E

Version 2010/1

Attachment

z

Face Shovel (FSA)

Insert the pin (Fig. 5-47, Pos. 1). Secure the pin with the axle stirrups (Fig. 5-47, Pos. 2) in the catches (Fig. 5-47, Pos. 3).

NOTE: Take care of the seals sticking on the cylinder. z

Install the shackle (Fig. 5-47, Pos. 4) and insert the bolts (Fig. 5-47, Pos. 5) with washers.

z

Remove the installation tool.

NOTE: The cylinder furthermore must be held uprightly by the forklift.

Fig. 5-47 z

Install the seal fixing rings (Fig. 5-48, Pos. 1) at the pin (Fig. 5-48, Pos. 4) located on both sides of the bucket cylinder (Fig. 5-48, Pos. 3) to fix the seals (Fig. 5-48, Pos. 2).

Fig. 5-48 z

Connect the hydraulic lines (Fig. 5-49, Pos. 2 and 3) to the bucket cylinder (Fig. 5-49, Pos. 1), refer to section 5.1.7.5 on page 5-86.

NOTE: Always use new O-rings at the SAE–flange connections.

Fig. 5-49

Version 2010/1

PC8000-6E

5 - 53

Face Shovel (FSA)

Attachment

z


z



Extend and retract the bucket cylinder slowly at Qmin 2...3 times as far as possible to partly bleed the cylinder. WARNING


z

Operate the bucket cylinder slowly at Qmin and align the bucket cylinder to the boom vertically. Use the forks of the forklift to align the stick cylinders with the boom horizontally. DANGER

Never put hands into the holes when aligning the bucket cylinder to the boom.

z

Insert the pin (Fig. 5-50, Pos. 4) with the catches (Fig. 5-50, Pos. 5).

z

Install the ring (Fig. 5-50, Pos. 3), the cover (Fig. 5-50, Pos. 2), and the bolts (Fig. 5-50, Pos. 1).

z


z


z


z

Perform the bleeding procedure for the bucket cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


z


5 - 54

PC8000-6E

Fig. 5-50

Version 2010/1

Attachment

Face Shovel (FSA)


Version 2010/1

PC8000-6E

5 - 55

Face Shovel (FSA)

Attachment

5.1.5.5 REMOVAL OF THE CLAM CYLINDERS

Fig. 5-51 Clam cylinders, removal and installation

5 - 56

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


Clam cylinder

(2)

Clam

(3)

Seal

(4)

Pin

(5)

Cover

(6)

Bolt

(7)

Bush

(8)

Seal

(9)

Bush

(10)

Hydraulic hose

(11)

O-ring

(12)

Pin

(13)

Bolt

(14)

Plate

(15)

Catch

Special tools:

n/a


Crane Oil drain pan Clam cylinder: 1475 kg Clam cylinders upper pin: 72 kg Clam cylinders lower pin: 95 kg

Dogman/rigger


z

Prepare an area of flat ground large enough to accommodate the machine boom and crane.

z

Park the machine on the prepared flat area and position the bucket horizontally on the ground (Fig. 5-52).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition.

Fig. 5-52 Version 2010/1

PC8000-6E

5 - 57

Face Shovel (FSA)

Attachment

z


z


z

Support the clam cylinder with appropriate blocks (Fig. 5-53, arrows) to fix it in its position.

z

Disconnect the grease feeding lines from the clam cylinder.

Fig. 5-53 z

Remove the bolts (Fig. 5-54, Pos. 1) and the cover (Fig. 5-54, Pos. 2) to access the pin connecting the clam cylinder to the clam.

Fig. 5-54 z


z

Pull out the pin (Fig. 5-55, Pos. 3) to clear the clam cylinder (Fig. 5-55, Pos. 2) from the clam (Fig. 5-55, Pos. 1).

z


z

Switch S155 to Qmin and retract the clam cylinder fully.

NOTE: Use only one engine at Qmin.

Fig. 5-55 WARNING Both clam cylinders are connected to the same hydraulic line, so when the cleared cylinder is fully retracted, the other cylinder will start to retract and the clam will open. Do not open the clam.

5 - 58

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

z


z




z

Disconnect the hydraulic hoses from the clam cylinder, refer to section 5.1.7.6 on page 5-92.

NOTE: When the hydraulic hoses are disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. Discard the O-rings.

z

Sling the clam cylinder at both ends.

z

Remove the bolt (Fig. 5-56, Pos. 1) and the plate (Fig. 5-56, Pos. 2).

z

Pull out the pin (Fig. 5-56, Pos. 3) using pulling bolts.

z

Remove the clam cylinder from the bucket using a crane. DANGER

Risk of falling weights! Death or serious injury may result. When moving the clam cylinder, make sure that nobody steps below the lifted cylinder.

Version 2010/1

PC8000-6E

Fig. 5-56

5 - 59

Face Shovel (FSA)

Attachment

5.1.5.6 REPLACEMENT OF THE CLAM CYLINDERS Special tools:

n/a


Crane Clam cylinder: 1475 kg Clam cylinders upper pin: 72 kg Clam cylinders lower pin: 95 kg

Dogman/rigger

If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. NOTE: When performing the installation procedures, comply to the following: Always discard used seals and install new seals! Apply the appropriate grease on every bush and pin on assembly! z

Insert new bushes (Fig. 5-57, Pos. 1) into the clam cylinder if required, refer to the PARTS & SERVICE NEWS No. "AH06545".

z

Install new seals (Fig. 5-57, Pos. 2) into the bushes (Fig. 5-57, Pos. 1). CAUTION


Fig. 5-57 z

Insert the clam cylinder into the bucket using a crane and align the cylinder with the bucket to insert the lower pin. DANGER

Never put hands into the holes when aligning the clam cylinder to the bucket.

NOTE: For easier alignment it is recommended to support the clam cylinder with appropriate blocks (Fig. 5-58, arrows) to fix it in its position. Fig. 5-58

5 - 60

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

z

Insert the pin (Fig. 5-59, Pos. 3) and install the seals. Fix the pin with the plate (Fig. 5-59, Pos. 2).

z

Secure the plate with the bolt (Fig. 5-59, Pos. 1).

Fig. 5-59 z

Connect the hydraulic hoses to the clam cylinder, refer to section 5.1.7.6 on page 5-92.

NOTE: Use new O-rings at the SAE–flange connections. z


z



Extend and retract the clam cylinder slowly at Qmin 2...3 times as far as possible to partly bleed the cylinder. WARNING


z

Operate the clam cylinder slowly at Qmin and align the cylinders piston rod to with the clam. WARNING

Never put hands into the holes when aligning the clam cylinder to the clam.

Version 2010/1

PC8000-6E

5 - 61

Face Shovel (FSA)

Attachment

z

Insert the pin (Fig. 5-60, Pos. 3) connecting the clam cylinder (Fig. 5-60, Pos. 2) and the clam (Fig. 5-60, Pos. 1).

z


z


z

Install the cover (Fig. 5-60, Pos. 4) and the bolts (Fig. 5-60, Pos. 5).

Fig. 5-60 z


z

Perform the bleeding procedure for the clam cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


z


5 - 62

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


Version 2010/1

PC8000-6E

5 - 63

Face Shovel (FSA)

5.1.6

Attachment

GROUND ENGAGING TOOLS (GET)

Fig. 5-61 GET

5 - 64

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


Shroud

(2)

Toplok boss

(3)

Wedge

(4)

Point (tooth)

(5)

Wedge

(6)

Tooth adapter (centre/corner)

(7)

Pin

(8)

Wear plate

(9)

Base plate

(10)

Wear cap

(11)

Spool

As ground engaging tools, the ESCO POSILOK Tooth System is used. Up to now, there is no approval for other tooth systems by KOMATSU.

Version 2010/1

PC8000-6E

5 - 65

Face Shovel (FSA)

Attachment

5.1.6.1 REMOVAL AND REPLACEMENT OF THE GET Special tools:

POSILOK Pin removal tool: PN 793 502 73 POSILOK Lifting tool: PN 793 503 73


ESCO POSILOK Tooth System S145 Forklift (if no lifting tool is available) Point (tooth): 362 kg (ESCO) Shroud: 245 kg (ESCO) Tooth adapter: 91 kg (ESCO)

Dogman/rigger


CAUTION Hazard of injuries from splinters! When working on the locking pins, always wear hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep people not directly involved well out of the way.

z

Prepare an area of flat ground large enough to accommodate the machine, bucket and a forklift.

z

Park the machine on the prepared flat ground area and position the bucket in an appropriate height for work.



z

For removing and installing the ESCO Tooth System, refer to PARTS & SERVICE NEWS No. "AH03510".

NOTE: Use a forklift to remove and install the GET.

5 - 66

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


Version 2010/1

PC8000-6E

5 - 67

Face Shovel (FSA)

5.1.7

Attachment

HYDRAULIC HOSES AT THE FACE SHOVEL ATTACHMENT

5.1.7.1 SUBSTITUTE THE BOOM ARC HOSES

Fig. 5-62 Boom arc hoses, removal and installation

5 - 68

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


Hose clamp

(2)

Clamp line

(3)

Nut

(4)

Distribution block

(5)

Hydraulic pipe (to manifold)

(6)

Hydraulic hose (boom arc hose)

(7)

Bolt

(8)

O-ring

(9)

Hydraulic pipe (on boom)

(10)

Chain

Special tools:

n/a


Safety harness in conformity with EN 361 Crane Oil drain pan Boom arc hose (depending on type): 25...30.5 kg

Dogman/rigger

Observe the safety hints for hydraulic hose installation, refer to section 2.2.6 on page 2-22. If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10. For further information about the needed blind plugs, refer to section 6.6 on page 6-14.

WARNING Always wear a safety harness when working at the attachment.

Version 2010/1

PC8000-6E

5 - 69

Face Shovel (FSA)

Attachment

z


z

Park the machine on the prepared flat area with the stick cylinder fully retracted and position the bucket horizontally on the ground (Fig. 5-63).

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-63

Fig. 5-64 Boom arc hoses, removal and installation

5 - 70

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

z


z


z

Open the hose clamps (Fig. 5-64, Pos. 1) and clear the hydraulic hose (Fig. 5-64, Pos. 6) to be removed from the clamp lines (Fig. 5-64, Pos. 2). WARNING



z

Sling the hydraulic hose (Fig. 5-64, Pos. 6) to be removed.

z

Remove the bolts (Fig. 5-64, Pos. 7) and disconnect the SAE–flanges from the hydraulic tube (Fig. 5-64, Pos. 5) at the distributor block (Fig. 5-64, Pos. 4) and from the hydraulic tube (Fig. 5-64, Pos. 9) at the boom.


Remove the hydraulic hose using a crane.

z

Replace the boom arc hoses by new ones and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-64, Pos. 8) at the SAE–flange connections. z

Substitute the other boom arc hoses if required, using the same procedure.

z

Perform the bleeding procedure for all cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z

Check hydraulic oil level again and add oil if required.

Version 2010/1

PC8000-6E

5 - 71

Face Shovel (FSA)

Attachment

5.1.7.2 SUBSTITUTE THE BOOM CYLINDER HOSES

Fig. 5-65 Boom cylinder hoses, removal and installation

5 - 72

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


Hydraulic hose

(2)

Hydraulic hose

(3)

Bolt

(4)

O-ring

(5)

Ring

(6)

Boom cylinder

Special tools:

n/a


Safety harness in conformity with EN 361 Crane Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Boom cylinder hose: 24 kg (each)

Dogman/rigger


WARNING z


z


z


z


Fig. 5-66

NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Version 2010/1

PC8000-6E

5 - 73

Face Shovel (FSA)

Attachment

Fig. 5-67 Boom cylinder hoses, removal and installation

5 - 74

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

z


z




z

Sling the hydraulic hose (Fig. 5-67, Pos. 1 or 2) to be removed.

z

Remove the bolts (Fig. 5-67, Pos. 3) and disconnect the SAE–flanges from the boom cylinder (Fig. 5-67, Pos. 6) and from the hydraulic tube at the boom.



z

Replace the boom cylinder hoses by new ones and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-67, Pos. 4) and the rings (Fig. 5-67, Pos. 5) at the SAE–flange connections. z

Substitute the other boom cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the boom cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


Version 2010/1

PC8000-6E

5 - 75

Face Shovel (FSA)

Attachment

5.1.7.3 SUBSTITUTE THE STICK ARC HOSES

Fig. 5-68 Stick arc hoses, removal and installation

5 - 76

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


Hydraulic hose

(2)

Hose clamp line

(3)

Bolt

(4)

O-ring

(5)

Ring

(6)

Hydraulic tube

Special tools:

n/a


Safety harness in conformity with EN 361 Crane Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Stick arc hose: 30...31 kg

Dogman/rigger


WARNING z


z


NOTE: In case that two hose clamp lines (Fig. 5-68, Pos. 2) are installed, KOMATSU recommends the replacing of the hydraulic lines on the stick and the boom and the hydraulic hoses between stick and boom (stick arc hoses). Follow the instructions given in the PARTS & SERVICE NEWS No. "AH08516" resp. No. "AH08532".

Version 2010/1

PC8000-6E

5 - 77

Face Shovel (FSA)

Attachment

Fig. 5-69 Stick arc hoses, removal and installation

5 - 78

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

z


z




z


z

Remove the hose clamp lines (Fig. 5-69, Pos. 2).

z


Fig. 5-70



z

Remove the bolts (Fig. 5-69, Pos. 3) and disconnect the SAE–flanges from the hydraulic tubes (Fig. 5-69, Pos. 6).



z

Replace the stick arc hoses by new ones and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-69, Pos. 4) and the rings (Fig. 5-69, Pos. 5) at the SAE–flange connections.

Version 2010/1

PC8000-6E

5 - 79

Face Shovel (FSA)

Attachment

z

Substitute the other stick arc hoses if required, using the same procedure.

z

Perform the bleeding procedure for the bucket and clam cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


5 - 80

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


Version 2010/1

PC8000-6E

5 - 81

Face Shovel (FSA)

Attachment

5.1.7.4 SUBSTITUTE THE STICK CYLINDER HOSES

Fig. 5-71 Stick cylinder hoses, removal and installation (1)

Hydraulic hose

(2)

Hydraulic hose

(3)

Bolt

(4)

O-ring

(5)

Ring

5 - 82

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

Special tools:

n/a


Safety harness in conformity with EN 361 Forklift Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Stick cylinder hose (depending on length): 18.5 kg

Dogman/rigger


WARNING z


z


z


z




z


Version 2010/1

PC8000-6E

5 - 83

Face Shovel (FSA)

Attachment

Fig. 5-73 Stick cylinder hoses, removal and installation

5 - 84

PC8000-6E

Version 2010/1

Attachment

z

Face Shovel (FSA)

Sling the hydraulic hose (Fig. 5-73, Pos. 1 or 2) to be removed using a forklift. WARNING



z

Remove the bolts (Fig. 5-73, Pos. 3) and disconnect the SAE–flanges.

NOTE: When the hydraulic hose is disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the openings with blind plugs to avoid contamination. z

Remove the hydraulic hose using a forklift.

z

Replace the stick cylinder hoses by new ones and carry out installation in reverse order to removal.


Substitute the other stick cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the stick cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


Version 2010/1

PC8000-6E

5 - 85

Face Shovel (FSA)

Attachment

5.1.7.5 SUBSTITUTE THE BUCKET CYLINDER HOSES

Fig. 5-74 Bucket cylinder hoses, removal and installation (1)

Hydraulic hose

(2)

Hydraulic hose

(3)

Bolt

(4)

O-ring

(5)

Ring

(6)

Intermediate flange

(7)

Bucket cylinder

(8)

Stick

5 - 86

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

Special tools:

n/a


Safety harness in conformity with EN 361 Crane Mobile elevator working platform (telescopic or articulated boom lift) Oil drain pan Bucket cylinder hose (depending on length): 31...34 kg

Dogman/rigger


WARNING z


z


NOTE: In case that two hose clamp lines (Fig. 5-68, Pos. 2) are installed, KOMATSU recommends the replacing of the hydraulic lines on the stick and the boom and the hydraulic hoses between stick and boom (stick arc hoses). Follow the instructions given in the PARTS & SERVICE NEWS No. "AH08516" resp. No. "AH08532". z


z


NOTE: If the ground condition is too poor to guarantee safe and stable stand of the machine and the additional working equipment (crane, mobile working platforms, forklift, etc.), make sure that the machine is moved to any location with appropriate ground condition. Fig. 5-75

Version 2010/1

PC8000-6E

5 - 87

Face Shovel (FSA)

Attachment

Fig. 5-76 Bucket cylinder hoses, removal and installation z


z


5 - 88

PC8000-6E

Version 2010/1

Attachment

z

Face Shovel (FSA)

Sling the hydraulic hose (Fig. 5-76, Pos. 1 or 2) to be removed. WARNING



z

Remove the bolts (Fig. 5-76, Pos. 3) and disconnect the SAE–flanges. z

Remove the intermediate flange (Fig. 5-76, Pos. 6) from the cylinder when removing the bucket cylinder hose (Fig. 5-76, Pos. 1) on the piston rod side of the bucket cylinder (Fig. 5-76, Pos. 7).


Remove the hydraulic hose using a crane and replace the bucket cylinder hose by a new one.

NOTE: Always replace the O-rings (Fig. 5-76, Pos. 4) and the rings (Fig. 5-76, Pos. 5) at the SAE–flange connections.

Version 2010/1

PC8000-6E

5 - 89

Face Shovel (FSA)

Attachment

z

Connect the hydraulic lines (Fig. 5-77, Pos. 2 and 3) to the bucket cylinder (Fig. 5-77, Pos. 1).

z


NOTE: When connecting the hydraulic hose (Fig. 5-77, Pos. 2) at the piston rod observe the next step.

Fig. 5-77 z

The SAE–flange at the piston rod of the bucket cylinder must be mounted in an angle of 45°.

Fig. 5-78 z

Substitute the other bucket cylinder hoses if required, using the same procedure.

z

Perform the bleeding procedure for the bucket cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


5 - 90

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


Version 2010/1

PC8000-6E

5 - 91

Face Shovel (FSA)

Attachment

5.1.7.6 SUBSTITUTE THE CLAM CYLINDER HOSES The clam cylinder hose set contains two hydraulic hoses at the stick and four (two for each cylinder) hydraulic hoses at the clam cylinders. Substitute the clam cylinder hoses at the stick

Fig. 5-79 Clam cylinder hoses at stick, removal and installation (1)

Hydraulic hose

(2)

Bolt

(3)

O-Ring

(4)

Ring

5 - 92

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)

Special tools:

n/a


Safety harness in conformity with EN 361 Mobile elevator working platform (telescopic or articulated boom lift) Forklift Oil drain pan Clam cylinder hose: 30 kg

Dogman/rigger


WARNING z


z


z


z




z


z


Version 2010/1

PC8000-6E

5 - 93

Face Shovel (FSA)

Attachment

Fig. 5-81 Clam cylinder hoses at stick, removal and installation WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.


5 - 94

PC8000-6E

Version 2010/1

Attachment

z

Face Shovel (FSA)

Remove the bolts (Fig. 5-81, Pos. 2) and disconnect the SAE–flanges.


Remove the hydraulic hose using a forklift.

z

Replace the clam cylinder hose by a new one and carry out installation in reverse order to removal.


Substitute the other clam cylinder hose if required, using the same procedure.

z

If required, substitute the clam cylinder hoses at the clam cylinders as described in the next section on on page 5-96.

z

Perform the bleeding procedure for the clam cylinders. Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


Version 2010/1

PC8000-6E

5 - 95

Face Shovel (FSA)

Attachment

Substitute the clam cylinder hoses at the cylinders

Fig. 5-82 Clam cylinder hoses, removal and installation

5 - 96

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


Hydraulic hose

(2)

Hydraulic hose

(3)

Hydraulic hose

(4)

Hydraulic hose

(5)

Bolt

(6)

O-ring

(7)

Distributor block

(8)

Clam cylinder

Special tools:

n/a


Oil drain pan Clam cylinder hose (depending on length): 9 ...14 kg

Dogman/rigger


z


z



z


Fig. 5-83


Version 2010/1

PC8000-6E

5 - 97

Face Shovel (FSA)

Attachment

Fig. 5-84 Clam cylinder hoses, removal and installation WARNING Hot hydraulic oil! Do not carry out the following work on a hot machine. Wait until the temperature of the hydraulic oil is below 50 °C. Disobedience may result in personal injury from heated oil.

5 - 98

PC8000-6E

Version 2010/1

Attachment

Face Shovel (FSA)


z

Remove the bolts (Fig. 5-84, Pos. 5) and disconnect the SAE–flanges from the distributor block (Fig. 5-84, Pos. 7) and from the clam cylinder (Fig. 5-84, Pos. 8).


Replace the hydraulic hoses (Fig. 5-84, Pos. 1 to 4).

z

Replace the clam cylinder hoses by a new one and carry out installation in reverse order to removal.

NOTE: Always replace the O-rings (Fig. 5-84, Pos. 6) at the SAE–flange connections. z

Perform the bleeding procedure for the clam cylinder(s). Refer to PARTS & SERVICE NEWS No. "AH06524".

z


z


z


Version 2010/1

PC8000-6E

5 - 99

Metering valves (grease injectors) at the attachment

5.2

Attachment

METERING VALVES (GREASE INJECTORS) AT THE ATTACHMENT

Fig. 5-85 Position of the grease injectors at the FSA attachment

5 - 100

PC8000-6E

Version 2010/1

Attachment



Indicator stem

(2)

Output adjusting screw

(3)

Boom

(4)

Stick

(5)

Bucket

(6)

Metering valve group on the boom

(7)

Metering valves on the bucket

(8)

Metering valve group on the stick

5.2.1

CHECK THE OPERATION OF THE METERING VALVES (GREASE INJECTORS)

Check the operation of all metering valves (Fig. 5-85, Pos. 6...8) on the attachment visually, by watching the cycle indicator stem (Fig. 5-85, Pos. 1) while operating the central lubrication system manually. The stem must move in and out one time in a complete lubrication cycle. NOTE: Remember the timing setting which may cause a delay of up to 11 minutes, before a manual lubrication loop may start after its release. If in doubt, refer to the relating timing diagram in your flowchart. If any indicator stem does not move during a lubrication cycle, the grease supply to the lubrication point of the respective valve is interrupted or clogged. NOTE: There are two types of metering valves installed: type "SL1” and type “SL11”.

Version 2010/1

PC8000-6E

5 - 101


5.2.2

Attachment

REMOVAL OF THE METERING VALVES (GREASE INJECTORS)

Special tools:

n/a


Safety harness in conformity with EN 361 Mobile elevator working platform

WARNING z


z

The work requires the use of men safety cages on elevator working platforms.

z

Prepare an area of flat ground large enough to accommodate the machine and mobile elevator working platform.

z

Park the machine on the prepared flat area and position the attachment in the "defined position" (Fig. 5-86).


Isolate the machine according to local regulations. Fig. 5-86

NOTE: It is described how to remove metering valves at the boom exemplarily, all other metering valves at the attachment are removed analogously. z

Disconnect all grease lines (Fig. 5-87, Pos. 2) from the metering valve assembly (Fig. 5-87, Pos. 5).

z

Disconnect the grease feeding line at the union (Fig. 5-87, Pos. 3).

z

Remove the bolts (Fig. 5-87, Pos. 4) and remove the metering valve assembly (Fig. 5-87, Pos. 5) from the boom (Fig. 5-87, Pos. 1).

Fig. 5-87

5 - 102

PC8000-6E

Version 2010/1

Attachment

z


Remove the adapter bolt (Fig. 5-88, Pos. 2) and remove the valve housing (Fig. 5-88, Pos. 1) from the metering valve assembly (Fig. 5-88, Pos. 4).

Fig. 5-88

5.2.3

REPLACEMENT OF THE METERING VALVES (GREASE INJECTORS)

Special tools:

n/a


Safety harness in conformity with EN 361 Mobile elevator working platform If there is nothing mentioned explicitly, tighten all bolts according to ISO, refer to section 6.5 on page 6-10.

WARNING z


z

The work requires the use of men safety cages on elevator working platforms.

z


z

Use new seals (Fig. 5-88, Pos. 3) at the valve housing (Fig. 5-88, Pos. 1) and at the adapter bolt (Fig. 5-88, Pos. 2).

z

Check the metering valves at the attachment for proper operation, refer to section 5.2.1 on page 5-101.

NOTE: Remember the timing setting which may cause a delay of up to 11 minutes, before a manual lubrication loop may start after its release. If in doubt, refer to the relating timing diagram in your flowchart.

Version 2010/1

PC8000-6E

5 - 103

Cylinder bypass test

5.3

Attachment

CYLINDER BYPASS TEST

Special tools:

n/a Safety harness in conformity with EN 361 Mobile elevator working platform Infrared thermometer Oil drain pan

Additional equipment: Hydraulic hose with 2" 6000 PSI SAE–flange The SAE–flange size depends on the cylinder flange size, the hose should be long enough to lead from the respective cylinder to an oil pan. For further information about the needed blind plugs, refer to section 6.6 on page 6-14. The cylinder bypass test can be performed to check if a hydraulic cylinder has an internal leakage. NOTE: A cylinder with an internal leakage also has a higher temperature (at working temperature of the machine) than a hydraulic cylinder which has no internal leakage. WARNING Always wear a safety harness when working at the attachment.

NOTE: First check the hydraulic cylinder temperature using an infrared thermometer if an internal leakage is assumed. If the temperature is not higher than the temperature of the other cylinders, another reason e.g. leakage of a valve may be the reason for loosing pressure. If the temperature is higher than the temperature of the other cylinders, perform the following steps: z


z



5 - 104

PC8000-6E

Version 2010/1

Attachment


DANGER Danger of hydraulic pressure. May result in blindness, serious injury, permanent disfigurement, or scaring. The hydraulic system may be pressurized. Make sure that the pressure is relieved before any hydraulic lines will be removed.

z

Disconnect the hydraulic hose from the piston rod side of the respective cylinder (Fig. 5-89, Pos. 2).

NOTE: When the hydraulic hose is disconnected, the oil inside the piping will flow out. Catch it in an oil pan. Cap the hydraulic hose with a blind plug to avoid contamination. z

Connect a hydraulic hose (Fig. 5-89, Pos. 1) to the piston rod side of the cylinder. Put the open end of the hose into an oil pan.

z


z


Fig. 5-89

NOTE: Use only one engine at Qmin. WARNING Make sure that nobody is at close range of the hydraulic hose’s open end when extending the cylinder.

z

Fully extend the hydraulic cylinder at Qmin.

NOTE: The oil inside the cylinder will flow out of the hydraulic hose (Fig. 5-89, Pos. 1) connected to the piston rod side of the cylinder. Catch it in the oil pan. z

When the piston of the cylinder reaches its mechanical stop, continue to extend the cylinder.

If the cylinder has an internal leakage, some oil will continuously flow out of the hydraulic hose (Fig. 5-89, Pos. 1) connected to the piston rod side of the cylinder. If the cylinder has no internal leakage, oil will stop flowing out of the hydraulic hose (Fig. 5-89, Pos. 1).

Version 2010/1

PC8000-6E

5 - 105


Attachment


5 - 106

PC8000-6E

Version 2010/1

Service information

6 SERVICE INFORMATION

Version 2010/1

PC8000-6E

6 -1

Fluids and lubricants

6.1

Service information

FLUIDS AND LUBRICANTS

Due to extremely different environmental and working conditions for the excavator as well as special customized approvals for lubricants it is not possible to get a general conclusion about the used fluids and lubricants. Therefore, no lubrication or other fluids are listed at this point in this R&R-Manual. NOTE: For proper fluids and lubricants refer to the Service Manual of your machine.

6 -2

PC8000-6E

Version 2010/1

Service information

6.2

Filling capacities

FILLING CAPACITIES

NOTE: Capacities listed below are approximate values. For proper checking use level plugs, dipsticks, and inspection openings, provided for this purpose and refer to the service manual of the excavator. Units or system

Liters (approximate)


8350

Complete hydraulic system

11500

Pump distributor gear (PTO), each

*1

1.5*1

Main hydraulic pumps, drive shaft housing Slew gear (L&S), each

42

Motor adapter housing

0.6

Slew gear (Siebenhaar), each

60

Motor adapter housing

*1

Brake housing

0.2 390*1

Travel gearbox Motor adapter housing

0.5*1

Travel brake housing

0.2*1 250*1

Final drive housing Carrier rollers

*2

Track rollers

*2

Guide wheel

3.2

NOTE: *1) Fill up to level gauge marking, do not overfill! *2) Fill up to the specified level, refer to section 4.2.12 on page 4-63.

Version 2010/1

PC8000-6E

6 -3

Work instructions

Service information

6.3

WORK INSTRUCTIONS

6.3.1

REMOVE / INSTALL THE CRAWLER CARRIER

Special tools:


NOTE: Fig. 6-1 shows the following: (Fig. 6-1, Pos. 1) Hydraulic wrench PN 793 374 73. (Fig. 6-1, Pos. 2) Special wrench socket PN 793 376 73. (Fig. 6-1, Pos. 3) Electro-hydraulic pump set PN 795 922 73 (picture as example). For information about the Electro-hydraulic pump set, refer to chapter 9 "Supplier’s documentation", "AVANTI HYTORQUE".

Fig. 6-1

6 -4

PC8000-6E

Hydraulic torque wrench

Version 2010/1

Service information

Weight tables

6.4

WEIGHT TABLES

6.4.1

SUPERSTRUCTURE Part or assembly

Weight

Service crane MKG

2050 kg

Roof plate "cooling air intake"

175 kg

Roof plate "motor"

85 kg

Roof plate "PTO"

165 kg

Roof plate "main pumps"

175 kg

Front roof plate

162 kg

Front roof frame

310 kg

Front wall (front roof)

136.5 kg

Battery

62 kg

Electric motor

5600 kg

Capacitor assembly

50 kg

Coupling assembly

38 kg

Cover ring

94 kg

Main pump assembly with flanged gear pump

524 kg

PTO oil pump (auxiliary pump)

34 kg

Oil circulation pump (auxiliary pump)

34 kg

PTO (pump distributor gearbox)

2450 kg

Control- and filter plate assembly

237 kg

Hydraulic oil cooler fan drive pump

74 kg

Additional hydraulic oil cooler fan assembly

104 kg

Additional hydraulic oil cooler fan

17 kg

Additional hydraulic oil cooler fan adapter

3 kg

Additional hydraulic oil cooler fan cross-head

44 kg

Additional hydraulic oil cooler fan motor

10 kg

Additional hydraulic oil cooler

230 kg

Additional hydraulic oil cooler frame

1300 kg

Hydraulic oil cooler fan assembly

262 kg

Hydraulic oil cooler fan

78 kg

Hydraulic oil cooler fan mounting assembly

262 kg

Hydraulic oil cooler fan motor

49 kg

Hydraulic oil cooler fan support assembly

61 kg

Version 2010/1

PC8000-6E

Remark

each

each

each element

6 -5

Weight tables

Service information

Part or assembly

Weight

Remark

Hydraulic oil cooler fan bar

74 kg

Hydraulic oil cooler

230 kg

Hydraulic oil cooler frame incl. Hydraulic oil coolers

7320 kg

Pilot oil pump

34 kg

Main gate valve

54 kg

Hydraulic oil reservoir incl. Back pressure valve

7170 kg

Main control valve block incl. ACVs & SRVs

683 kg

High pressure filter

50 kg

Single anti cavitation valve on manifold

32 kg

Double anti cavitation valve on manifold

50 kg

Throttle check valve on manifold (long version)

31 kg

Throttle check valve on manifold (short version)

28 kg

Manifold incl. ACVs & SRVs

1925 kg

Manifold without ACVs & SRVs

725 kg

Slew gear

1700 kg

Siebenhaar

Slew gear

1880 kg

L&S

Swing motor

120 kg

Swing motor with attached slew service brake valve

330 kg

Bearing ring of the slew parking brake assembly

28.5 kg

L&S

Slew parking brake

115 kg

Siebenhaar

Slew brake valve

110 kg

Swing circle

16,300 kg

Pinion cover

1.2 kg

Lubrication pinion assembly

15 kg

Double lubrication pump station

412 kg

Tripple lubrication pump station

618 kg

Lubrication pump

28 kg

Operator's cab

3785 kg

Viscous mount

4 kg

Absorber plate incl. 2 viscous mount

12 kg

Absorber plate incl. 3 viscous mounts

18 kg

Front window

112 kg

Operator's seat

62 kg


5410 kg

6 -6

PC8000-6E

each element

FSA

Version 2010/1

Service information

Weight tables

Part or assembly

Weight

Emergency ladder

68 kg

Platform

135 kg

Support frame

987 kg

Access ladder

162 kg

Access ladder cylinder

23 kg

Counterweight

54,000 kg

Superstructure complete with swing circle

298,000 kg

Superstructure without counterweight and attachment

202,000 kg


7000 kg

Platform assembly at the high voltage switch cabinet

235 kg

Slip ring unit

255 kg

Version 2010/1

PC8000-6E

Remark

Special

6 -7

Weight tables

Service information

6.4.1.1 UNDERCARRIAGE Part or assembly

Weight

Remark

Track group 1500 mm

50,000 kg

Pin between track shoes (track group 1500 mm)

28 kg

Track group 1900 mm

56,000 kg

Pin between track shoes (track group 1900 mm)

30 kg

Sprocket assembly

6164 kg 6357 kg

Hollow shaft

790 kg

Drive shaft

1140 kg

Guide wheel assembly

4938 kg

Low pressure accumulator

12 kg

High pressure accumulator

23 kg

Track tensioning valve block

46 kg

Hydraulic hoses of the track tensioning system

2...15 kg

Travel brake valve block

80 kg

Track tensioning cylinder

570 kg

Travel motor

161 kg

Travel parking brake

44 kg

Travel gearbox

7350 kg

Carrier roller assembly

294 kg

Track roller assembly

925 kg

Car body without crawler carrier

55,000 kg

Mounting pins

Crawler carrier assembly without track group

46,000 kg

Mounting pins

Car body without crawler carrier

59,000 kg

Bolted type

Crawler carrier assembly without track group

55,000 kg

Bolted type

Rotary joint

261 kg

Cable drum assembly (empty)

10,000 kg

6 -8

PC8000-6E

Standard Oversize

depending on type

Version 2010/1

Service information

Weight tables

6.4.1.2 FACE SHOVEL ATTACHMENT (FSA) Part or assembly

Weight

Remark

Boom with attached stick and boom cylinders

71,020 kg

Boom

48,600 kg

Pin boom/superstructure

339 kg

Pin boom cylinder/boom

255 kg

Pin boom cylinder/superstructure

243 kg

Boom cylinder

7500 kg

Stick

25,170 kg

Pin stick/boom

373 kg

Stick cylinder

4007 kg

Pin stick cylinder/stick

98 kg

Pin stick cylinder/boom

225 kg

Bucket

63,316 kg

Pin bucket cylinder/bucket

238 kg

Pin bucket/stick

365 kg

Bucket cylinder

5358 kg

Pin bucket cylinder/boom

209 kg

Clam cylinder

1475 kg

Upper pin at clam cylinder

72 kg

Lower pin at clam cylinder

95 kg

Point (tooth) (ESCO)

362 kg

Shroud (ESCO)

245 kg

Tooth adapter (ESCO)

91 kg

Boom arc hose

25...30.5 kg

depending on type

Boom cylinder hose

24 kg

each

Stick arc hose

30...31 kg

Stick cylinder hose

18.5 kg

each

Bucket cylinder hose

31...34 kg

depending on length

Clam cylinder hose at stick

30 kg

each

Clam cylinder hose at clam cylinder

9 ...14 kg

depending on length

Version 2010/1

PC8000-6E

6 -9

Torque charts according to ISO

Service information

6.5

TORQUE CHARTS ACCORDING TO ISO

6.5.1

METRIC STANDARD THREAD

Bolt diameter

Wrench size [mm]

Tightening torque [Nm] Bolt quality grades

Metric regular 8.8

10.9

12.9

M 8

13

6

21

31

36

M 10

17

8

43

63

73

M 12

19

10

74

108

127

M 14

22

12

118

173

202

M 16

24

14

179

265

310

M 18

27

14

255

360

425

M 20

30

17

360

510

600

M 22

32

17

485

690

810

M 24

36

19

620

880

1030

M 27

41

19

920

1310

1530

M 30

46

22

1250

1770

2080

M 33

50

24

1690

2400

2800

M 36

55

27

2170

3100

3600

M 39

60

2800

4000

4700

M 42

65

3500

4950

5800

M 45

70

4350

6200

7200

M 48

75

5200

7500

8700

M 52

80

6700

9600

11200

M 56

85

8400

12000

14000

M 60

90

10400

14800

17400

M 64

95

12600

17900

20900

M 68

100

15200

21600

25500

32

35

41

46

NOTE: Threads and bolts must be greased carefully with grease KP2K. Contact surfaces which should be screwed together must be free of grease.

6 - 10

PC8000-6E

Version 2010/1

Service information

6.5.2


METRIC FINE THREAD

Bolt diameter

Wrench size [mm]

Tightening torque [Nm] Bolt quality grades

Metric fine

8.8

10.9

12.9

M 8 x 1.0

13

6

23

33

39

M 10 x 1.0

17

8

48

70

82

M 12 x 1.25

19

10

81

119

139

M 14x1.5

22

12

127

187

219

M 16 x 1.5

24

14

191

280

330

M 18 x 2.0

27

14

270

385

450

M 20 x 2.0

30

17

380

540

630

M 22 x 2.0

32

17

510

720

850

M 24 x 2.0

36

19

680

960

1130

M 27 x 2.0

41

19

990

1410

1650

M 30 x 2.0

46

22

1380

1960

2300

M 33 x 2.0

50

24

1850

2650

3100

M 36 x 3.0

55

27

2300

3250

3850

M 39 x 3.0

60

3000

4200

4950

M 42 x 3.0

65

3750

5300

6200

M 45 x 3.0

70

4600

6600

7700

M 48 x 3.0

75

5700

8100

9500

M 52 x 3.0

80

7300

10400

12100

M 56 x 4.0

85

8900

12600

14800

M 60 x 4.0

90

11000

15600

18300

M 64 x 4.0

95

13300

19000

22200

M 68 x 4.0

100

16100

22900

27000

32

35

41

46

NOTE: Threads and bolts must be greased carefully with grease KP2K. Contact surfaces which should be screwed together must be free of grease. CAUTION Bolts at the slew rings have different torques, refer to Service NEWS No. "AH00511" last edition!

Version 2010/1

PC8000-6E

6 - 11


Service information

6.5.3

SAE FLANGE CONNECTIONS

Fig. 6-2

Torques for SAE–flange connections

6 - 12

PC8000-6E

Version 2010/1

Service information



Version 2010/1

PC8000-6E

6 - 13

Blind plugs

Service information

6.6

BLIND PLUGS

6.6.1

DUMMY PLATES FOR SAE–FLANGES

Fig. 6-3

Forms / types of dummy plates for SAE–flanges Up to 3000 PSI

6 - 14

SAE size

Form / type according to Fig. 6-36-3

PN

DN (hose / pipe)

1/2"

A

506 521 98

12

3/4"

A

506 583 98

20

1 1/4"

A

506 584 98

32

1 1/2"

A

506 522 98

40

2"

A

506 523 98

50

2 1/2"

A

506 585 98

65

3"

A

512 570 98

80

3/4"

B

516 826 98

20

1 1/4

B

517 479 98

32

1 1/2"

B

506 528 98

40

2"

B

506 529 98

50

2 1/2"

B

506 530 98

65

3"

B

512 571 98

80

PC8000-6E

Version 2010/1

Service information

Blind plugs

Up to 6000 PSI

SAE size

Form / type according to Fig. 6-36-3

PN

DN (hose / pipe)

3/4"

A

506 580 98

20

1"

A

506 519 98

25

1 1/4"

A

506 520 98

32

1 1/2"

A

506 581 98

40

2"

A

506 582 98

50

1"

B

506 524 98

25

1 1/4"

B

506 525 98

32

1 1/2"

B

506 526 98

40

2"

B

506 527 98

50

1 1/4"

C

516 499 98

32

1 1/2"

C

509 375 98

40

2"

C

509 376 98

50

Version 2010/1

PC8000-6E

6 - 15

Blind plugs

6.6.2

Service information

CLASSIFICATION OF THREADS TO THE NOMINAL WIDTH Heavy class (up to 6000 PSI)

Light class (up to 3000 PSI)

Size

Ra

DN

Ra

DN

M 12 x 1.5

-

-

6

5

M 14 x 1.5

-

-

8

6

M 16 x 1.5

8

5

10

8

M 18 x 1.5

10

6

12

10

M 20 x 1.5

12

8

-

-

M 22 x 1.5

14

10

15

12

M 24 x 1.5

16

12

-

-

M 26 x 1.5

-

-

18

16

M 30 x 1.5

-

-

-

-

M 30 x 2

20

16

22

20

M 36 x 2

25

20

28

25

M 38 x 1.5

-

-

-

-

M 42 x 2

30

25

-

-

M 45 x 1.5

-

-

-

-

M 45 x 2

-

-

35

32

M 52 x 1.5

-

-

-

-

M 52 x 2

38

32

42

40

M 65 x 2

-

-

-

-

Method of using the above table to find an appropriate plugs and fittings according to Table 6.6.3 on page 17: EXAMPLE: To cover up a hose / tube with a diameter of 25 mm, for a pressure up to 3000 PSI perform the following steps: z

Locate the 25 in the column "DN" in the category "up to 3000 PSI".

z

Check the digit in the column "Ra" next to DN 25 in the same row and category. For this example the proper plug and fitting is BUZ 28-L and ROV 28-L, refer to Table 6.6.3 on page 17.

NOTE: The column "Size" indicates the thread-size for the ROV-fittings.

6 - 16

PC8000-6E

Version 2010/1

Service information

6.6.3

Blind plugs

PLUGS AND FITTINGS ACCORDING TO EN ISO 84 34-1 Up to 3000 PSI BUZ (plugs)

PN

ROV (fittings)

PN

8-L

501 692 98

8-L

518 113 98

10-L

371 852 99

10-PL

513 789 98

12-L

371 854 99

12-PL

513 547 98

15-L

371 855 99

15-PL

507 051 98

18-L

371 856 99

18-PL

513 787 98

22-L

371 857 99

22-PL

513 788 98

28-L

371 858 99

28-PL

509 377 98

35-L

371 859 99

35-PL

516 770 98

42-L

371 860 99

42-PL

513 790 98

Up to 6000 PSI BUZ (plugs)

PN

ROV (fittings)

PN

-

-

8-PS

515 921 98

-

-

10-PS

507 023 98

-

-

12-PS

507 022 98

16-S

371 866 99

-

-

20-S

371 853 99

20-PS

512 005 98

25-S

371 867 99

25-PS

508 033 98

30-S

371 868 99

30-PS

507 021 98

38-S

371 869 99

38-PS

507 020 98

Version 2010/1

PC8000-6E

6 - 17

Conversion table

Service information

6.7

CONVERSION TABLE

6.7.1

METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE: Method of using the Conversion Table to convert from millimeters to inches. Convert 55 mm into inches: z

Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A).

z

Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B).

z

Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches.

Convert 550 mm into inches: z

The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm.

z

Carry out the same procedure as above to convert 55 mm to 2.165 inches.

z

The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

6 - 18

PC8000-6E

Version 2010/1

Service information

6.7.2

Conversion table

MILLIMETER - INCH & KILOGRAM - POUND

Version 2010/1

PC8000-6E

6 - 19

Conversion table

6.7.3

6 - 20

Service information

LITER - U.S. GALLON & LITER - U.K. GALLON

PC8000-6E

Version 2010/1

Service information

6.7.4

Conversion table

NM- FT.LB 0

1

2

3

4

5

6

7

8

9

0

0

0.74

1.47

2.21

2.95

3.69

4.42

5.16

5.90

6.63

10

7.37

8.11

8.84

9.58

10.32

11.06

11.79

12.53

13.27

14.00

20

14.74

15.48

16.21

16.95

17.69

18.43

19.16

19.90

20.64

21.37

30

22.11

22.85

23.58

24.32

25.06

25.80

26.53

27.27

28.01

28.74

40

29.48

30.22

30.95

31.69

32.43

33.17

33.90

34.64

35.38

36.11

50

36.85

37.59

38.32

39.06

39.80

40.54

41.27

42.01

42.75

43.48

60

44.22

44.96

45.69

46.43

47.17

47.91

48.64

49.38

50.12

50.85

70

51.59

52.33

53.06

53.08

54.54

55.28

56.01

56.75

57.49

58.22

80

58.96

59.07

60.43

61.17

61.91

62.65

63.38

64.12

64.86

65.59

90

66.33

67.07

67.80

68.54

69.28

70.02

70.75

71.49

72.23

72.96

100

73.70

74.44

75.17

75.91

76.65

77.39

78.12

78.86

79.60

80.33

110

81.07

81.81

82.54

83.28

84.02

84.76

85.49

86.23

86.97

87.70

120

88.44

89.18

89.91

90.65

91.39

92.13

92.86

93.60

94.34

95.07

130

95.81

96.55

97.28

98.02

98.76

99.50

100.23

100.97

101.71

102.44

140

103.18

103.92

104.65

105.39

106.13

106.87

107.60

108.34

109.08

109.81

150

110.55

111.29

112.02

112.76

113.50

114.24

114.97

115.71

116.45

117.18

160

117.92

118.66

119.39

120.13

120.87

121.61

122.34

123.08

123.82

124.55

170

125.29

126.03

126.76

127.50

128.24

128.98

129.71

130.45

131.19

131.92

180

132.66

133.40

134.13

134.87

135.61

136.35

137.08

137.82

138.56

139.29

190

140.03

140.77

141.50

142.24

142.98

143.72

144.45

145.19

145.93

146.66

200

147.40

148.14

148.87

149.61

150.35

151.09

151.82

152.56

153.30

154.03

1 Nm = 0.737 FT.LB

Version 2010/1

PC8000-6E

6 - 21

Conversion table

6.7.5

Service information

BAR - PSI - KPA - MPA 1...200 Bar

205...400 Bar

Bar

PSI

kPa

MPa

Bar

PSI

kPa

MPa

1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200

14.5037 72.52 145.03 217.55 290.07 362.58 435.1 507.62 580.13 652.65 725.17 797.68 870.2 942.71 1015.23 1087.75 1160.26 1232.78 1305.3 1377.81 1450.33 1522.85 1595.36 1667.88 1740.4 1812.91 1885.43 1957.95 2030.46 2102.98 2175.5 2248.01 2320.53 2393.04 2465.56 2538.08 2610.59 2683.11 2755.63 2828.14 2900.66

100 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 12000 12500 13000 13500 14000 14500 15000 15500 16000 16500 17000 17500 18000 18500 19000 19500 20000

0.1 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11 11.5 12 12.5 13 13.5 14 14.5 15 15.5 16 16.5 17 17.5 18 18.5 19 19.5 20

205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350 355 360 365 370 375 380 385 390 395 400

2973.18 3045.69 3118.21 3190.73 3263.24 3335.76 3408.28 3480.79 3553.31 3625.83 3698.34 3770.86 3843.37 3915.89 3988.41 4060.92 4133.44 4205.96 4278.47 4350.99 4423.51 4496.02 4568.54 4641.06 4713.57 4786.09 4858.61 4931.12 5003.64 5076.16 5148.67 5221.19 5293.7 5366.22 5438.74 5511.25 5583.77 5656.29 5728.8 5801.32

20500 21000 21500 22000 22500 23000 23500 24000 24500 25000 25500 26000 26500 27000 27500 28000 28500 29000 29500 30000 30500 31000 31500 32000 32500 33000 33500 34000 34500 35000 35500 36000 36500 37000 37500 38000 38500 39000 39500 40000

20.5 21 21.5 22 22.5 23 23.5 24 24.5 25 25.5 26 26.5 27 27.5 28 28.5 29 29.5 30 30.5 31 31.5 32 32.5 33 33.5 34 34.5 35 35.5 36 36.5 37 37.5 38 38.5 39 39.5 40

1 Bar = 14.5037 PSI

6 - 22

PC8000-6E

Version 2010/1

Service information

6.7.6

Conversion table

BASIC VALUES IN OHM ACCORDING TO DIN 4376 / IEC 751

Conversion Table - Ohm to Centigrade of PT100 sensors °C

-0

-1

-2

-3

-4

-5

-6

-7

-8

-9

-50

80.31

79.91

79.51

79.11

78.72

78.32

77.92

77.52

77.13

76.73

-40

84.27

83.88

83.48

83.08

82.69

82.29

81.89

81.50

81.10

80.70

-30

88.22

87.83

87.43

87.04

86.64

86.25

85.85

85.46

85.06

84.67

-20

92.16

91.77

91.37

90.98

90.59

90.19

89.80

89.40

89.01

88.62

-10

96.09

95.69

95.30

94.91

94.52

94.12

93.73

93.34

92.95

92.55

0

100.00

99.61

99.22

98.83

98.44

98.04

97.65

97.26

96.87

96.48

°C

0

1

2

3

4

5

6

7

8

9

0

100.00

100.39

100.78

101.17

101.56

101.95

102.34

102.73

103.12

103.51

10

103.90

104.29

104.68

105.07

105.46

105.85

106.24

106.63

107.02

107.40

20

107.79

108.18

108.57

108.96

109.35

109.73

110.12

110.51

110.90

111.28

30

111.67

112.06

112.45

112.83

113.22

113.61

113.99

114.38

114.77

115.15

40

115.54

115.93

116.31

116.70

117.08

117.47

117.85

118.24

118.62

119.01

50

119.40

119.78

120.16

120.55

120.93

121.32

121.70

122.09

122.47

122.86

60

123.24

123.62

124.01.

124.39

124.77

125.16

125.54

125.92

126.31

126.69

70

127.07

127.45

127.84

128.22

128.60

128.98

129.37

129.75

130.13

130.51

80

130.89

131.27

131.66

132.04

132.42

132.80

133.18

133.56

133.94

134.32

90

134.70

135.08

135.46

135.84

136.22

136.60

136.98

137.36

137.47

138.12

100

138.50

138.88

139.26

139.64

140.02

140.39

140.77

141.15

141.53

141.91

110

142.29

142.66

143.04

143.42

143.80

144.17

144.55

144.93

145.31

145.68

120

146.06

146.44

146.81

147.19

147.57

147.94

148.32

148.70

149.07

149.45

130

149.82

150.20

150.57

150.95

151.33

151.70

152.08

152.45

152.83

153.20

140

153.58

153.95

154.32

154.70

155.07

155.45

155.82

156.19

156.57

156.94

150

157.31

157.69

158.06

158.43

158.81

159.18

159.55

159.93

160.30

160.67

Version 2010/1

PC8000-6E

6 - 23

Conversion table

6.7.7

Service information

TEMPERATURE

The figures in the table below refer to the temperature in either degree Fahrenheit or degree Celsius. If it is desired to convert from degree Fahrenheit to degree Celsius, consider the centre column as a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left. If it is desired to convert from degree Celsius to degree Fahrenheit, consider the centre column as a table of Celsius values, and read the corresponding Fahrenheit temperature on the right.

6 - 24

PC8000-6E

Version 2010/1

Service information

Tools

6.8

TOOLS

6.8.1

STANDARD TOOL CASE

Komatsu provides a standard tool case, PN 232 709 40.

Q‘ty 1

Part name

Part number

Measuring tape 3 m long

470 615 40

1

Hammer 500 g

232 130 40

1

Sliding caliper, 200 mm long

232 107 40

1

Reamer (countersink, stem diameter 10 mm; reamer diameter 20 mm)

232 690 40

1

Socket wrench ½“ - set (WS 10 - 32)

232 691 40

1

Internal hexagon socket, ½“ - set (WS 5 - 17)

232 570 40

1

Double ended open wrench - set (WS 6 - 32)

232 692 40

1

Combination wrenches - set, (WS 10 - 32)

232 693 40

1

Twist drill - set (1 - 13 mm)

232 207 40

1

Needle files - set

232 199 40

1

Tool bag

232 694 40

1

Toolbox (460 x 170 x 310)

232 695 40

1

Socket wrench ¼“ - set (WS 3 - 13)

232 696 40

1

Drift punch (3 - 8 mm)

232 697 40

1

Socket wrench with ball head - set (1.5 - 10 mm)

232 698 40

1

Side cutter insulated up to 1000 Volt, 190 mm

232 401 40

1

Combination pliers insulated up to 1000 Volt, 185 mm

232 400 40

1

Bent nose pliers, Knipex

232 403 40

1

Water pump pliers 250 mm long

232 139 40

1

Cable stripping knife 4 - 16 mm

232 699 40

1

Screwdriver for slotted screws 11 x 300 mm

232 120 40

1

Screwdriver for slotted screws 13 x 390 mm

232 121 40

1

Crosstip screwdriver size 0

232 111 40

1


232 112 40

1


232 113 40

1

Infrared thermometer IR 1

232 665 40

1

LCD-Digital Multimeter VC 444

232 688 40

1

VDE Screwdriver, WERA

232 689 40

1

Hydraulic mini testing kit

232 591 40

2

Pressure gauge 400 bar

793 363 73

3

Measuring hose 2.5 m

896 483 40

2

Pressure gauge fitting G¼

232 501 40

1

Set – Screwdriver

907 696 40

1

Side cutting pliers, Knipex

232 700 40

1

Stripping- and cutting tool Stripax for PVC-isolation up to 6 mm², 20 mm

232 663 40

1

Crimp pliers, crimp capacity 0.5 - 4 mm²

232 661 40

1

Crimp pliers HTN 21

232 701 40

2

Testing wire 4mm Type 410 (red)

232 702 40

2

Testing wire 4mm Type 410 (black)

232 703 40

Version 2010/1

PC8000-6E

6 - 25

Tools

Service information

Q‘ty

Part name

Part number

1

Testing tip "Hirschmann Prüf 2" (red)

232 704 40

1

Testing tip "Hirschmann Prüf 2" (black)

232 705 40

1

Clip terminal "Hirschmann Ak 2 S" (red)

232 706 40

1

Clip terminal "Hirschmann Ak 2 S" (black)

232 707 40

1

Fluke 179 Digital-Multimeter

232 708 40

1

Rollbox K 412 (740 x 365 x 375)

232 711 40

1

Manual non-contact revolution counter (digital)

232 551 40

1

Magnet-stick

232 712 40

1

Electric set with pliers

793 265 73

1

Software (Bodem 24)

796 726 73

1

Bodem connection cable

896 791 40

1

Crimp-pliers for revolved contacts

793 729 73

1

Cable set

796 443 73

1

Prostat Cable VL 3 (X27 -PC)

659 820 40

1

Prosyd Cable VL 12 (PLC-PC)

926 503 40

1

TazETM Cable VL 10 (ETM-PC)

891 175 40

1

Cable VL 9a

891 176 40

1

Cable VL 9b

891 177 40

1

PC4000-6 VHMS download-cable (new for 08156 and up)

894 580 40

1

Converter, cable, and software as set

796 442 73

1

Converter

796 439 73

1

USB extension wire

796 440 73

1

UMG diagnostic software (CD)

796 441 73

6 - 26

PC8000-6E

Version 2010/1

Service information

6.8.2

Tools

USED SPECIAL TOOLS (OVERVIEW)

Component

Part number

Part name

Q‘ty

PN 232 386 40

Universal grounding short-circuting device

1

PN 232 390 40

Measuring rod 3...6 kV

PN 232 389 40

Measuring rod 5...10 kV

PN 232 267 40

55 mm hexagon impact socket wrench

1

PN 232 615 40

Hydraulic torque wrench (7800 Nm)

1

PN 232 613 40

Electro-hydraulic pump set

1

PN 793 374 73 + PN 793 376 73

Hydraulic torque wrench + Wrench socket with supporting bar

1

PN 795 922 73


1

PN 928 476 40

Measuring device

PN 274 703 40

Measuring jaw

1

PN 909 004 40

Measuring bolt

8

PN 898 287 40

Measuring bolt (cold weather)

8

PN 375 795 40

Test block

1

Safety unit for changing track rollers

1

Removal and installation of the track rollers

PN ??? (P&S-news under development)

Tool for changing track rollers

1

Removal and installation of the track rollers

PN 761 520 73

Testing- and refilling device

1

Refilling pressure accumulators

PN 923 828 40

Installation tool

1

Removal and installation of the bucket cylinders FSA

PN 923 824 40

Installation tool

1

Removal and installation of the stick cylinders FSA

PN 934 606 40

Installation tool

1

Removal and installation of the boom cylinders FSA


Car body/crawler carrier

Swing circle mounting

PN 921 142 40

Nature of work, remarks

Grounding procedure

Removal and installation of the high voltage switch cabinet

Removal and installation of the car body/crawler carrier

Installation of the crawler carriers

Installation of the swing circle. Assembly of superstructure onto undercarriage

Track rollers

Pressure accumulators of the track tensioning system

Attachment

Version 2010/1

PC8000-6E

6 - 27

Tools

Service information

Component

Part number

Part name

Q‘ty

PN 793 502 73

POSILOK pin removal tool

1

PN 793 503 73

POSILOK lifting tool

1

Sprocket

locally made (refer to PARTS & SERVICE NEWS No. "AH05511")

Assembly tool for dual-cone seals

1

Installation of new dual-cone seals

Hydraulic system (general)

PN 232 591 40

Hydraulic testing kit

1

Measurements of hydraulic pressures

PN 793 788 73

Rotational speed infrared probe DS03s

1

Measurements of rotation fan speed

PN 232 269 40


1

PN 232 615 40


1

PN 232 613 40


1

PN 232 267 40


1

PN 232 615 40


1

PN 232 613 40


1

PN 232 267 40


1

PN 232 615 40


1

PN 232 613 40


1

PN 232 265 40


1

PN 232 615 40


1

PN 232 613 40


1

GET

Hydraulic cooler fan drive pump Hydraulic cooler fan assembly

Counterweight

Superstructure

Cab base

Hydraulic oil reservoir

6 - 28

PC8000-6E


Removal and installation of the GET

Removal and installation of the counterweight

Removal and installation of the superstructure

Removal and installation of the cab base

Removal and installation of the hydraulic oil reservoir

Version 2010/1

Service information

Component

Tools

Part number

Part name

Q‘ty


PN 232 713 40

Laser alignment set

1

PN 232 714 40

Bracket set

2

Alignment procedure for the electric motors

Electric motor

Version 2010/1

PC8000-6E

6 - 29

Tools

Service information


6 - 30

PC8000-6E

Version 2010/1

Tools catalogue

7 TOOLS CATALOGUE

Version 2010/1

PC8000-6E

7 -1

Tools catalogue

7 -2

PC8000-6E

Version 2010/1

Tools and Accessories Werkzeuge und Zubehör

Release: March 09th, 2010 Ausgabe: 09. März 2010

Content / Inhalt

Page No. Seite Section 1

Assembly Tools for Screws and Nuts

3

Gruppe 1

Schraubwerkzeuge

3

Section 2

Pliers

19

Gruppe 2

Zangen

19

Section 3

Metal Working Tools

22

Gruppe 3

Werkzeuge für die Metallbearbeitung

22

Section 4

Measuring Tools

25

Gruppe 4

Messwerkzeuge

25

Section 5

Data Transfer and IT Tools

34

Gruppe 5

Datenübertragung und IT-Zubehör

34

Section 6

Others

37

Gruppe 6

Sonstiges

37

Section 7

Paint and Accessories

43

Gruppe 7

Lackiermaterialien

43

Section 8

Auxiliaries, Cleaner, Adhesive & Sealant

45

Gruppe 8

Hilfsstoffe, Reiniger, Kleber

45

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Combination wrenches, single Gabelringschlüssel, einzeln 232 001 40 232 002 40 232 002 40 232 003 40 232 004 40 232 005 40 232 006 40 232 007 40 232 008 40 232 009 40 232 010 40 232 011 40 232 012 40 323 013 40 232 014 40 232 015 40 232 016 40 232 017 40 232 018 40 232 019 40 232 557 40

SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW

6 7 7 8 9 10 11 12 13 14 15 17 19 22 24 27 30 32 36 41 46

232 693 40

Combination wrenches, set SW 10 - 32 Gabelringschlüssel, Satz SW 10 - 32 Combination wrenches, single Gabelringschlüssel, einzeln

232 432 40 232 433 40 232 434 40 232 435 40 232 436 40 232 437 40 232 438 40 232 439 40 232 440 40 232 441 40 232 442 40 232 443 40 232 444 40 232 445 40 232 446 40 232 447 40

SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW

1/4” 5/16” 3/8” 7/16” 1/2” 9/16” 5/8” 11/16” 3/4” 13/16” 7/8” 15/16” 1” 11/16” 11/8” 11/4”

991-1010 Tools


Werkzeug

Schraubwerkzeuge

Section / Gruppe 1 Page / Seite Continued / Fortsetzung

3 4

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Special ring wrench – open Spezial-Ringschlüssel – offen 232 305 40 232 306 40 232 307 40 232 308 40

SW SW SW SW

41 46 50 60

Double ended open wrenches, single Doppelgabelschlüssel, einzeln 232 020 40 232 021 40 232 022 40 232 023 40 232 024 40 232 025 40 232 026 40 232 027 40 232 028 40 232 029 40 232 030 40 232 031 40 232 032 40 232 033 40

SW SW SW SW SW SW SW SW SW SW SW SW SW SW

6x7 8x9 10 x 11 12 x 13 14 x 15 16 x 17 18 x 19 20 x 22 21 x 23 24 x 27 25 x 28 30 x 32 36 x 41 50 x 55

Single ended open wrenches, single Einfachgabelschlüssel, einzeln 232 361 40 232 211 40 232 212 40 232 213 40 232 214 40 232 215 40 232 362 40 232 216 40 232 363 40 232 217 40

SW SW SW SW SW SW SW SW SW SW

41 46 50 55 60 65 70 75 80 85

991-1010 Tools


Werkzeug

Schraubwerkzeuge


4 5

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Hook wrenches, single Hakenschlüssel, einzeln 232 275 40 232 276 40 232 277 40 232 278 40 232 279 40 232 280 40

120 – 130 mm Ø 155 – 165 mm Ø 180 – 195 mm Ø 205 – 220 mm Ø 260 – 270 mm Ø 280 – 300 mm Ø Push-pull ratchet Knarre

232 337 40 232 047 40 232 562 40 232 563 40

1/4” 1/2” 3/4” 1” Reversible ratchet Umschaltknarre 1” x 660 mm (26”)

232 380 40 232 218 40

3/4” x 620 mm 1” x 660 mm (26”) Torque wrench Drehmomentschlüssel

232 262 40 232 285 40 232 477 40 232 478 40 232 379 40 232 304 40 232 220 40 232 221 40

7 – 32 mkp 30 – 75 mkp 50 – 130 mkp 80 – 200 mkp 3/4” x 200 mm 3/4” x 430 mm 1” x 250 mm (8”) 1” x 405 mm (16”)

70 – 320 Nm 300 – 750 Nm 500 – 1300 Nm 800 – 2000 Nm

991-1010 Tools


Werkzeug

Schraubwerkzeuge


5 6

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe: 232 285 40

March 09th, 2010 09. März 2010

Torque wrench with scale DSG-5S, measuring range: 300 - 750Nm Drehmomentschlüssel mit Skala DSG-5S, Messbereich: 300 - 750 Nm

232 477 40

Torque wrench with scale DSG-6S, measuring range: 500 - 1300 Nm Drehmomentschlüssel mit Skala DSG-6S, Messbereich: 500 - 1300 Nm

232 478 40

Torque wrench with scale DSG-7S measuring range: 800 - 2000 Nm Drehmomentschlüssel mit Skala DSG-7S, Messbereich: 800 - 2000 Nm

232 681 40

Elbow socket, 28/5 - 3/4 x 70 Einsteck-Winkelstück, 28/5 - 3/4 x 70

232 682 40

Elbow socket, 28/6 - 7; 1” x 70 Einsteck-Winkelstück, 28/6 - 7; 1” x 70

232 574 40

Reducer socket, 1 1/2 - 1 Reduzierstück, 1 1/2 - 1

232 577 40

Extension socket, 1 1/2 - 1 Vergrößerungsstück, 1 1/2 - 1 Sliding & tommy bar Griff mit Gleitstück

232 339 40 232 050 40 232 303 40 232 219 40

1/4” 1/2” x 290 mm (12”) 3/4” x 500 mm (20”) 1” x 640 mm (25”)

991-1010 Tools


Werkzeug

Schraubwerkzeuge


6 7

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Universal joint Kardangelenk 232 051 40

1/2” Socket wrench 1/4", single Stecknuss, 1/4”, einzeln

232 326 40 232 327 40 232 328 40 232 329 40 232 330 40 232 331 40 232 332 40 232 333 40 232 334 40 232 335 40 232 336 40

SW SW SW SW SW SW SW SW SW SW SW

4 4,5 5 5,5 6 7 8 9 10 11 13

Socket wrench, 1/2”, single Steckschlüsseleinsatz, 1/2”, einzeln 232 034 40 232 035 40 232 036 40 232 037 40 232 038 40 232 039 40 232 040 40 232 041 40 232 042 40 232 340 40 232 043 40 232 044 40 232 045 40 232 046 40

SW SW SW SW SW SW SW SW SW SW SW SW SW SW

9 10 11 12 13 14 15 17 19 21 24 27 30 32

991-1010 Tools


Werkzeug

Schraubwerkzeuge


7 8

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Socket wrench, 1/2”, single Steckschlüsseleinsatz, 1/2”, einzeln 232 448 40 232 449 40 232 450 40 232 451 40 232 452 40 232 453 40 232 454 40 232 455 40 232 456 40 232 457 40 232 458 40 232 459 40 232 460 40 232 461 40 232 462 40 232 463 40 232 464 40 232 465 40

SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW

3/8” 13/32” 7/16” 1/2” 9/16” 19/32” 5/8” 11/16” 3/4” 25/32” 13/16” 7/8” 15/16” 1” 1 1/16” 1 1/8” 1 3/16” 1 1/4”

Socket wrench, 3/4”, single Steckschlüsseleinsatz, 3/4”, einzeln 232 369 40 232 370 40 232 371 40 232 372 40 232 373 40 232 374 40 232 375 40 232 376 40 232 377 40 232 378 40


22 24 27 30 32 36 38 41 46 50

991-1010 Tools


Werkzeug

Schraubwerkzeuge


8 9

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Socket wrench, 1”, single Steckschlüsseleinsatz, 1”, einzeln 232 223 40 232 224 40 232 225 40 232 226 40 232 227 40 232 228 40 232 229 40 232 230 40 232 231 40 232 232 40


36 41 46 50 55 60 65 70 75 80

232 569 40

Extra deep socket wrench for grease nipple of grease cylinder 1/2”, long, SW 27 Steckschlüsseleinsatz für Schmiernippel am Schmierzylinder 1/2”, lang, SW 27

Internal hexagon socket, 1/2“ , single Innensechskant Steckschlüsseleinsatz, 1/2”, einzeln 232 052 40 232 053 40 232 054 40 232 055 40 232 056 40 232 057 40 232 058 40 232 059 40 232 060 40

SW SW SW SW SW SW SW SW SW

5 6 7 8 9 10 12 14 17

Internal hexagon socket, 1/2", single Innensechskant Steckschlüsseleinsatz, 1/2”, einzeln 232 423 40 232 424 40 232 425 40 232 426 40 232 427 40 232 428 40 232 429 40 232 430 40 232 431 40


3/16” 7/32” 1/4” 9/32” 5/16” 3/8” 1/2” 9/16” 5/8”

991-1010 Tools


Werkzeug

Schraubwerkzeuge


9 10

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Internal hexagon socket, 1/2“, single Innensechskant-Steckschlüsseleinsatz, 1/2”, einzeln 232 341 40 232 342 40 232 343 40 232 344 40 232 345 40 232 346 40

SW SW SW SW SW SW

5 x 180 mm 6 x 90 mm 8 x 120 mm 10 x 140 mm 12 x 140 mm 14 x 140 mm

Internal hexagon socket, 3/4” Innensechskant Steckschlüsseleinsatz, 3/4” 232 347 40 232 348 40 232 349 40 232 350 40

SW SW SW SW

14 17 19 22

Internal hexagon socket,1” Innensechskant Steckschlüsseleinsatz, 1” 232 351 40 232 352 40 232 353 40

SW 19 SW 22 SW 24 Internal Torx socket Innen-Torx Steckschlüsseleinsatz

232 597 40 232 598 40 232 599 40 232 600 40 232 601 40 232 602 40 232 603 40

SW SW SW SW SW SW SW

4–5 4,5 – 5 4,5 – 5 – 6 6–7 7–8 8 – 10 10

991-1010 Tools


Werkzeug

Schraubwerkzeuge


10 11

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

External Torx socket Außen-Torx Steckschlüsseleinsatz 232 604 40 232 605 40 232 606 40 232 607 40 232 608 40 232 609 40 232 610 40

SW SW SW SW SW SW SW

4 5 6 6–7 8 10 12

Reducing socket Reduzierstück 232 573 40 232 096 40 232 574 40

1 – 3/4 3/4 – 1/2 1 1/2 – 1 Expansion socket Vergrößerungsstück

232 575 40 232 576 40 232 577 40

1/2 – 3/4 3/4 – 1 1 – 1 1/2

232 146 40

Strap wrench (fuel-water filter) Bandschlüssel (Kraftstoff-Wasserfilter)

232 511 40

Torque multiplier max. 2700 Nm (2000 lbf-ft) Drive 3/4” Reduction 1 : 5 Drehmomentvervielfältiger max. 2700 Nm Antrieb 3/4” Untersetzung 1 : 5

232 611 40

High-power pneumatic torque drive wrench, 900 - 4.200 Nm Square tool socket 1'' Including reaction arm (long type), torque adjustment and service unit, pneumatic hose 6m, torque certificate, and silencer Hochleistungs-Pneumatik-Getriebeschrauber, 900 - 4.200 Nm Antriebsvierkant 1'' Inklusive Reaktionsarm (lange Ausführung), Drehmomenteinstell- und Wartungseinheit, Druckluftschlauch 6m, Drehmomentzertifikat und Schalldämpfer

991-1010 Tools


Werkzeug

Schraubwerkzeuge


11 12

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

High-power pneumatic torque drive wrench, 1.500 - 7.100 Nm Square tool socket 1 ½'' Including reaction arm (long type), torque adjustment and service unit, pneumatic hose 6m, torque certificate, and silencer Hochleistungs-Pneumatik-Getriebeschrauber, 1.500 - 7.100 Nm Antriebsvierkant 1 ½'' Inklusive Reaktionsarm (lange Ausführung), Drehmomenteinstell- und Wartungseinheit, Druckluftschlauch 6m, Drehmomentzertifikat und Schalldämpfer

232 614 40

High-power hydraulic torque wrench Torque range 390 - 3,934 Nm Square tool socket 1'' incl. reaction arm Hochleistungs-Hydraulik-Drehmomentschrauber Drehmomentbereich 390 - 3.934 Nm Antriebsvierkant 1'' mit Reaktionsarm

232 615 40

High-power hydraulic torque wrench Torque range 741 - 7,402 Nm Square tool socket 1 ½'' incl. reaction arm Hochleistungs-Hydraulik-Drehmomentschrauber Drehmomentbereich 741 - 7.402 Nm Antriebsvierkant 1 ½'' mit Reaktionsarm

793 374 73

High-power hydraulic torque wrench for side member assembly* Torque range 1,049 - 10,671 Nm Square tool socket 1 ½'' incl. reaction arm * For mounting of crawler carriers the supplemental extended reaction arm 793 376 73 is required Hochleistungs-Hydraulik-Drehmomentschrauber für die Seitenträgermontage* Drehmomentbereich 1.049 - 10.671 Nm Antriebsvierkant 1 ½'' mit Reaktionsarm * Für die Seitenträgermontage wird zusätzlich der verlängerte Reaktionsarm 793 376 73 benötigt

991-1010 Tools


Werkzeug

Schraubwerkzeuge


12 13

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Electro-hydraulic pump aggregate, 220 Volt/800 bar Elektro-hydraulisches Pumpenaggregat, 220 Volt/800 bar 232 613 40

5 bar

232 269 40 232 366 40 232 367 40 232 097 40

SW 75 SW 80 SW 85 3 – 15 mkp

232 759 40

High-power hydraulic torque wrench & aggregate, set Torque range 390 - 3,934 Nm

30 – 150 Nm

The set contains: • High-power hydraulic torque wrench (232 614 40) Square tool socket 1'' incl. reaction arm • High pressure hydraulic aggregate with hoses (793 375 73) Supply voltage 230 V 3-stages-delivery Setting range up to 700 bar incl. digital manometer, oil, and 5 m remote control incl. safety couplings • High pressure twin-hose NS 6 x 5 m (795 923 73) Welded Burst pressure 2,800 bar • Transportation box (232 719 40) Hochleistungs-Hydraulik-Drehmomentschrauber & Aggregat, Satz Drehmomentbereich 390 - 3.934 Nm Der Satz beinhaltet: • Hochleistungs-Hydraulik-Drehmomentschrauber (232 614 40) Antriebsvierkant 1'' mit Reaktionsarm • Hochdruck-Hydraulikaggregat mit Schläuchen (793 375 73) Versorgungsspannung 230 V 3-Stufen-Förderleistung Einstellbereich bis 700 bar inkl. Digital-Manometer, Öl und 5 m Fernbedienung inkl. Sicherheitskupplungen • Hochdruck-Zwillingsschlauch NW 6 x 5 m (795 923 73) Verschweißt Berstdruck 2.800 bar • Transportkiste (232 719 40)

991-1010 Tools


Werkzeug

Schraubwerkzeuge


13 14

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

High-power hydraulic torque wrench & aggregate, set Torque range 741 - 7,402 Nm The set contains: • High-power hydraulic torque wrench (232 615 40) Square tool socket 1 ½'' incl. reaction arm • High pressure hydraulic aggregate with hoses (793 375 73) Supply voltage 230 V 3-stages-delivery Setting range up to 700 bar incl. digital manometer, oil, and 5 m remote control incl. safety couplings • High pressure twin-hose NS 6 x 5 m (795 923 73) Welded Burst pressure 2,800 bar • Transportation box (232 719 40) Hochleistungs-Hydraulik-Drehmomentschrauber & Aggregat, Satz Drehmomentbereich 741 - 7.402 Nm Der Satz beinhaltet: • Hochleistungs-Hydraulik-Drehmomentschrauber (232 615 40) Antriebsvierkant 1 ½'' mit Reaktionsarm • Hochdruck-Hydraulikaggregat mit Schläuchen (793 375 73) Versorgungsspannung 230 V 3-Stufen-Förderleistung Einstellbereich bis 700 bar inkl. Digital-Manometer, Öl und 5 m Fernbedienung inkl. Sicherheitskupplungen • Hochdruck-Zwillingsschlauch NW 6 x 5 m (795 923 73) Verschweißt Berstdruck 2.800 bar • Transportkiste (232 719 40)

232 757 40

High-power hydraulic torque wrench & aggregate, set for mounting crawler carriers Torque range 1,049 - 10,671 Nm The set contains: • High-power hydraulic torque wrench (793 374 73) Square tool socket 1 ½'' incl. reaction arm • High pressure hydraulic aggregate with hoses (793 375 73) Supply voltage 230 V 3-stages-delivery Setting range up to 700 bar incl. digital manometer, oil, and 5 m remote control incl. safety couplings • High pressure twin-hose NS 6 x 5 m (795 923 73) Welded Burst pressure 2,800 bar • Torque wrench accessory Extended reaction arm with tool drive unit M48 suitable for torque wrench 793 374 73, for bolts with resilient sleeve • Transportation box (232 719 40)

991-1010 Tools


Werkzeug

Schraubwerkzeuge


14 15

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Hochleistungs-Hydraulik-Drehmomentschrauber & Aggregat, Satz für die Seitenträgermontage Drehmomentbereich 1.049 - 10.671 Nm Der Satz beinhaltet: • Hochleistungs-Hydraulik-Drehmomentschrauber (793 374 73) Antriebsvierkant 1 ½'' mit Reaktionsarm • Hochdruck-Hydraulikaggregat mit Schläuchen (793 375 73) Versorgungsspannung 230 V 3-Stufen-Förderleistung Einstellbereich bis 700 bar inkl. Digital-Manometer, Öl und 5 m Fernbedienung inkl. Sicherheitskupplungen • Hochdruck-Zwillingsschlauch NW 6 x 5 m (795 923 73) Verschweißt Berstdruck 2.800 bar • Drehmomentschrauber-Zubehör Verlängerter Reaktionsarm mit Antriebseinheit M48 passend für den Drehmomentschrauber 793 374 73, für Schrauben mit Dehnhülse • Transportkiste (232 719 40)

232 718 40

Electro-hydraulic pump set, assy Hydraulikaggregat, Satz

793 375 73

Electro-hydraulic pump Hydraulikaggregat

232 719 40

Transportation box Transportbox

793 376 73

Extended reaction arm for crawler carrier mounting (in combination with high-power hydraulic torque wrench 793 374 73) Verlängerter Reaktionsarm für die Seitenträgermontage (in Verbindung mit Hochleistungs-Hydraulik-Drehmomentschrauber 793 374 73)

795 923 73

High pressure hose DN6 x 10000 Hochdruckschlauch DN6 x 10000

991-1010 Tools


Werkzeug

Schraubwerkzeuge


15 16

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Additional equipment / Zusatzteile 232 749 40

Reaction arm Reaktionsarm

232 750 40

Fixing screw for the reaction arm Fixierschraube für den Reaktionsarm

232 687 40

Electro-hydraulic aggregate, 230 Volt, for servicing undercarriage and slew ring. Max. pressure output 700 bar (10000 psi), double acting, with wired remote control for the motor Elektro-hydraulisches Aggregat, 230 Volt, für die Fahrwerks- und Zahnkranzwartung. Max. Betriebsdruck 700 bar, doppelt wirkend, mit Kabelfernsteuerung für den Motor Not applicable for high-power impact wrenches Nicht für Hochleistungs-Kraftschrauber geeignet Impact socket wrench, 1“, single Kraftschrauberstecknuss 1”, einzeln

232 264 40 232 515 40 232 516 40 232 265 40 232 266 40 232 267 40 232 494 40 232 268 40

SW SW SW SW SW SW SW SW

36 38 41 46 50 55 60 65

Impact socket wrench, 1 ½" Kraftschrauberstecknuss 1 1/2”

232 517 40 232 518 40 232 519 40 232 520 40 232 521 40

SW SW SW SW SW

46 50 55 60 65

Impact internal hexagon socket, 1", single Kraftschrauberstecknuss Innensechskant, 1 ", einzeln 232 765 40 232 766 40 232 767 40 232 768 40 232 769 40 232 770 40

SW SW SW SW SW SW

19 22 24 27 32 36

991-1010 Tools


Werkzeug

Schraubwerkzeuge


16 17

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Screwdriver for slotted screws Schraubendreher für Schlitzschrauben 232 120 40 232 121 40

11 x 300 mm 13 x 390 mm Screwdriver, insulated up to 1000 Volt Schraubendreher, isoliert bis 1000 Volt

232 391 40 232 764 40 232 392 40 232 393 40 232 394 40 232 395 40

2,5 x 75 mm 3,0 x 100 mm 3,5 x 100 mm 4 x 100 mm 5,5 x 125 mm 6,5 x 150 mm Crosstip screwdriver, insulated up to 1000 Volt Kreuzschlitzschraubendreher, isoliert bis 1000 Volt

232 397 40 232 398 40 232 399 40

Größe / size 0 Größe / size 1 Größe / size 2

232 208 40

Screw extractor kit with spiral drills to remove damaged or broken screws Schraubenausdrehersatz mit Spiralbohrern zum Entfernen beschädigter oder abgebrochener Schrauben

Allen head wrench “L” type, single Innensechskantschlüssel, einzeln 232 066 40 232 067 40 232 068 40 232 069 40 232 070 40 232 071 40 232 072 40 232 073 40 232 074 40 232 075 40 232 076 40 232 077 40 232 078 40 232 079 40 232 080 40 232 081 40 232 082 40 232 354 40 232 355 40 232 356 40

SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW

2 2,5 3 4 5 6 7 8 9 10 12 14 17 19 22 24 27 30 32 36

991-1010 Tools


Werkzeug

Schraubwerkzeuge


17 18

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Allen head wrench “L” type Innensechskantschlüssel 232 414 40 232 415 40 232 416 40 232 417 40 232 418 40 232 419 40 232 420 40 232 421 40 232 422 40


3/16” 7/32” 1/4” 5/16” 3/8” 1/2” 9/16” 5/8” 3/4”

Allen head wrench “L” type, with spherical head Innensechskantschlüssel, mit Kugelkopf 232 582 40 232 583 40 232 584 40 232 585 40 232 586 40 232 587 40 232 588 40 232 589 40

SW SW SW SW SW SW SW SW

2 3 4 5 6 8 10 12

232 698 40

Allen head wrenches "L" type, with spherical head, set 1.5 - 10 mm Innensechskantschlüssel, mit Kugelkopf, Satz 1.5 - 10 mm

232 666 40

Pneumatic impact wrench (Bosch) Druckluft-Schlagschrauber (Bosch)

232 667 40

Pneumatic impact wrench (Bosch) Druckluft-Schlagschrauber (Bosch)

793 828 73

Cordless impact wrench Torque 150 Nm, tool fitting 1/2'', including exchange accumulator 14.4V 3.3Ah in a tool case Akku-Schlagschrauber Drehmoment 150 Nm, Werkzeugaufnahme 1/2'', inkl. Wechselakku 14,4V 3,3Ah im Transportkoffer

991-1010 Tools


Werkzeug

Schraubwerkzeuge


18 19

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Water pump pliers 250 mm long Wasserpumpenzange 250 mm lang

232 140 40

Grip pliers 250 mm long Gripzange 250 mm lang

232 141 40

Stork beak pliers, straight, 200 mm long Storchschnabelzange, gerade, 200 mm lang

232 142 40

Telephone pliers, 200 mm long, bent jaws Storchschnabelzange, abgewinkelt, 200 mm lang

232 143 40

Wire strippers 160 mm long Abisolierzange 160 mm lang

232 663 40

Stripping- and cutting tool Stripax for PVC-isolation up to 6 mm², 20mm Abisolier- und Schneidewerkzeug Stripax für PVC-Isolation bis 6 mm², 20 mm

232 401 40

Side cutter insulated up to 1000 Volt, 190 mm Seitenschneider isoliert bis 1000 Volt, 190 mm

232 400 40

Combination pliers insulated up to 1000 Volt, 185 mm Kombizange isoliert bis 1000 Volt, 185 mm

232 147 40

Pipe wrenches, angeled jaws, with adjusting nut, 350 mm long Eckrohrzange abgewinkelt, mit Stellmutter, 350 mm lang

232 404 40

Flat nose pliers, insulated up to 1000 Volt, 185 mm Flachzange, isoliert bis 1000 Volt, 185 mm

232 405 40

Round nose pliers, insulated up to 1000 Volt, 185 mm Rundzange, isoliert bis 1000 Volt, 185 mm

991-1010 Tools

Pliers

Werkzeug

Zangen


19 20

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Circlip pliers, straight, for external circlips Sicherungsringzange, gerade, für Außenringe 232 150 40 232 151 40 232 152 40

19 – 60 Ø 40 – 100 Ø 85 – 140 Ø Circlip pliers, 90°, for external circlips Sicherungsringzange, gewinkelt, für Außenringe

232 156 40 232 157 40 232 158 40

19 – 60 Ø 40 – 100 Ø 85 – 140 Ø Circlip pliers, straight, for internal circlips Sicherungsringzange, gerade, für Innenringe

232 159 40 232 160 40 232 161 40

19 – 60 Ø 30 – 100 Ø 85 – 130 Ø Circlip pliers, angled, for internal circlips Sicherungsringzange, gewinkelt, für Innenringe

232 153 40 232 154 40 232 155 40

19 – 60 Ø 31 – 100 Ø 85 – 140 Ø

232 281 40

Circlip pliers, straight, for external circlips 122 – 300 mm Ø Seegerringzange, gerade, für Außenringe 122 – 300 mm Ø

232 282 40

Circlip pliers, angled, for external circlips 122 – 300 mm Ø Seegerringzange, gewinkelt, für Außenringe 122 – 300 mm Ø

232 283 40

Circlip pliers, straight, for internal circlips 122 – 300 mm Ø Seegerringzange, gerade, für Innenringe 122 – 300 mm Ø

232 284 40

Circlip pliers, angled, for internal circlips 122 – 300 mm Ø Seegerringzange, gewinkelt, für Innenringe 122 – 300 mm Ø

991-1010 Tools

Pliers

Werkzeug

Zangen


20 21

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Crimp set Crimp pliers, crimp capacity 0,5 - 4,0 mm² Crimp-Set Crimpzange, Crimpbereich 0,5 - 4,0 mm²

232 661 40

Crimp pliers Crimp capacity 0,5-4 mm² Crimpzange Crimpbereich 0,5-4 mm²

793 729 73

Crimp-pliers for revolved contacts Crimpzange für gedrehte Kontakte

232 209 40

Crimp pliers with cable lugs, set in a metal box Crimpzange im Kasten mit Kabelschuhsortiment

991-1010 Tools

Pliers

Werkzeug

Zangen


21 22

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Hammer Handhammer 232 129 40 232 130 40 232 131 40

300 g 500 g 1000 g

232 310 40

Sledge hammer, 5 kg Vorschlaghammer, 5 kg

232 579 40

Plastic hammer, 450 g Plastikhammer, 450 g

Flat chisel Flachmeißel 232 135 40 232 136 40

16 x 165 mm 19 x 180 mm

232 137 40

Cape chisel, 6 x 165 mm Kreuzmeißel, 6 x 165 mm

232 138 40

Center punch, 4 x 130 mm Körner, 4 x 130 mm Drift punch Durchtreiber

232 132 40 232 133 40 232 134 40

5 x 150 mm 6 x 160 mm 8 x 180 mm Cotter pin drive Splintentreiber

232 099 40 232 100 40 232 101 40 232 102 40 232 103 40 232 104 40

3 mm Ø 4 mm Ø 5 mm Ø 6 mm Ø 8 mm Ø 10 mm Ø

232 122 40

Hack saw with blade Metallbügelsäge mit Sägeblatt

991-1010 Tools

Metal Working Tools

Werkzeug



22 23

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Three square scraper (hollow), 250 mm long Dreikanthohlschaber, 250 mm lang

232 124 40

Flat scraper, 250 mm long Flachschaber, 250 mm lang Adjustable tap wrench for taps Verstellbares Wendeisen für Gewindebohrer

232 164 40 232 165 40 232 235 40

Gr. 1 M 1 – 10 Gr. 4 M 10 – 27 Gr. 6 M 20 – 42 Tap Gewindebohrer

232 166 40 232 167 40 232 168 40 232 169 40 232 170 40 232 171 40 232 172 40 232 173 40 232 174 40 232 357 40 232 175 40 232 240 40 232 241 40 232 242 40 232 243 40

M3 M4 M5 M6 M8 M 10 M 12 M 14 M 16 M 18 M 20 M 24 M 30 M 36 M 42 Tap Gewindebohrer

232 244 40 232 245 40 232 246 40 232 247 40 232 248 40 232 236 40 232 237 40R 232 238 40 232 239 40

M8x1 M 10 x 1 M 14 x 1,5 M 20 x 1,5 M 24 x 1,5 R 1/8” R 3/8” R 1/4” R 1/2”

991-1010 Tools

Metal Working Tools

Werkzeug



23 24

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Thread restorer Gewindefeile 232 162 40 232 163 40

Whitworth Metric Holder for threading dies Schneideisenhalter für Schneideisen

232 176 40 232 177 40 232 178 40 232 179 40 232 180 40 232 359 40 232 249 40 232 250 40 232 364 40 232 365 40 232 358 40

M3/M4 M5/M6 M 8 / M 8 x 1,0 M 10 / M 10 x 1 M 12 / M 14 M 16 / M 18 / M 20 M 24 M 30 / M 36 M 14 x 1,5 / R 1/8” / R 1/4” M 24 x M 1,5 R 3/8” / R 1/2”

20 x 5 mm 20 x 7 mm 25 x 9 mm 30 x 11 mm 38 x 14 mm 45 x 18 mm 55 x 22 mm 65 x 25 mm 38 x 10 mm 55 x 16 mm 45 x 14 mm

Threading die Schneideisen 232 181 40 232 182 40 232 183 40 232 184 40 232 185 40 232 186 40 232 187 40 232 188 40 232 189 40 232 360 40 232 190 40 232 261 40 232 260 40 232 259 40 232 255 40 232 256 40 232 257 40 232 258 40 232 251 40 232 252 40 232 253 40 232 254 40

M3 M4 M5 M6 M8 M 10 M 12 M 14 M 16 M 18 M 20 M 24 M 30 M 36 M8x1 M 10 x 1 M 14 x 1,5 M 24 x 1,5 R 1/8” R 1/4” R 3/8” R 1/2”

947 173 40

Auxiliary tool 1 for threaded pins M12 Hilfswerkzeug 1 für Gewindestift M12

947 178 40

Auxiliary tool 2 for threaded pins M16 Hilfswerkzeug 2 für Gewindestift M16

991-1010 Tools

Metal Working Tools

Werkzeug



24 25

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Inside caliper, 200 mm long Lochtaster, 200 mm lang

232 195 40

Outside caliper, 200 mm long Dickentaster 200 mm lang

232 107 40

Sliding caliper, 200 mm long Schieblehre, 200 mm lang

232 108 40

Measuring tape, 2000 mm long Rollbandmaß, 2000 mm lang

232 590 40

Metal rule, 1000 mm long Stahlmaß, 1000 mm lang

232 109 40

Feeler gauge set Fühlerlehrenset

232 110 40

Thread gauge, metric & whithworth Gewindeschablone, metrisch & Whitworth

232 668 40

Micrometer gauge Measuring range: 0 - 150 mm Bügelmessschraube Messbereich: 0 - 150 mm

232 669 40

Micrometer gauge Measuring range: 150 - 300 mm Bügelmessschraube Messbereich: 150 - 300 mm

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


25 26

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Hydraulic mini testing kit, consisting of: 1 pressure gauge 0 – 25 bar 1 pressure gauge 0 – 60 bar 2 pressure gauges 0 – 400 bar 2 instrument hoses 3 m each 1 hose 5 m and diverse adapters Hydraulik Mini-Messbox, bestehend aus: 1 Manometer 0 – 25 bar 1 Manometer 0 – 60 bar 2 Manometer 0 – 400 bar 2 Messschläuche je 3 m 1 Messschlauch 5 m und diverse Anschlüsse

79453773

Digital dial gauge, 0 - 12,5 mm Digitalmessuhr, 0 - 12,5 mm

232 673 40

Magnetic articulated stand, 390 mm, 60 x 50 x 55 mm Magnet-Gelenkstativ, 390 mm, 60 x 50 x 55 mm

232 720 40

Digital pressure manometer SPG-DIGI Digitales Druckmanometer SPG-DIGI

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


26 27

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Digital Multimeter Fluke 179 True-RMS-DMM Features: • True-RMS for precise measurement of non linear signals • 0,09% basic accuracy • 6000 count resolution • Large, easy-to-read display with analog bargraph and backlight for work in dimly lit areas • Manual and automatic ranging • Display Hold and Auto Hold • Smoothing mode allows filtering of rapidly changing inputs • Easy battery exchange without opening the case • Closed case calibration through front panel • Measuring frequency and capacity • Resistance, continuity and diode check • Measuring temperature • Min/Max/Avg recording • EN 61010-1 CAT III 1000 V/CAT iV 600 V Digitales Multimeter Fluke 179 True-RMS-DMM Ausstattung: • TrueRMS Echt-Effektivwert (AC) • 0,09% Grundabweichung • 6000 Digits Anzeigeumfang • Balkenanzeige und Hintergrundbeleuchtung • Bereichsautomatik; abschaltbar • Display-Hold und Auto-Hold • Filter-Modus zur Glättung sehr instabiler Signale • Leichter Batteriewechsel, ohne das Gehäuse zu öffnen • Kalibrierung bei geschlossenem Gehäuse über das Bedienfeld • Frequenz- und Kapazitätsmessung • Widerstand, Durchgangs- und Diodenprüfung • Temperaturmessung • Min-/Max-/Mittelwerterfassung • EN 61010-1 CAT III 1000 V/CAT iV 600 V

232 753 40

Fuse 440 mA Sicherung 440 mA

232 754 40

Fuse 11 A Sicherung 11 A

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


27 28

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Autorange digital multimeter incl. fuse set and temperature sensor Specification: V = : 100 µV – 1 KV accuracy ± 0,3% + 2 Dig. V ~ : 100 µV – 1 KV accuracy ± 0,5% + 3 Dig. A = : 100 nA – 20 A accuracy ± 1% + 5 Dig. A ~ : 100 nA – 20 A accuracy ± 1% + 5 Dig. Resistance: 100 mOhm– 40 MOhm Genauigkeit ± 0,5% + 3 Dig. Frequenz (Hz): 1 Hz – 200 kHz accuracy ± 0,2% + 2 Dig. Diode test: Test voltage (open) below 3 V Acust. continuity tester: sounds below 100 Ohm Voltage supply: 1 x 9 V block battery Autorange Digital-Multimeter inkl. Sicherungssatz und Temperatursensor Technische Daten: V = : 100 µV – 1 KV Genauigkeit ± 0,3% + 2 Dig. V ~ : 100 µV – 1 KV Genauigkeit ± 0,5% + 3 Dig. A = : 100 nA – 20 A Genauigkeit ± 1% + 5 Dig. A ~ : 100 nA – 20 A Genauigkeit ± 1% + 5 Dig. Widerstand: 100 mOhm– 40 MOhm Genauigkeit ± 0,5% + 3 Dig. Frequenz (Hz): 1 Hz – 200 kHz Genauigkeit ± 0,2% + 2 Dig. Diodentest: Prüfspannung (offen) unter 3 V akust. Durchgangsprüfer: ertönt unter 100 Ohm Spannungsversorgung: 1 x 9 V Block-Batterie

232 670 40

SUBITO Internal gauge, 280 - 510 mm, in a case without dial SUBITO Innenmessgerät, 280 - 510 mm, im Etui ohne Uhr

232 671 40

SUBITO Measuring depth extension Pipe Ø 18mm, 2000 mm long SUBITO Messtiefenverlängerung Rohr Ø 18mm, 2000 mm lang

232 384 40

Flow meter gauge incl. Accessories Volumenstrom-Messgerät inkl. Zubehör

793 787 73

Measuring turbine RE4 Measuring range: 16,0 up to 600 l/min Messturbine RE4 Messbereich: 16,0 bis 600 l/min

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


28 29

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Shock pulse measuring instrument Stossimpuls-Messgerät

232 665 40

Infrared thermometer Infrarot-Thermometer

694 944

Electric thermometer with temp. probe tip Temperaturmessgerät mit Temperaturfühler

793 788 73

Infrared revolution counter DS03, Measuring range : 1 to 9999 min-1 Infrarot-Drehzahlmesser DS03 Messbereich: 1 bis 999 min-1

793 789 73

Magnetic holder for DS03 Magnethalter für DS03

232 551 40

Manual non-contact revolution counter (digital) Berührungsloser Drehzahlmesser (digital)

232 756 40

Clamp-on ammeter AC/DC, Fluke 336 incl. carrying case, test lead, 2 batteries (AAA), user manual Technical data: Measurement range A/AC & A/DC: 0 - 600 A Measurement range V/AC & V/DC: 0 - 600 V Frequency range: 10 - 400 Hz Measurement range resistance: 0 – 6000 Ω Strommesszange AC/DC, Fluke 336 inkl. Tragetasche, Messleitung, 2 Batterien (AAA), Bedienungsanleitung Technische Daten: Messbereich A/AC & A/DC: 0 - 600 A Messbereich V/AC & V/DC: 0 - 600 V Frequenzbereich: 10 - 400 Hz Messbereich Widerstand: 0 – 6000 Ω

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


29 30

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Cable set for part no. 232 323 40 Kabelset für ET-Nr. 232 323 40 (s.o.)

Test manometer, incl. accessories Prüfmanometer, inkl. Zubehör 770 466 73 769 150 73 770 464 73 770 465 75

0 - 60 bar 0 - 400 bar 0 -16 bar 0 - 25 bar Pressure gauge Druckmanometer

793 361 73 793 362 73 793 363 73

0-25 bar (1 Stück / pc.) 0-60 bar (1 Stück / pc.) 0-400 bar (2 Stück / pcs.)

232 501 40

Pressure gauge fitting (4 pcs.) Anschluss für Druckmanometer (4 Stück)

Measuring hose Messschlauch 792 283 73 792 284 73

3200 mm lg (2 Stück / pcs.) 5000 mm lg (1 Stück / pc.)

761 520 73

Filling and testing device for piston, diaphragm and bladder accumulators 0 – 100 bar (with pressure reducer) Füll- und Prüfvorrichtung für Kolben-, Membran- und Blasenspeicher 0 – 100 bar (mit Druckminderer)

232 752 40

Tool case (without tools) Koffer (ohne Inhalt)

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


30 31

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Filling and testing device for piston and diaphragm and accumulators 0 – 25 bar Füll- und Prüfvorrichtung für Kolben- und Membranspeicher 0 – 25 bar

Thread reducing fitting (manometer) Gewindereduzierung (Manometer) 232 506 40 232 507 40 232 508 40

R 1/4” R 3/8” R 1/2”

232 385 40

Voltage tester 25 kV Spannungsprüfer 25 kV

232 386 40

Universal grounding short-circuiting device Ø 95/35, mm2 Universale Erdungs- und Kurzschließvorrichtung Ø 95/35, mm2

232 387 40

Insulation tester . . . 500 V Isolationsmesser . . . 500 V

232 713 40

ALIGNEO laser set, for the alignment of horizontal mounted machines ALIGNEO Laser-Set, für die Ausrichtung horizontal verbauter Maschinen

232 714 40

ALIGNEO Bracket set ALIGNEO Halterungssatz

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


31 32

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Phase-sequence indicator 100 . . . 600 V Drehfeldrichtungsanzeiger 100 . . . 600 V

Electronical unipolar voltage meter Elektronischer einpoliger Spannungsprüfer 232 389 40 232 390 40

5 – 10 kV 3 – 6 kV

232 594 40

Shock pulse transducer Stoßimpulsaufnehmer

232 595 40

Shock pulse transducer Stoßimpulsaufnehmer

232 596 40

Head receiver for shock pulse measuring instrument Kopfhörer für Stoßimpulsmessgerät

232 762 40

Test box for electrical components with Deutsch connectors Test-Box für elektrische Bauteile mit Deutsch-Steckern

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


32 33

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

System diagnostic for lubrication system Systemdiagnose für Schmieranlage

966 225

Crack detection testing kit, consisting of: Test-Set Rissprüfung, bestehend aus:

966 229

Permanent magnet Permanentmagnet

966 226

Magnetic powder Magnetpulver

996 228

Cleaner, spray can, 500 ml Reiniger, Sprühdose, 500 ml

966 227

Contrasting agent Kontrastmittel

232 723 40

Universal box Universalkoffer

991-1010 Tools

Measuring tools

Werkzeug

Messwerkzeuge


33 34

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Hand-held measuring unit MH 3020, 3 channels, USB interface, ISDS Memory: max. 1 million readings incl. power supply unit, USB cable and software Handmessgerät MH 3020, 3 Kanäle, USB-Schnittstelle, ISDS Speicher: max. 1 Million Messwerte inkl. Netzgerät, USB-Kabel und Software

793 781 73

Pressure sensor (2 pcs), 0 - 400 bar, ISDS Druckaufnehmer (2 Stck.), 0 - 400 bar, ISDS

793 783 73

Direct connector for pressure sensor no. 1620 (2 pcs) Direktanschluss für Drucksensor Nr. 1620 (2 Stck.)

793 784 73

Screw-in temperature sensor no. 1620 (2 pcs) -50°C up to 200°C, ISDS Temperatur-Einschraubfühler Nr. 1620 (2 Stck.) -50°C bis 200°C, ISDS

793 785 73

Rev counter sensor DS 03, incl. 25 reflection foils Drehzahlsonde DS 03, inkl. 25 Reflexionsfolien

793 787 73

Measuring cable (2 pcs), 5.0 m Messkabel (2 Stck.), 5,0 m

793 786 73

Measuring extension cable, 5.0 m Messkabel-Verlängerung, 5,0 m

793 782 73

Carrier box Transportkoffer

991-1010 Tools


Werkzeug



34 35

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

USB extension wire USB-Kabel

793 796 73

Data communication cable USB Datenübertragungskabel USB

796 441 73

UMG diagnostic software (CD) UMG-Diagnosesoftware (CD)

796 439 73

Converter Konverter

796 443 73

Cable set Kabel-Set

873 570 40

Content:

Inhalt:

Cable VL3 Cable VL12 Cable VL10 Cable VL9a Cable VL9b

Kabel VL3 Kabel VL12 Kabel VL10 Kabel VL9a Kabel VL9b

Data transfer, grease, memory ETM, ECS, 1 set Datenübertragung, Fett, Speicher ETM, ECS, 1 Satz

796 726 73

Bodem PC software Bodem PC-Software

896 791 40

Bodem connection cable Bodem Verbindungskabel

991-1010 Tools


Werkzeug



35 36

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Vibrotip-Set „Trend“ Engine analyzer and data collector Vibrotip-Paket ”Trend” Maschinen-Analysator und Datensammler

232 686 40

Drill for Vibrotip Bohrer für Vibrotip

232 685 40

Sensor with quick coupling Aufnehmer mit Schnellkupplung

232 747 40

LAN card, USB 2.0, 10/100 Mbit/s This USB-RJ45-adapter is a high-performance network converter for the USB 2.0 port LAN-Karte, USB 2.0, 10/100 Mbit/s Dieser USB-RJ45-Adapter ist ein leistungsstarker Netzwerkkonverter für die USB 2.0-Schnittstelle

232 748 40

CAT-5 Crossover adapter For fast direct PC connection via LAN (RJ45) CAT-5 Crossover-Adapter Für die schnelle PC-Direktverbindung über LAN (RJ45)

232 755 40

Crossover cabel, for CAT-5 Crossover adapter, double shielded, 1 meter Crossover-Patchkabel, für CAT-5 Crossover-Adapter, doppelt geschirmt, 1 Meter

991-1010 Tools


Werkzeug



36 37

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Cordless headphone intercom Sprechfunkanlage

232 623 40

Vacuum pump + adaptor Vakuumpumpe + Adapter

Puller, grip width/depth Abzieher, Spannweite/Spanntiefe 232 300 40 232 301 40 232 302 40

120 mm/100 mm 200 mm/150 mm 350 mm/200 mm

232 287 40

Grease gun, hand-lever type, with couplings, 400 bar Handhebelfettpresse, mit Anschlüssen, 400 bar

232 288 40

Fitters tub Montagewanne

232 000 40

Tool box, 5 trays 420 x 200 x 210 mm Werkzeugkasten, 5-teilig 420 x 200 x 210 mm

232 761 40

Tool chest With 3 wide & 3 small drawers and 1 removable element Width 663 mm, height 364 mm, depth 308 mm, weight 25.5 kg Delivery without tools Werkzeugtruhe Mit 3 großen & 3 kleinen Schubladen und 1 Trageeinsatz Breite 663 mm, Höhe 364 mm, Tiefe 308 mm, Gewicht 25,5 kg Lieferung ohne Werkzeuge

991-1010 Tools

Others

Werkzeug

Sonstiges


37 38

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Universal tool box Outside: Width 600 mm, height 330 mm, depth 400 mm, weight 4.5 kg Inside: Width 550 mm, height 310 mm, depth 350 mm, capacity 60 ℓ Universalbox Außen: Breite 600 mm, Höhe 330 mm, Tiefe 400 mm, Gewicht 4.5 kg Innen: Breite 550 mm, Höhe 310 mm, Tiefe 350 mm, Volumen 60 ℓ

232 299 40

Pinch bar with pointed and claw ends, 1000 mm long Brechstange mit Klaue und Spitze, 1000 mm lang

793 639 73

Removal tool for double-level terminals Lösewerkzeug für Doppelstockklemmen

232 542 40

Oil analysis Öl-Analyse

232 622 40

Suction pump, extracting oil for testing Pumpe zur Entnahme einer Ölprobe

Flat-link chain hoist Hubzug mit Gelenkkette 232 368 40 232 289 40 ???

Lifting capacity 0,75 t Lifting capacity 1,5 t Lifting capacity 3,0 t

324460 40

Cable suspension, 5 t

Tragkraft 0,75 t Tragkraft 1,5 t Tragkraft 3,0 t

Drahtseilgehänge, 5 t

991-1010 Tools

Others

Werkzeug

Sonstiges


38 39

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Edge protector Kantenschoner

792 006 73

Edge protector Kantenschoner

232 616 40

4-hook chain WMH S6 A = 1500 mm 4-Strang-Kette WM 1401 A = 1500 mm

232 617 40

Nylon lifting belt, AL 4 Width 75 mm, length 3500 mm 1500 kg Nylon Hebegurt, AL 4 Breite 75 mm, Länge 3500 mm 1500 kg

232 618 40

Nylon lifting belt Width 25 mm, length 1500 mm 1000 kg Nylon Hebegurt, AL 5 Breite 25 mm, Länge 1500 mm 1000 kg Lifting bolt Ringschraube

941 650 40 941 651 40 906 519 40 906 780 40 906 782 40 906 783 40 906 421 40 906 233 40

M8 M10 M12 M16 M20 M24 M30 M36

991-1010 Tools

Others

Werkzeug

Sonstiges


39 40

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Pin-driving press, complete set for crawler chassis Bolzenpresse, komplett für Traktorenlaufwerk

232 313 40

100 t, for all excavators up to H 121 100 t, für alle Bagger bis H 121

232 381 40

150 t, for all excavators up to H 185 150 t für alle Bagger bis H 185

232 626 40

Mounting bushing set for cylinder repair. When ordering tools, please always state the identification number of the cylinder. Montage-Buchsensatz für Zylinder-Reparatur. Bei Bestellung der Werkzeuge unbedingt die Ident-Nr. des Zylinders angeben.

999 860 73

5 finger gloves, with textile extension, with lining 5-Finger-Handschuhe mit Strickbund, gefüttert

999 861 73

Rubber gloves, size F3 and F4 Gummi-Handschuhe, Größe F3 und F4

991-1010 Tools

Others

Werkzeug

Sonstiges


40 41

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Working gloves, pork leather, with lining Arbeits-Handschuhe, Schweinsleder mit Futter

950 642

Canister 10 l (plastics) Kanister 10 l (Kunststoff)

950 643

Canister 25 l (plastics) Kanister 25 l (Kunststoff)

232 683 40

Combination angle set Satz Kombinationswinkel

232 717 40

Stud welding unit for threaded pins, with welding gun Bolzenschweiß-Kompaktanlage, mit Schweißpistole

991-1010 Tools

Others

Werkzeug

Sonstiges


41 42

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Magnet-Stick Magnetfeldprüfer

232 715 40

Hydro-pump, type IPV 3-8 101 Hydropumpe, Typ IPV 3-8 101

232 716 40

Coupling Kupplung

766 307 73 766 308 73 766 309 73 766 310 73 766 311 73 766 312 73 766 313 73 766 314 73 766 315 73 766 316 73 766 317 73 766 318 73 766 319 73 766 320 73 766 321 73 766 322 73 766 323 73 768 881 73 797 549 73

Mounting tools for dual cone seal rings at the undercarriage Montagewerkzeuge für Gleitdichtringe am Unterwagen

For detailed information refer to PARTS & SERVICE NEWS AH05511 Ausführliche Informationen siehe PARTS & SERVICE NEWS AH05511

991-1010 Tools

Others

Werkzeug

Sonstiges


42 43

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Thinner, 10 kg Verdünner, 10 kg

767 567 73

Primer, lemon yellow, 1 kg Grundierung, zitronengelb, 1 kg

083 026

Paint yellow, RAL 1007 Spray can, 400 ml Farbe gelb, RAL 1007 Spraydose, 400 ml

501 415 98

Paint sky-blue, RAL 5015 Can, 2,5 kg Farbe himmelblau, RAL 5015 Dose, 2,5 kg

767 568 73

Paint black, RAL 9005 Can, 1 kg Farbe Schwarz, RAL 9005 Dose, 1 kg

991-1010 Tools

Paint and accessories

Werkzeug

Lackiermaterialien


43 44

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Paint yellow = DEMAG KOMATSU colour Can, 1 kg Farbe gelb = DEMAG KOMATSU-gelb Dose, 1 kg

767 570 73

Paint grey = KOMATSU colour Can, 1 kg Farbe grau = KOMATSU-grau Dose, 1 kg

999 019

Nickel spray can, Metaflux 70-81 Nickelspray, Metaflux 70-81

991-1010 Tools

Paint and accessories

Werkzeug

Lackiermaterialien


44 45

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Liquid sealing compound (Epple blue, No. 28), 250 ml Flüssigdichtung (Epple blau, Nr. 28), 250 ml

461 798 40

Adhesive Sicomet 85, in tubes, for sealing the rotary joint (with rollers or balls) Klebstoff Sicomet 85, in Tuben, für die Abdichtung der Rollendrehverbindung, Kugeldrehverbindung

390 905

Teflon tape Teflonband

464 814

Insulating tape, 33-19 Tesa PVCd Isolierband, 33-19 Tesa PVCd

691 959

Filler bottle Startpilot Füllflasche Startpilot

989 967

Oil binding agent (paper sacks, 8 kg each) Ölbindemittel (Papiersäcke à 8 kg)

993 528 73

Cleaning agent Bio Pent E, for steam blasting cleaners Reinigungsmittel Bio Pent E, für Dampfstrahler

993 529 73

Cleaning agent Bio Versal, for steam blasting cleaners Reinigungsmittel Bio Versal für Dampfstrahler

999 926 73

Cleaning rags (fleece rags) 35 x 35 cm, bale of 30 kg Paket Putzlappen (Vliestücher) 35 x 35 cm, in 30 kg-Ballen

991-1010 Tools

Auxiliaries, cleaners, adhesive & sealant

Werkzeug

Hilfsstoffe, Reiniger, Kleber & Dichtungsmittel


45 46

Part-No.

Description

ET-Nr.

Gegenstand

Release: Ausgabe:

March 09th, 2010 09. März 2010

Loctite products Loctite-Produkte 414 299 40

Loctite No. 222 E, bolt lock fluid, 50 ml low stability, up to M36 Loctite Nr. 222 E, Schraubensicherung, 50 ml niedrigfest, bis M 36

973 125

Loctite No. 241, bolt lock fluid, 50 ml medium stability, up to M12 Loctite Nr. 241, Schraubensicherung, 50 ml mittelfest, bis M 12

973 130


255 242 40


170 470 40

Loctite No. 245, bolt lock fluid, 250 ml medium stability, up to M80 Loctite Nr. 245, Schraubensicherung, 250 ml mittelfest, bis M80

158 856 40

Loctite No. 27041, bolt lock fluid, 250 ml high stability, up to M20 Loctite Nr. 27041, Schraubensicherung, 50 ml hochfest, bis M20

167 644 40

Loctite No. 307, 50 ml metal adhesive (only in conjunction with 7471) Loctite Nr. 307, 50 ml Metallkleber (nur in Verbindung mit 7471)

288 906 40

Loctite No. 330, bonding set bonds nearly all materials (except Gi) Loctite Nr. 330, Klebeset verbindet nahezu alle Materialien (außer Gi)

461 798 40

Loctite No. 401, 20 g, Cyanacrylat bonds Kn, rubber, paperboard, leather, wood, and many more Loctite Nr. 401, 20 g, Cyanacrylat zum Verkleben von Kn, Gummi, Pappe, Leder, Holz, u.v.m.

991-1010 Tools


Werkzeug



46 47

Part-No.

Description

ET-Nr.

Gegenstand


March 09th, 2010 09. März 2010

Loctite No. 511, fluid sealing, 50 ml low stability, sealing threaded connections up to R2” Loctite Nr. 511, Flüssigdichtung, 50 ml niedrigfest, zum Abdichten von Verschraubungen bis R2”

232 554 40

Loctite No. 511, fluid sealing, 250 ml low stability Loctite Nr. 511, Flüssigdichtung, 250 ml niedrigfest

083 399 40

Loctite Nr. 586, fluid sealing, 50 ml high stability, up to R 2” Loctite Nr. 586, Flüssigdichtung, 50 ml hochfest, bis R 2”

255 239 40

Loctite 574, sealant for surfaces, 50ml gap size up to 0,5 mm Loctite Nr. 574, Flächendichtung, 50 ml Spaltgröße bis 0,5 mm

255 237 40

Loctite No. 603, for join connections, 50 ml high stability Loctite Nr. 603, Fügeverbindung, 50 ml hochfest

288 907 40

Loctite No. 706, fast cleaner, 400 ml Loctite Nr. 706, Schnellreiniger, 400 ml

321 32240

Loctite, removal of adhesives and sealants spray can, 300 ml Loctite, Klebstoff- u. Dichtungsentferner 300 ml-Sprühdose

083 376 40

Loctite Nr. 7471, activator, 500 ml (for hardening of 307 and for the acceleration of the hardening process) Loctite Nr. 7471, Aktivator, 500 ml (zur Aushärtung von 307 und zur Beschleunigung des Aushärtevorgangs)

991-1010 Tools


Werkzeug



47 48

Parts & Service News

8 PARTS & SERVICE NEWS

Version 2010/1

PC8000-6E

8 -1

Parts & Service News

Contents of this chapter: SB-No.

Subject

AH00511

Installation procedure for the swing circle / Slew Ring (SR)

AH00514

Track group - Hints for sprocket exchange

AH00515

Final drive: Wear and tear measurements Mounting procedures

AH00519

Adhesive lubricants for the Slew Ring Gear

AH01513

Bleeding of hydraulic pumps

AH01516

Lift off the superstructure platform from the undercarriage for instance to change the swing circle (slew ring)

AH01523

Replacement of the elastic coupling (Electro drive shovels)

AH01531

Hydraulic accumulators - testing and refilling

AH02513

Testing wear and tear of swing circle bearing

AH02521

Track group – wear measurement

AH03506

Hydraulic oil cooler and water cooler fan bearings

AH03510

ESCO bucket tooth system

AH03528

Pilot control safety line

AH04518

Welding procedure for welded counterweight

AH05501

Abnormal vibration on hydraulic pipes

AH05510

Bearing flushing of the A4VS variable displacement axial piston pump

AH05511

Dual cone seal ring mounting

AH05518

Swing circle pinion

AH05525

Suction elbows of the main Pumps

AH05535

Hints for replacing by the slewing gear of an other manufacturer

AH05546

Automatic lubrication system - Vent valve (PN 769 879 73)

AH06512

Travel gears - Brake and motor adapter housings - Oil Change

AH06524

Hydraulic cylinder

AH06530

Relieving of the track chain tension

AH06544

Hydraulic track tensioning system –Pressure increasing valve

AH06545

Hydraulic cylinder bushings

AH08504

Windscreen

AH08507

Steel structure

AH08508

Bushings of the attachment and at the undercarriage

AH08516

Hoses between boom and stick

AH08532


The numbers of the PARTS & SERVICE NEWS do not label the latest edition. Ensure that the latest edition is always filed to the binder of this manual. 8 -2

PC8000-6E

Version 2010/1

COMPONENT CODE:

2500

REF NO.

AH00511f

PARTS & SERVICE NEWS

DATE

February 12, 2009 Page 1 of 20

This PARTS & SERVICE NEWS supersedes the previous issue No. AH00511e which should be discarded. SUBJECT:

Installation procedure for the swing circle / Slew Ring (SR)

PURPOSE:

Revision

APPLICATION:

From H185S (06078) up to PC8000

FAILURE CODE:

2500Z9

DESCRIPTION: Content

Page

1. 2. 3. 4. 5. 6.

List of swing circle types Safety instructions General Measurements Determination of tightening torques Mounting of a swing circle Adjustment: Unhardened spot “s” Tooth back lash Hints for rotating the slew ring 7. Checking of fastening bolts 8. Lubrication and maintenance 8.1 Races of roller bearings 8.2 Outer toothing 8.3 General

1.

Type

H 185S H 255S / PC3000 H 285S PC4000 H 455S / PC5500 H 485S H 655S / PC8000 ( - 12036) PC8000 (12037 - ) H 685SP H 685SX (12030)

Slew ring Weight [t] 3,5 3,5 6,0 6,7 9,0 / 10,0 14,0 14,0 16,3 14,0 16,3

01 02 03 04 06 08 11 12 14 16 16 16 18 20 Mounting cross P/N

Tooth back lash [mm]

379 383 40 379 383 40 379 128 40 379 128 40 477 577 40 379 129 40 379 129 40 379 129 40 379 129 40 379 129 40

0.4 – 0.8 0.4 – 0.8 0.6 –1.0 0.6 – 1.0 0,6 – 1,0 0.5 – 0.9 0.5 – 0.9 0.5 – 2.5 0.5 – 0.9 0.5 – 2.5

AH00511f

Page 2 of 20

2. Safety Instructions •

Assign trained or well-instructed personnel only, and clearly define the respective spheres of responsibility for the repair work.

•

Inform the operating personnel prior to the commencing special and regular maintenance work.

•

Secure the maintenance area amply enough, as far as required.

•

Carry out repair and maintenance work only with the machine standing on firm and level ground and secured against rolling away and sinking in.

•

During exchange action, fix and secure individual parts and assemblies carefully to the lifting devices so that they cannot become dangerous in any way. Use exclusively suitable lifting devices consistent with sound engineering and load-lifting elements with sufficient load-bearing capacity! Never stay or work beneath suspended loads!

•

Entrust experienced personnel only with fastening and securing of loads and guiding crane operators! The guide has to be within the operator's visual range or have voice contact with him.

•

In case of assembly work exceeding body height, use suitable and otherwise secure means of access and working platforms. Never step on machine parts as an access! For maintenance work at higher levels, use the appropriate safety devices! Keep all handles, steps, handrails, landings, working platforms, ladders, etc. free from dirt, snow and ice!

•

Retighten immediately all bolted connections loosened during repair and maintenance work!

•

If disassembly of safety devices is required for rigging, maintenance, and repair, reassembly and checking of such safety devices has to be carried out immediately after having finished the respective work.

•

Strictly observe all safety instructions and warnings in the country of destination.

AH00511f

Page 3 of 20

3. General •

Before removing swing circle mark location of both slew rings to superstructure and the carbody as well for further investigations.

•

Shocks to the swing circle, especially radial ones, must be avoided.

•

Transport and store exclusively with transport star fitted. It is strictly forbidden to hook up the SR (Slew Ring) at the transport star.

•

Hang up and/or transport and store swing circle only horizontally. If a special attachment is available, the transportation and storage in oblique position may be carried out.

•

Only hang SR at four/three eyebolts evenly distributed in screw circle of the upper ring.

•

Prior to mounting the SR clean all supporting surfaces and the toothing, if necessary clean those areas with fat solvents, methylene chloride, cold cleaners. The cleaning agents must not enter the races. Hence, the swing circle has to be thoroughly lubricated before and after cleaning.

•

With each replacement swing circle and each new machine, fastening bolts, measuring bolts, a measuring device and mounting compound P/N. 324 969 40 will be delivered. If this parts delivery is not complete, please get immediately in contact with KOMATSU MINING GERMANY, because a proper mounting may not be possible in case of missing items.

AH00511f

Page 4 of 20

4. Measurements • •

Check the level of bearing area (only center section undercarriage) with a laser device before installing a new slew ring. To prevent incorrect measuring results caused by partial sun radiation onto the pedestal /carbody it is recommended that the whole area be protected from the direct sunlight.

Legend ID = Inner diameter slewring (mm) OD = Outer diameter slewring (mm) Π = 3.14 P = Maximum Deviation (deflection) (mm)

P = (OD – ID) ÷ 1000

Example: OD = 4000 mm ID = 3600 mm

W

P= P= P=

(4000mm – 3600mm) ÷ 1000

400mm ÷ 1000 0.4 mm

• If the measured value exceeds the calculated value P, the surface has to be remachined.

AH00511f

Page 5 of 20 • •

Check the outer diameter of the new slewring top surface and compare with the outer diameter of the factory machined surface of the superstructure. Remove the shoulder by machining if necessary.

)

• A shoulder exists only at some excavators.

AH00511f

Page 6 of 20

5. Determination of tightening torque The required tightening torque for all fastening bolts (inner and outer) has to be determined with the measuring bolts, which dimension is analogous to the outer fastening bolts mounted to carbody / swing circle. • The required axial tension force of the bolts is determined by means of the elongation of the fastening bolts, carbody and swing circle. • The tightening torque must be determined each time the SR (Slew Ring) is replaced as well as at the first assembling of the excavator at the operation site and for the first and final inspection after 1000 operation hours. • The required measuring device is delivered with the excavator or with the SR (Slew Ring) (see ill.). • To determine the tightening torque, eight specially prepared test bolts are supplied besides the normal fastening bolts. The test bolts can be recognized at the centering (Z) in the bolt head and in the end of the threads. The measuring device is composed of the following items and will be delivered with each replacement swing circle and each new machine:

(1) Measuring jaw (2) Test block

1pce. 1pce.

(3) Measuring bolt (4) Washer

8pcs. 1pce.

For the determination of the tightening torque, the eight measuring bolts have to be mounted one by one to the measuring device as illustrated. Then the bolt has to be tightened in steps to the prescribed elongation (see table page 05). The needed tightening torque will be determined as a result of average of eight tightening torque's. For the exactly procedure refer to the following pages.

AH00511f

Page 7 of 20

For the determination of the torque / or pressure (hydr. torque multiplier) for the elongation of the test bolts proceed according to illustration on page 03 and the following description. Before the mounting of the measuring bolts (3) to the jaw, the bearing surface of head, threads and washers have to be applied with compound P/N. 324 969 40. • Screw test bolt (3) with washer (4) in test block (2) and tighten manually. • Fit jaw (1) and micrometer gauge into the centering "Z" of the bolt and set gauge to zero. • Increase tightening torque of test bolts by steps of app. 200 Nm until the required elongation of the bolt according to the table is reached. Measuring bolts Type

Analogous to the dimension of the outer fastening bolts (8)

Quality grade

Wrench size

Elongation [mm]

H 185S

M 30 x 230

10.9

46 mm

0.55 ±0.015

H 255S / PC3000/1

M 30 x 230

10.9

46 mm

PC3000/6

M 30 x 230

10.9

46 mm

0.55 ±0.015 0.550±0.015

PC3000/6

M 30 x 190

10.9

46 mm

0.442±0.013

H 285S

M 36 x 220

10.9

55 mm

0.61 ±0.020

PC4000

M 36 x 220

10.9

55 mm

0.61 ±0.020

H 455S / PC5500

M 36 x 230

10.9

55 mm

0.58 ±0.020

H 485S (to 12010) H 485S (12011 up)

M 36 x 230 M 36 x 270

10.9 10.9

55 mm 55 mm

0.58 ±0.020 0.65 ±0.020

M 36 x 270

10.9

55 mm

0.65 ±0.020

M 36 x 295

10.9

55 mm

0.71 ±0.020

H 685SP

M 36 x 270

10.9

55 mm

0.65 ±0.020

H 685SX (12030)

M 36 x 295

10.9

55 mm

0.71 ±0.020

H 655S PC8000 (to 12036) PC8000 (12037 up)

• Note down the tightening values in Nm, ft. lbf. resp. bar. • Repeat this procedure with all eight test bolts. • Add all 8 tightening values and than divide by 8. • Tighten bolts (7) and (8) to the calculated value (refer to the drawing at the next page).

AH00511f

Page 8 of 20

6. Mounting of a Swing circle (refer to ill. pages 06/08)

Depending on the model, bushes (11) or washers (10) have to be mounted.

AH00511f

Page 9 of 20

)

• When replacing the swing circle, all fastening bolts must also be replaced.

The eight measuring bolts have to be mounted equally distributed on the outer ring of the swing circle. If scratches are found at supporting surfaces of washers or bushes, they must be reworked or replaced. Replacement swing circles has to be mounted without dowel pins. If the mounted SR (Slew Ring) was fixed to the platform with dowel pins, remove these ones. •

Clean fat-free supporting surfaces (A) carbody and platform.

•

Supporting surfaces (A) must be absolutely fat-free. Even the solvent must be rinsed away before assembling.

•

Check surface evenness (A).

•

The swing circles (5/6) must have good contact to the carbody and superstructure platform.

•

Check mating surfaces with feeler gauge.

•

Check lube lines for correct condition and grease passage.

•

Check accordance of tapped and through holes in SR (Slew Ring) with those in carbody and platform. Discordance's may easily cause distortions of SR.

AH00511f

Page 10 of 20

• For removal and assembly always use a mounting cross (M). Fabricate mounting cross (M) according to the drawing or order it under giving the corresponding P/N. The construction drawing of the mounting cross has to be ordered from the Parts Department if necessary. Swing circle weight

Mounting cross

[t]

P/N

H 185S

3.5

379 383 40

H 255S / PC3000

3.5

379 383 40

H 285S

6.0

379 128 40

PC4000

6.7

379 128 40

9.0 / 10.0

477 577 40

14.0

379 129 40

14.0

379 129 40

16.3

379 129 40

H685SX (12030)

16.3

379 129 40

H 685SP

14.0

379 129 40

Type

H 455S / PC5500 H 485S H 655S PC8000 ( - 12036) PC8000 (12037 - )

AH00511f

Page 11 of 20 • • •

Deposit and center SR with transport star (T, see page 07) on mounting cross (M). Check length of threads in platform and SR, if necessary retap. Place SR at its fastening position under the jacked-up platform.

Adjustment: Unhardened spot „S“ For the adjustment of the Unhardened spot "S", see illustration. The Unhardened spot of race surfaces (changeover area between beginning and ending of hardening process) is punch marked with a "S" at the inner resp. outer side of each race ring (5 and 6), see illustration. These spots "S" must not be placed within the main load area of the swing circle. Hence, the unhardened spot "S" has to be turned in an angle of 90° to the main load area as illustrated.

AH00511f

Page 12 of 20 • Lift SR until approx. 10 mm below the platform (observe unhardened spot "S"). • Screw fastening bolts (7) with washers (10) through swing circle into the platform. Slightly treat bolt heads, threads and washers with Compound, P/N 324 969 40. • Lift SR to the supporting surface by screwing in the bolts crosswise. • Lower mounting cross. • Remove transport cross.

Tooth back lash

The tooth back lash is the play measured by a feeler gauge in point D if tooth A press on the reference circle (B) against tooth C. On swing circle where you find a green color marking on 3 teeth, rotate the lower ring (6) until the 3 green marked teeth are mating with the teeth of a slew pinion.

Type

Tooth back lash [mm]

H 185S H 255S/PC3000 H 285S PC4000 H 455S/PC5500 H 485S H 655S/PC8000 ( -12036) PC8000 (12037 - ) H685SX (12030) H 685SP

0.4 – 0.8 0.4 – 0.8 0.6 – 1.0 0.6 – 1.0 0.6 – 1.0 0.5 – 0.9 0.5 – 0.9 0.5 – 2.5 0.5 – 2.5 0.5 – 0.9

Note: The green teeth indicate the point of the SR having the greatest circularity deviation of the reference circle (positive deviation). At this narrowest spot, a tooth backlash clearance according to the chart should be measured. On machines without green color marking at the teeth, adjust backlash at 4 points evenly distributed according to the following dimensions.

AH00511f

Page 13 of 20 Before lowering the platform with SR on center section of the undercarriage: 1. Mark 4 teeth(1; 2; 3; 4 - refer to illustration) displaced by 90 °. The slew gears are marked gear 1, gear 2 and gear 3 (if so present). 2. Rotate the slew ring so far that tooth 1 is engaged at pinion of slew gear 1. 3. Measure play between A and D. Note value in the table below. C means tooth 1 and must have contact at point B. 4. Rotate superstructure further until tooth 1 is engaged at pinion of slew gear 2. Measure play as described under step 3. 5. Rotate superstructure further until tooth 1 is engaged at pinion of slew gear 3. Measure play as described under step 3. 6. Rotate superstructure further that tooth two is engaged at pinion of slew gear 1. Measure play and note value in table. 7. Carry out same measuring procedure as described for the other teeth. At the end for every slew gear, four dimensions are noted in the table. 8. If necessary, adjust the backlash by displacement of the SR. For the correct backlash, refer to chart above. 9. Hints for the three slew gear version: Adjust an equal play at pinion of slew gear 1 and 3 by shifting the slew ring. For this use the installed adjusting bolts. Afterwards adjust play at slew gear 2 to the same value before adjusted at 1 and 3.

Tooth backlash Slew gear gear 1 gear 2 gear 3

Play – nominal value

Tooth 1 Tooth 2 Tooth 3 Tooth 4

refer to table at page 10

AH00511f

Page 14 of 20 Hints for rotating the slew ring 1. Remove the slew motor. 2. If the excavator is equipped with more than one slew motor: Remove the hoses at the other slew motor(s). 3. Loosen the slew brake(s) by applying external pressure (25 - 60 bar). 4. Use the below shown tool in place of the removed slew motor for rotating the slew ring (drive: 36 mm).

36 mm

)

• The shown tool can be used for Series: PC3000; PC4000; PC5500; PC8000.

Toothed shaft: DIN 5480 W 60x2x30x28x9g

Part no.: 864 501 40

AH00511f

Page 15 of 20

Tighten all SR fastening bolts with the torque determined. Use the same torque multiplier you have used for the determination.

) •

•

• Before mounting the bearing surface of bolt head, threads and washers have to be applied with compound P/N 324 969 40.

Fasten crosswise fastening bolts (7) with the previously determined tightening torque (see page 05). This has to be performed twice or three times, to ensure a setting of the bolts. During tightening check permanently toothed outer ring (6) for easy running. For this purpose unscrew hydraulic lines of slew motor and loosen all slew brakes by applying external pressure (25 - 60 bar). Check for easy motion in all ranges by turning the outer ring (6).

•

After tightening of all bolts (7) from SR to the superstructure, the tooth backlash has to be checked once more at 4 points, if necessary adjust again.

•

Lower platform with SR on center section of the undercarriage. Watch position of not hardened spot "S" of the ring (6) according to illustration on page 09. If necessary turn ring (6).

•

Screw in 8 measuring bolts with washers resp. bushings (11) evenly distributed and the other fastening bolts (8) with washers (10), and bushings (11).

•

Tighten crosswise all fastening bolts (7/8) with the previously determined tightening torque. This has to be performed twice or three times, to ensure a setting of the bolts.

AH00511f

Page 16 of 20

7. Checking of bolts To compensate settling between SR and parts connected to it the bolts must be checked after 1000 operation hours. If necessary retighten bolts with the determined torque (refer to page 05). • • • •

Unscrew the eight test bolts (4) of the connection SR / carbody. Determine the required torque with these eight test bolts (4) in the test block (2). For the procedure, refer to the pages 03 - 05. Retighten all bolts (4/7/8) with the same torque multiplier you have used for the determination. On the models H 285 - H 685 for the retightening of the bolts of the connection SR / platform you need an extension, Part-No. 232 511 40.

8. Lubrication and maintenance (RDV) 8.1.

Races of roller bearings

Races must be lubricated regularly using high quality brands of lubricants. This is particularly important before and after longer interruptions of operation (e.g. winter intermission). The grease content in the race system is intended to avoid friction, to seal and to prevent corrosion. Greasing must be done abundantly until a continuous collar of grease pours out of the entire circumference of the upper seal "L" and the lower bearing gap "G". When greasing check visually the upper bearing seal "L" and, if necessary, replace immediately in order to prevent dirt and/or water to penetrate into the race system.

)

• Avoid cleaning agents to enter the race system when cleaning the excavator with high-pressure water or with vapor blast apparatuses. Before and after each cleaning grease thoroughly. The even distribution of grease requires slewing of the superstructure during greasing.

AH00511f

Page 17 of 20

Lubricating by central lube systems use With central lube systems, the lubricating intervals are controlled by the time control unit and the grease quantity is controlled by the adjustable metering valves / distributor valves in order to meet the local requirements. Manual greasing The lubrication intervals can be found in the Lubrication and Maintenance Manual. Before greasing clean grease nipples. Shorter intervals must be selected in tropical climate, in high humidity, under important effects of dust and dirt, considerable changes of temperature and continuous slewing motions e.g. during material transfer. Lubricants For greasing only use high quality grease which meets the requirements of the KOMATSU MINING GERMANY Lubricant Specification 011 597 99 (published in July 1995) section A. When choosing the grease, consider the ambient temperature range. Exchange of the lip type seal "L" (see ill., page 06) If a damage of the seal is determined while greasing operation, it has to be exchanged immediately, to avoid damages, caused by contamination. The exchange has to be performed as follows: • • • •

Remove the complete lip type seal. Clean groove fat-free, remove lip remainder completely Insert new lip type seal (P/N, refer Parts Catalogue). The seal must not be stretched during pushing in. Finally, the seal has to be cut to the needed length and the ends has to be glued together. The gluten is available under P/N 989 965.

AH00511f

Page 18 of 20

8.2.

Outer toothing

Adhesive lubricants may be applied by means of an automatic swing circle gear lubrication system or manually by a spatula, a brush or a spray tin. Lubrication with automatic lubrication system •

Spray lube system

•

Drop lube system

•

Swing circle gear lubrication system

The most important requirement of a swing circle gear lubricant, besides the extreme pressure resistance, is its optimum adhesion to the tooth flanks, which can only be obtained by using the recommended lubricants in the prescribed temperature ranges. The following table includes several adhesive lubricants providing excellent results on several machines under different working conditions. The use of other lubricants is not recommended before consultation of Dept. 8151.

AH00511f

Page 19 of 20

The following table includes several adhesive lubricants providing excellent results on several machines under different working conditions. The use of other lubricants is not recommended before consultation of Dept. 8151. Note: Use these Greases for Swing Circle open Gear Lubrication only Ambient Temperature °C ⇒ °F ⇒ Supplier

-50 -58

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

30 86

40 104

50 122

60 140

Castrol Molub-Alloy 936 SF Heavy NG BP / Castrol Industrie GmbH

Castrol Molub-Alloy 936 SF Heavy Castrol Molub-Alloy 958 SF Castrol Molub-Alloy 936 SF Arctic BERULIT GA 2500 / BERUGEAR W4000

BECHEM

BERULIT GA 800 BERUGEAR W 3000 Beru Gear FG 34 (Biodegradable) Molub unee lubricant 7059 Molub Gear Tac 6895

BEL RAY Molub Gear Tac 6894 / 6899 ESSO

Dynagear Extra Ceplattyn KG 10 HMF

FUCHS LUBRITECH

Ceplattyn KG 10 HMF LT URETHYN HG O *1)

MOLYBOND

TSG Heavy Malleus GL 500

SHELL

Malleus GL 400 Malleus GL 25

TEXACO LUBRITENE *1)

*2)

Crater 2X Fluid *2) Lubrene Multi ServOGL

The URETHYN HG O Grease should only be used in Arctic climates where the ambient temperatures fall to –50° C. In regions where the ambient temperatures do not fall below –40° C, a grease of the temperature range to –40° C should be used. Use the Crater 2X Fluid for Spray systems only.

AH00511f

Page 20 of 20

Lubrication: Manual The manually lubrication has to be carried out with the following adhesive lubricants. Those lubricants are suitable for all temperature ranges. Company Product Komatsu Voler Compound 2000 E Mining Germany Spray (0,625kg) Voler Compound 2000 E Special Adhesive lub grease (indicate quantity in kg)

T1 -5°C ⇒ +60°C +23°F ⇒ +140°F

T2 -20°C ⇒ +10°C -4°F ⇒ +10°F

T3 -40°C ⇒ -10°C -40°F ⇒ +14°F

P/N 500 893 98

P/N 006 057 98

8.3 General The adhesive lubricants protect the tooth profile against dust, dirt, and damage resulting from driving or braking actions. However, this protection is effective only when the adhesive greases have been applied to clean surfaces where it can form a continuous coating. When bright spots show up at the tooth profile the toothing must be sprayed or laid on immediately with the special adhesive grease. When visiting customers, the service staff or dealers should also check the machine equipment and stock of lubricant and advise the exchange, if necessary, to prevent premature wear of the toothing. •

The adhesive lubricants provide totally different features compared to the Bearing greases / MPG (e.g. used in the central lubrication system). Hence, those lubricants must not be replaced against each other or mixed. Example: This may happen when grease pressed out of the upper sealing system of the races forms too big collar at the swing circle and penetrates into the toothing. This eventuality must be avoided by removing the excess grease.

• If tooth profiles of the slewing connection have been damaged due to one of the above mentioned reasons they do not fall under our warranty.

AH00511f


COMPONENT CODE:

3000

REF NO.

AH00514

DATE

08162000 Page 1 of 11

This PARTS & SERVICE NEWS supercedes the previous issue No. 21 – 251c dated May 2000 which should be discarded. SUBJECT:

Track group - Hints for sprocket exchange

PURPOSE:

Sprocket exchange in case of normal wear

APPLICATION:

H 185S; H 241; H 285; H 285S; PC4000; H 485; H 485S; H 685S/SX; H 655S; PC8000

FAILURE CODE:

3000CA

DESCRIPTION: 1. Sprocket types 1.1 Standard sprocket 1.2 Oversize sprocket 2. Part no. 2.1 Sprockets with hub 2.2 Sprockets without hub / shaering pins 3. Removal sprocket 4. Conversion of the hub 5. Preparing the shearing pins 6. Determination of the Axial Play 7. Remachining 8. Assembly 9. Torque Data for Standard Application

AH00514

Page 2 of 11

1. Sprocket types 1.1 Standard sprocket The standard sprocket has to be used in case of assembling new machine or regenerating the track group in connection with new track pads. 1.2 Oversize sprocket The oversize sprocket has to be used to compensate chain elongation, wear on sprocket diameter and wear in the roller path on track pads, caused by the wear of the chain, if the X-dimension / circular pitch, comes up to 0.5 mm (see Service Bulletin 21-205 latest edition). This retrofitting assures assembly condition of the X – dimension of a new machine, furthermore the service life of the track group will be increased. The oversize sprocket is available without a sprocket hub, if the old one is reuseable. For the part no. of sprockets and the mounting procedure, refer to the following pages. The conversion of the sprockets is very time- and cost-intensive, so it is recommended to exchange the final-drive bearings at the same time if the dimensions have reached the wear tolerances, to avoid a standstill of the machine for the final-drive bearing exchange only. Before placing the order, pay attention to Service News AH00515 and Parts Catalogue for correct choice of the bush type. Basically, all seals (4; 5; 6; 10, see page 04) according to Parts Catalogue have be replaced.

.

• The difference between the standard version (NT) and the very low temperature version (TT) are only the bolts. The sprocket and the shearing pins are the same.

AH00514

Page 3 of 11

2. Part no. 2.1 Standard sprocket (T) with hub

Oversize sprocket with hub (T)

Type H 185S H 241 H 285 H 285S PC4000 H 485 H 485S H 685S/SX H 655S/ PC8000

Type H 185S * H 241 H 285 H 285S

Part No. 429 206 40 261 678 40 352 433 40 643 940 40 643 936 40 313 343 40 643 930 40 643 930 40 643 930 40

Part No. 448 943 40 425 656 40 425 654 40 643 936 40

PC4000 643 940 40 H 485 426 016 40 H 485S 643 926 40 H 685S/SX 643 926 40 H 655S/ PC8000 643 926 40 * Oversize sprocket for H 185S is available only with hub

AH00514

Page 4 of 11

2.2 Oversize sprocket without hub (R) / Shearing pins (O) Type H 241 H 285 H 285S PC4000 H 485 H 485S H 685S/SX H 655S/ PC8000

Sprocket (R) Part No. 425 655 40 448 961 40 887 105 40 887 105 40 448 969 40 643 923 40 643 923 40 887 115 40

Pin numbers 4 6 6 6 8 8 8 8

Pin (O) Part No. 429 638 40 429 691 40 429 691 40 429 691 40 429 640 40 429 692 40 429 692 40 429 692 40

AH00514

Page 5 of 11

3. Removal sprocket • • • • • • • •

Suspend travel gear (1) to a crane, remove mounting bolts. Remove travel gear by using the pulling bolts, put aside. Remove cover (2). Underpin sprocket (T/R) from below, suspend to a crane. Pull out drive shaft (8). Remove mounting bolts in flange bearing (7), loosen by using the pulling bolts, extract. Extract hollow shaft (9) to cover side (2), lift sprocket (T/R) out. Remove mounting bolts in flange bearing (3), loosen by using the pulling bolts, extract. 14

22

50

34 AH00514

Page 6 of 11

4. Conversion of the hub

Loosen bolts and bore into shearing pins.

Pin

Do not drill through !

Model H 241 H 285/ H 285S PC4000 H 485/ H 485S H 685S/SX H 655/ PC8000

Pin dia. (mm) standard 42 50 50 55 55 55

Drill dia. (mm) 36 44 44 49 49 49

Pin dia. (mm) oversize 44 52 52 57 57 57

Drill dia. (mm) 36 44 44 49 49 49

Pull out shearing pins. Separate hub and sprocket, if necessary heat up sprocket to approx. 100°C. Insert hub into the new sprocket and align corresponding to the existing holes. Insert bolts and tighten.

AH00514

Page 7 of 11

Drill holes on a vertical boring machine. The sprocket has to be on top. Use Shell counterbores of high speed steel. Model H 241 H 285/ H 285S PC4000 H 485/ H485S H 685S/SX H 655/ PC8000

Holes for the shearing pins 4 x 43.5 mm 6 x 51.5 mm 6 x 51.5 mm 8 x 56.5 mm 8 x 56.5 mm 8 x 56.5 mm

Ream the holes for the shearing pins. Model H 241 H 285/ H 285S PC4000 H 485/ H485S H 685S/SX H 655/ PC8000

Holes for the shearing pins 4 x 44 H7 6 x 52 H7 6 x 52 H7 8 x 57 H7 8 x 57 H7 8 x 57 H7

After reaming bur the holes carefully. 5. Preparing the shearing pins “A” sprocket

hub “B” By means of a 3 point inside micrometer measure the diameter “A” and “B” at the spots as shown in the illustration. Add 0.04 mm to the larger diameter and grind the oversize sharing pin to this dimension. Repeat this procedure separately for all pins. Example: “A” = 57.01 mm “B” = 57.02 mm “B” is bigger.

The diameter of the pin has to be : 57.02 mm + 0.04 mm = 57.06 mm

Shearing pins have to be deep-freezed by using liquid nitrogen (-196°C/-320°F and pushed into the reamed holes. AH00514

Page 8 of 11

4

29

50 29

AH00514

Page 9 of 11

6. Determination of the Axial Play After removal, all seals have to be renewed. • • • • • • • • • • •

Slide O-ring (5) over flange bearing (3). Mount flange bearing (3) without dual-cone seal (29). Pay attention to the lubrication-grooves position, they have to be displaced by 22.5° to the vertical line. Mount all bolts (50) and tighten according to tightening torques on the last page. Suspend sprocket (T/R) to a crane , insert without dual-cone seals(29). Mount hollow shaft (9) and slide against collar “B”. By this, the sprocket (T/R) is moved against the collar of the bushing. Mount flange bearing (7) with 3 bolts (22) without dual-cone seal (29). Measure dimension “X”. Slide sprocket (T/R) to direction “C” until the hollow shaft (9) rests against the collar “D” of the flange bushing. Measure dimension “Y”. The axial play result in X – Y .

7. Remachining If the amount of axial play exceeds 0.9 mm (H 241 > 0.5mm). area E has to be remachined until the original dimension, is reached. If the amount of axial play is less than 0.2 mm, area F has to be remachined until the original dimension, is reached. Type H 185S H 241 H 285/ H 285S PC4000 H 485/ H485S H 685S/SX H 655S/ PC8000 •

Original 0.2 – 0.9 0.2 – 0.5 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9

Wear limit 2.75 2.00 2.75 2.75 2.75 2.75 2,75

Suspend sprocket (T/R) to crane, pull out hollow shaft (9), lift sprocket (T/R) out.

AH00514

Page 10 of 11

5

29

9

29

50

AH00514

Page 11 of 11

8. Assembly • • • • • • • • • • • • •

Mount dual-cone seal (29) according to SB 10-33 into flange bearing (3). Mount dual-cone seals (29) according to SB 10-33 into sprocket (T/R). Place sprocket (T/R) into the side frame by using a crane, align and underpin sprocket in mounting position. Mount hollow shaft (9). Mount dual-cone seal (29) according to SB 21-558 into flange bearing (7). Mount flange bearing (7). The lubrication grooves of the bushing(4) have to be displaced by 22.5° to the vertical line. Tighten bolts (22), according to the tightening torques below. Insert O-ring(6) in cover (2). Mount cover (2) with bolts (14). Tighten bolts (14), according to the tightening torques below. Insert O-ring (10). Suspend travel gear (1) to a crane and mount to side frame. Tighten bolts (34), according to the tightening torques below. Refill oil and check levels.

.

• When selecting tightening torques, observe size and quality grade of the bolts.

9. Torque Data for Standard Application

Bolt dia. [mm] M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 33 M 36

Wrench size [mm] 17 19 22 24 27 30 32 36 41 46 50 55

8.8 43/32 74/54.6 118/87 179/132 255/188 360/265 485/358 620/457 920/679 1250/922 1690/1246 2170/1600

Tightening torque Nm/lbs.ft. Quality grades 10.9 63/47 108/80 173/128 265/196 360/265 510/376 690/509 880/649 1310/966 1770/1305 2400/1770 3100/2286

12.9 73/54 127/94 202/149 310/229 425/313 600/443 810/597 1030/760 1530/1128 2080/1534 2800/2065 3600/2655

Insert all bolts lubricated with MPG, KP2K type lubricant.

AH00514


COMPONENT CODE:

30

REF NO.

AH00515c

DATE

July 5, 2006 Page 1 of 10

This PARTS & SERVICE NEWS supersedes the previous issue No. AH00515b which should be discarded. SUBJECT:

Final drive:

Wear and tear measurements Mounting procedures

PURPOSE:

Revision

APPLICATION:

H 185S; H 285; H 285S; PC4000; PC5500 (#15026 and up); H 485; H485S; H 685S/SX; H 655S; PC8000

FAILURE CODE:

3000CA

DESCRIPTION: 1. Wear and tear measurements 1.1 Radial wear determination a) Preparation b) Measuring procedure Method A c) Measuring procedure Method B d) Determination of wear depending on the Bushing version Old or New 1.2. Axial play determination of the hollow shaft a) Measuring procedure b) Reducing the axial play by remachining 2. Mounting procedures 2.1 Mounting of drive shaft a) Gap between drive shaft and cover plate b) Measuring procedure c) How to establish the recommended gap 2.2 Exchange bushings a) Freeze shrinking bush b) Flange Assy. with freezed in bush 3. Final works

1. Wear and tear measurements The wear- and tear-measurements on the bearing bushings in mounted condition inform quickly and exactly about the axial and parallel abrasion, without quickly a time and cost-intensive disassembly of the final drive. It is recommended to perform the measurements every 5000 working hours to avoid consequential damages as a result of a too high abrasion amount. The wear- and tear-measurements are described and illustrated on the following pages.

AH00515c

Page 2 of 10

1. Wear and tear measurements 1.1. Radial wear determination a) Preparation For the measurements proceed according to the following sequence: • • • • •

Place suitable oil pan for outflowing oil and remove cover (H). Operate travel gear that the bores (B) in the hollow shaft are placed in vertical position (see illustration). Turn the superstructure to the illustrated position. Hoist the sprocket side by using the attachment, until a wooden plank can be placed under the track (middle of sprocket). Lift attachment until the bucket no longer touches the ground.

AH00515c

Page 3 of 10 b) Measuring procedure Method A • • • •

Place dial gauge bracket with magnet (1), dial gauge (2) and bolt (3) as shown in illustration below. Set dial gauge (2) to “0” when attachment is lifted. Wooden plank must lie under the sprocket. Hoist the sprocket side by using the attachment until the wooden plank is free. Take reading of dial gauge.

c) Measuring procedure Method B •

Check by using a feeler gauge between hollow shaft and bearing bush.

AH00515c

Page 4 of 10 d) Determination of wear depending on the Bushing version Old or New Because of technical development the bushings (P/N 429 649 40 for H 485; H485S; H 685S/SX; H 655S; PC8000) and (P/N 429 652 40 for PC4000) are made of a new material and have spiral grooves instead of radial grooves of the former version.

Type H 485; H485S; H 685S/SX; H 655S; PC8000 H 285; H 285S; PC4000 PC5500 (#15026 and up)

Bearing assy.* (outside) old new

Bearing assy.* (inside) old new

Bushings * old

new

31335540

91159540

31335640

92298040

42964940

92298440

36103640 ----

92253840 93360240

36103740 ---

92253940 93360440

42965240 ---

92253740 93360040

* Refer to the respective Parts Catalogue of the machines.

Old bushing version

)

• The radial play after new machine assembly amounts to 0.35 mm to 0.45 mm *. • If the maximum permissible parallel play comes up to 2 mm, the bushings have to be changed *. * – H 485; H485S; H 685S/SX; H 655S; PC8000 only up to S/N 12041. – PC4000 only up to S/N 08155.

New bushing version

)

• For machines with the new bushings (P/N 922 984 40) the radial play after installation amounts to 0.74 mm to 0.85 mm. If the maximum permissible parallel play comes up to 2.0 mm, the bushings have to be changed. • For machines with the new bushings (P/N 922 537 40) the radial play after installation amounts to 0.56 mm to 0.66 mm. If the maximum permissible parallel play comes up to 2.0 mm, the bushings have to be changed. • For machines with the new bushings (P/N 933 600 40) the radial play after installation amounts to 0.67 mm to 0.77 mm. If the maximum permissible parallel play comes up to 2.0 mm, the bushings have to be changed.

AH00515c

Page 5 of 10

1.2. Axial play determination of the hollow shaft a) Measuring procedure • • • • • • • • •

Make bracket (1) as shown in the illustration. The bores dia. have drilled respectively to the thread diameter (see table). Screw threaded rods (4) into the hollow shaft. Mount nuts (3), bracket (1) and bolts (2) as shown in the illustration. Hoist the sprocket side by using the attachment until the sprocket no longer touches the ground. Slide hollow shaft in by using nuts (3) until it comes against the final stop. Place dial gauge with bracket, set dial gauge to “0”. Slide hollow shaft out by nuts (3) until it comes against the final stop. Take reading of dial gauge. When the maximum values (see table) are reached, the play can be reduced to the new machine value by remachining according to page 5.

Type

H 185 / S H 285 / S PC4000 PC5500 H 485 / S H 685S / SX H 655S/PC8000

Mounting bolt (2)

Threaded shaft (mm)

M 12 M 16 M 16 M 12 M 16 M 16 M 16

M 16 M 20 M 20 M 20 M 20 M 20 M 20

Gauge (S) (mm)

316 360 360 435 460 460 460

Axial play new (mm)

0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9 0.2 – 0.9

Max. permissible axial play (mm) 2.75 2.75 2.75 2.75 2.75 2.75 2.75

AH00515c

Page 6 of 10 b) Reducing the axial play by remachining When the axial play comes up to the maximum value according to the table on page 4, flange (2) can be remachined in area (E) , to bring the axial play to the new machine condition. • • • •

Underpin sprocket, suspend to a crane. Remove bolts (S) (see page 06), remove flange (2) by means of puller bolts. Remachine flange (2) in area (E), until the axial play (new value) is reached. For the mounting , proceed in inverse sequence of the removal.

AH00515c

Page 7 of 10

2. Mounting procedures 2.1 Mounting of drive shaft a) Gap between drive shaft and cover plate • Install drive shaft (12)

)

• The drive shaft has a multi-spline shaft at both ends. • The correct mounting position is when the longer toothing faces the gear.

b) Measuring procedure • Check if the drive shaft rests completely against the stop in the gear by means of a hit with a mounting bar and a metallic click is audible. • Measure dimension “A” at the cover plate (7). • Measure dimension “B” according to the illustration by mean of measuring device (1). • Calculate the existing play with formula: “B” minus “A” = 2 mm.

c) How to establish the recommended gap Play too much, machine cover plate at surface “C”. Play too low, machine cover plate at surface “D”. C

Cover (Drawing enlarged)

7

D „B“

1

12

5

„A“ AH00515c

Page 8 of 10

2.2 Exchange bushings

)

• The removal of the travel gear is described in Service News AH00514 (latest version), the mounting of the dual-cone seals (4) is described in Service Bulletin AH05511 (latest version).

Exchange bushings are available in the following types: a) Freeze shrinking bush Exchange bush (3) has to be fixed by freeze- shrinking according to Service Bulletin 21 – 62a. Afterwards, it has to be remachined to the final dimension according to table below. Parts (3; 4; 5 and 6) have to be ordered for the conversion. For the part no. refer to the respective Part Catalogue of the machines. Type

Dnew (mm)

H 185 / S

355.35+0.07

H 285 / S

400.56+0.06

PC4000 PC5500

400.56+0.06 480.67+0.06

H 485 / S

520.74+0.07

H 685S / SX

520.74+0.07

H655S/PC8000 520.74+0.07

AH00515c

Page 9 of 10 b) Flange Assy. with freezed in bush If the remachining of the flange under consideration of the tolerances and diameters is not possible, it is recommended to order the flanges with freezed–in and machined bushings , to shorten the standstill of the machine. For conversion, the parts shown below (3; 4; 5; 6 and 7) have to be ordered according to the respective Parts Catalogue of the machines.

AH00515c

Page 10 of 10 3. Final works (For detailed informations refer to the respective Maintenance Manual of the machines.) 1. Fill in new oil up to the ”MAX” marking on oil level gauge (3). 2. After short operating period check oil level and gear for leaks.

AH00515c


COMPONENT CODE:

25

REF NO.

AH00519e

DATE

January 15, 2007 Page 1 of 4

This PARTS & SERVICE NEWS supercedes the previous issue AH00519d which should be discarded. SUBJECT:

Adhesive lubricants for the Slew Ring Gear

PURPOSE:

Revision

APPLICATION:

All types

FAILURE CODE:

2500Z9

DESCRIPTION: The transmission of a torque from the slew pinion to the toothing of the slew ring causes the slewing of the superstructure. The existing extreme force in this section requires the separating of the engaged gears by means of grease film, to ensure a proper damping of shocks and to prevent metallic abrasion. Adhesive lubricants may be applied by means of an automatic slew ring gear lubrication system or manually by a spatula, a brush or a spray tin. Automatically tooth lubrication systems provides the upper most protection because of the continuously uninterrupted lubrication, permanent checks are not required.

AH00519e

Page 2 of 4

)

• Independent of the lubricant and lubrication system, the toothing should be visually checked approx. every 500 working hours. If the check is not possible because of applied lubricant, the toothing has to be cleaned at several points equally distributed on the circumference of the slew ring. In case of wear or damages, Dept. 8151 has to be informed to discuss suitable remedies.

ã

• These adhesive lubricants provide totally different features compared to the Bearing greases / MPG (e.g. used in the central lubrication system). Hence, those lubricants must not replace against each other or mixed. Example: This may happen when grease (1) pressed out of the upper sealing system of the races forms too big collar at the slew ring and penetrates into the toothing (2). This eventuality must be avoided by removing the excess grease.

AH00519e

Page 3 of 4 The following table includes several adhesive lubricants providing excellent results on several machines under different working conditions. The use of other lubricants is not recommended before consultation of Dept. 8151. Note: Use these Greases for Swing Circle open Gear Lubrication only Ambient Temperature °C ⇒ °F ⇒ Supplier

-50 -58

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

30 86

40 104

50 122

60 140

Castrol Molub-Alloy 936 SF Heavy NG Castrol Industrie GmbH

Castrol Molub-Alloy 936 SF Heavy Castrol Molub-Alloy 958 SF Castrol Molub-Alloy 936 SF Arctic BERULIT GA 2500 / BERUGEAR W4000

BECHEM

BERULIT GA 800 BERUGEAR W 3000 Beru Gear FG 34 (Biodegradable) Molub unee lubricant 7059 Molub Gear Tac 6895

BEL RAY Molub Gear Tac 6894 / 6899 ESSO

Dynagear Extra Ceplattyn KG 10 HMF

FUCHS LUBRITECH

Ceplattyn KG 10 HMF LT URETHYN HG O *1)

MOLYBOND

TSG Heavy Malleus GL 500

SHELL

Malleus GL 400 Malleus GL 25

TEXACO LUBRITENE *1)

*2)

Crater 2X Fluid *2) Lubrene Multi ServOGL

The URETHYN HG O Grease should only be used in Arctic climates where the ambient temperatures fall to –50° C. In regions where the ambient temperatures do not fall below –40° C, a grease of the temperature range to –40° C should be used. Use the Crater 2X Fluid for Spray systems only.

AH00519e

Page 4 of 4 The manually lubrication has to be carried out with the following adhesive lubricants. Those lubricants are suitable for all temperature ranges.

Company

Product

T1 -5°C ⇒ +60°C +23°F ⇒ +140°F

T2 -20°C ⇒ +10°C -4°F ⇒ +10°F

T3 -40°C ⇒ -10°C -40°F ⇒ +14°F

Voler Compound

KOMATSU

2000 E Spray (0,625kg)

P/N 500 893 98

Voler Compound

Special grease

)

2000 E Adhesive lub (indicate quantity in kg)

P/N 006 057 98

• What has to be done in case of grease exchange according to the chart on page 03 ? • The new adhesive grease may directly be changed without a complete cleaning of the toothing. An increased grease supply after the exchange is recommended until the toothing is completely applied.

AH00519e

COMPONENT CODE:

K1; J1

REF NO.

AH01513

DATE

06252001


Page 1 of 4 This PARTS & SERVICE NEWS supercedes the previous issues No.: 21–491 which should be discarded. SUBJECT:

Bleeding of hydraulic pumps

PURPOSE:

Avoiding of cavitation

APPLICATION:

All types

FAILURE CODE:

J100PH; K100PH

DESCRIPTION:

The bleeding of the hydraulic pumps (Axial piston and Gear pumps) and the complete filling of the suction oil reservoir and the suction lines has strictly be done, to prevent damages caused by air in the suction system (cavitation). If the oil level decreases in the suction oil reservoir or the pump flows empty in case of commissioning or repairs the bleeding of the system is momentous and has to carried out as follows.

.

The bleeding procedure has to be carried out on all pumps !

Hydraulic pump

PTO

Suction line Hydraulic oil reservoir Cock closed

Suction oil reservoir

AH01513

Page 2 of 4

Hydraulic pumps at the Pump Distributer gear (Example PC4000)

3; 4

Gear pumps

1; 2

Axial piston pump (bent axis design)

I; II; III; IV

Axial piston pump (swashing plate design)

AH01513

Page 3 of 4

1. Gear pump

5 4

1

Cock closed

Precondition Þ • Hydraulic oil reservoir (1) filled • Cock (2) closed • Suction oil reservoir (3) totally empty or decreased level • Suction line (4) empty • Hydraulic pump (5) empty

3 2

5 outflowing oil

4

1

Measure Þ • Place oil pan for out coming oil. • Loosen suction line (4) • Open cock (2), when oil runs out, reconnect suction line (4)

Cock opened

3 2 The a.m. precondition has also be observed for the axial piston pumps.

2.a Axial piston pump (bent axis design)

Precondition (see above) Measure Þ • Remove plug (6) • Open cock (2) • When oil flows out of the bore, insert plug (6) tighten.

6

Cock opened

.

• The bleeding plug (6) may be placed different, it depends on

the design and mounting position.

AH01513

Page 4 of 4

2.a Axial piston pump (swashing plate design) The pump housings has to be filled up with hydraulic oil before installation and after repairs via the special bore (A) or via the leak oil connection (B).

A

B

C

.

• The suction lines of the Axial piston pumps (swashing plate

design) have to be bled via plug “C”. For that open the plug and wait until oil is coming out.

After the bleeding procedure, the hydraulic oil reservoir has to be refilled to the permissible level.

AH01513

COMPONENT CODE:

2500

REF NO.

AH01516a


DATE

09062001 Page 1 of 7

This PARTS & SERVICE NEWS supersedes the previous issue No. AH01516 which should be discarded. SUBJECT:

Lift off the superstructure platform from the undercarriage for instance to changing the swing circle (slew ring)

PURPOSE:

Description of the method for preparing the repair works

APPLICATION:

H 485; H 685; H655; PC8000-1 (from serial number 12001 up)

FAILURE CODE:

2500CA

DESCRIPTION:

1. Preparation 1.1 Park the excavator at a smooth, solid and big enough mounting place. 1.2 Make available the following tools and aids (see Fig. Z 21169): • Two cranes 40t for disassembly and assembly with various rigging materials (for a time) • Forklift • Four hydraulic jacks (200t) • 4 chain hoists for the cylinder assembly and cylinder securing respective • 1 hydraulic torque wrench • Lifting brackets (3)* for lifting up the superstructure at the front lever arms • 2 concrete blocks (1) - 150/400/200 cm - and 4 concrete blocks (2) - 100/150/50 cm - all blocks with reinforcing and pull eyes; the upper sides and the undersides have to be even. For the statics of the concrete blocks contact our Department Service Information (8151.30). • 2 wedges(5) for the compensation of the slope of the girder at the back of the superstructure • 2 metal sheets(6) 300/300/30 for power allocation • Dummy flanges for closing of the pipes and hoses (part of the excavator delivery). * Excavators with serial numbers 12001 to 12011: You can borrow 2 lever arms from the Komatsu Service Department. * Excavators with serial numbers from 12012 up

Special device must be prepared according the attached drawing.

AH01516a

Page 2 of 7

2. Weights (bullclam attachment) Boom with 4 cylinders approx. 55.000 kg Stick with cylinders approx. 32.000 kg Counterweight approx. 2 x 30.000 kg or 1 x 50.000 kg Swing circle with mounting cross approx. 18.000 kg

3. Working sequence (see illustration Z 21169) • Removal of the bullclam bucket; close all pipes and hoses. • Removal of the stick Loosen the stick cylinders at the stick and secure by means of a chain hoist. Retract the cylinder and secure against extending. Remove the stick. • Removal of the boom Remove and close the hoses at the boom. Loosen the boom cylinder at the superstructure and secure it by means of a chain hoist. Remove the boom. • Remove the Counter weights (only at excavators with serial numbers 12001 to 12011) • Preparation for the excavator disassembly Put the 2 big concrete blocks (1) in the middle beside the crawlers. Put on every big concrete block 2 little concrete blocks (2) with a distance of about 1 m. Turn the superstructure for about 90°. Mount the lifting brackets (3) with the boom cylinder pins to the superstructure. Line up 2 little concrete blocks, 2 hydraulic jacks and 2 metal sheets under the lifting brackets (the lifting height has to be approx. 80 mm). Line up the other 2 little concrete blocks, 2 hydraulic jacks and 2 metal sheets at the back site of the excavator under the longitudinal girders of the superstructure. Put the metal wedges for compensating of the slope between metal sheets and carrier; tack weld the wedges with longitudinal welding seams. • Remove the collector ring • Remove the swivel joint; close the pipes • Disconnect the swing circle (slew ring) from the undercarriage by removing the outer bolts of the swing circle. Before removing the lube lines from the swing circle number line and respective injector with the same number. Extend the 4 hydraulic jacks so far that they touch the lever arms and superstructure. Disconnect the high pressure hoses from the ports (manifold) at the travel motors of the excavator. Temporarily reconnect the flow and return line hoses to prevent unnecessary loss of system hydraulic oil. Connect the supply and return lines of the foreign hydraulic system to the excavator travel motors by means of long hoses. Use small diameter hoses e.g. inner dia. 16 or 20 mm, because even under pressure these ones are easier to handle (more flexible).

AH01516a

Page 3 of 7

• Check these hoses for suitability for pressure up to 350 bar.

• To connect these hoses to the travel motors make use of the plug flanges that are used to plug the ports when the excavator is shipped from factory. Drill a hole into these and weld on a welding - flange. • Release the parking brakes by means of manual pump (pressure among 26 and 50 bar). Connect both brake pressure lines by a T-union and connect this to the manual pump. Release pressure: 26 bar. Connect the leakage lines of the excavator travel motors to the hydraulic tank of the foreign hydraulic system. It is vital to check the hydraulic oil level of the foreign hydraulic continuously. • Lift up the superstructure for about 80 mm and secure it against lowering. Travel out the undercarriage backwards. Install a mounting cross and remove the slew ring downwards by using of a crane. • Assembly of the new swing circle Carry out the preparation and the assembly corresponding to the Service Bulletin AH00511. • Note that the superstructure is turned for 90°! Therefore the unhardened spot “S” of the inner and the outer ring of the swing circle have to be turned in an angle of 90° to each other for installation (Z22137). After finishing of replacement of the swing circle both punchmarked unhardened spots ”S” are at the same place. • Assembly of the removed components. • After removing of the wedges at the back of the superstructure smooth the girder.

.

• Bleed all hydraulic cylinders carefully after the assembly, otherwise serious damages are possible (see service bulletin 21-531).

AH01516a

Page 4 of 7

AH01516a

Page 5 of 7

For the statics of the concrete blocks please contact our Department Service Information (8151.30).

AH01516a

Page 6 of 7

AH01516a

Page 7 of 7

Special device for excavators with serial number 12012 up

AH01516a

COMPONENT CODE:

10

REF NO.

AH01523c


DATE


This PARTS & SERVICE NEWS supersedes the previous issue No.AH01523b which should be discarded. SUBJECT:

Replacement of the elastic coupling (Electro drive shovels)

PURPOSE:

Revision (Addition of a new model)

APPLICATION:

H 185SE (06099 and up); H 255SE (06122 and up); H 285SE (78137 and up); H 655SE; PC3000; PC4000; PC5500; PC8000

FAILURE CODE:

1000FA

DESCRIPTION: The above mentioned excavators are equipped with highly flexible couplings. The inspection for the indicated tightening torques and the visual inspection for cracks have to be carried out in the following intervals (refer also to the Maintenance Manual of your excavator): • •

250 working hours after commissioning Every 2000 working hours or every 6 month

When should the elastic elements be changed? • •

In case of cracks in the marked area (arrows in illustration A and B) After 15.000 working hours or after 10 years.

In case of new installation or exchange, the following alignment tolerances have to be checked by using a gauge and, if necessary, corrected. Excavator Type H 185 SE H 255 SE H 285 SE H 655 SE PC3000 E PC4000 E PC5500 E

Clutch Part-No. 551 980 40 655 615 40 896 479 40 902 215 40 655 615 40

Radial (x)* misalignment ± 1,0 mm ± 1,0 mm ± 1,0 mm ± 0,35 mm ± 1,0 mm ± 0,35 mm ± 1,0 mm

Axial (y)* misalignment ± 2,0 mm ± 2,0 mm ± 2,0 mm ± 2,0 mm ± 2,0 mm ± 2,0 mm ± 2,0 mm

907 174 40 655 615 40 902 215 40 ± 0,35 mm ± 2,0 mm PC8000-E 907 174 40 * Explanation refers to illustrations at the next page.

Angular (z)* misalignment ± 0,5 ° ± 0,5 ° ± 0,5 ° ± 0,5 ° ± 0,5 ° ± 0,5 ° ± 0,5 °

Installation Dimension (a) 477 ± 2 mm 527 ± 2 mm 645 ± 2 mm 866 ± 2 mm 527 ± 2 mm 866 ± 2 mm 527 ± 2 mm

± 0,5 °

866 ± 2 mm

AH01523c

Page 2 of 3

axial

radial

z

angular

x

y

Inspection of the coupling elements 1. Move the cover ring(3) to the left (refer to the removing procedure) 2. Inspect the surface of the rubber elements visually (If there are 2 rubber elements – illustration B - use a small mirror) Removing of the coupling element/s 1. Remove nuts (1) and bolts (2). 2. Move the cover ring (3) to the left. 3. Remove the bolts (4). 4. Move the rubber element/s(5) to the right and remove it/them. 5. Remove the screws (6) and the ring (7). Installing of the new coupling element/s 1. Bolt ring (7) and the rubber element (5) together with the screws (6). 2. Further installation reverse order to the removal.

Excavator type H 185SE

Tightening torques Tightening torques Tightening torques A (Nm)* B (Nm)* C (Nm)* 215.0

560.0

H 255SE; PC3000; 480.0 + 50 175.0 +20 PC5500; H 285 SE H 655SE; PC8000; 250.0 +30 960.0 +110 PC4000 * Threads and bolt heads must be greased carefully with engine oil.

86.0 70.0 +

9

960.0 +110

AH01523c

Page 3 of 3 3

Illustration A

1

2 A 5 B 7

4

a

gearbox side C 6

motor side

Illustration B

3 1

2 A B 4

a

C motor side

gearbox side 5b

5a

AH01523c

COMPONENT CODE:

30; 63

REF NO.

AH01531A


DATE

06122002 Page 1 of 9

This PARTS & SERVICE NEWS supersedes the previous issues No. 21-426; 21-549 and AH01531 which should be discarded. SUBJECT:

Hydraulic accumulators – testing and refilling

PURPOSE:

Regular check

APPLICATION:

All types

FAILURE CODE:

307EPB; 6347PB

DESCRIPTION: The testing and refilling of the hydraulic accumulators have to be performed by testing- and refilling device Part no. 761 520 73. When ordering this particular device, please always indicate country of destination.

1. Testing of existing gas pressure at piston and diaphragm accumulators For testing of existing gas pressure at bladder accumulators, refer to page 7 – 9. •

Stop engine.

•

Allow pressure relief of the system to be checked.

•

Remove protective cap from accumulator.

•

Unscrew a union of the feeding line in order to allow the hydraulic oil to pour out.

AH01531A

Page 2 of 9

The testing- and refilling device includes following pressure gauges:

0 to 25 bar 0 to 100 bar 0 to 250 bar •

Screw the pressure gauge with the correct pressure range into the testing and refilling device.

•

Screw home screw (14) at the filling device.

•

Loosen the socket-head screw of the gas valve by ½ turn with a hex key 6 mm.

•

Screw filling device without hose carefully by hand onto accumulator.

•

Observe correct position of the o-ring.

. •

• Check valve in hose connection is operative only if hose is not connected.

Turn T-handle (12) several times in both directions until it is engaged in socket head of gas filler screw (11).

•

By means of the T-handle unscrew gas filler screw (11) by 4 to 5 turns until pressure gauge indicates the existing gas pressure.

AH01531A

Page 3 of 9

For the specified gas pressure of the piston-diaphragm and bladder type accumulator, refer to the circuitry diagrams in the Operation Manual.

Compare the pressure reading on the gauge with the specified gas pressure.

If the pressure reading is too low, the accumulator has to be refilled. • To fill the accumulator, a pressure – reducing valve must be used. • Only nitrogen must be used to fill the accumulator.

2. Filling of the accumulator •

Close shut-off valve (5) at the bottle pressure – reducing valve. Turn in completely outlet screw (14) of filling device and install the hose.

AH01531A

Page 4 of 9

•

Open valve (8) of nitrogen bottle and check bottle pressure. The bottle pressure must always be higher than the pressure specified for the accumulator.

•

adjust specified accumulator pressure with pressure-reducing valve (6).

•

Turn out the filling screw (11) by means of the T-handle of the filling device.

•

Open slowly shut-off valve at bottle pressure reducing valve and let nitrogen flow into accumulator, until pressure gauge on filling device indicates the specified pressure. Then close shut – off valve.

AH01531A

Page 5 of 9

•

Wait for temperature to be equalized (approx. 5 min.) and open outlet screw (14) to let the pressure drop to the specified value.

•

Close outlet screw (14).

•

Screw in tightly screw (11) by means of T – handle (12).

•

Open outlet screw to let nitrogen escape from filling device.

•

Disconnect hose connection and unscrew filling device.

•

Fasten O - ring (13) to the testing device.

•

Tighten the screw (11) by means of a hex key 6 mm.

AH01531A

Page 6 of 9

•

Reinstall protective card and retighten union in feeding line.

•

Close bottle valve (8).

•

Turn out completely the T – handle at the pressure reducing valve (6).

AH01531A

Page 7 of 9

3. Testing of existing gas pressure bladder accumulators The testing- and refilling device includes pressure gauges: 0 to 25 bar 0 to 100 bar 0 to 250 bar. •

• • • •

Screw the pressure gauge with the correct pressure range in the testing- and refilling device. Shut down the engine. Allow pressure relief of the system to be checked. Unscrew the feeding line in order to allow the hydraulic oil to pour out. Remove cap (1) and nut (2). Do not remove O - ring (3).

. • • • • • • •

• Check valve in hose connection is operative only when hose is not connected.

Turn the socket head screw (4) installed in the adapter (2) a little bit. Mount testing- and refilling device to adapter (2). Install adapter (2) to testing connection (3). Turn in completely outlet screw of the filling device. Turn T – handle (12) several times in both directions until it is engaged in the screw (4) of the adapter (2). By means of the T – handle (12) turn in the screw so far that the existing gas pressure is indicated by the pressure gauge. Do not turn in the screw any further; the gas valve may be destroyed.

AH01531A

Page 8 of 9

If the pressure reading does not correspond with the nominal filling pressure, the accumulator has to be refilled.

4. Filling of the bladder accumulator • To fill the accumulator, a pressure – reducing valve must be used. • Only nitrogen must be used to fill the accumulator. •

Close the shut off valve (5) on the pressure-reducing valve.

•

Turn in completely the outlet screw (14), see illustration on page 5.

•

By means of the T-handle (12), turn out the screw (4) of the adapter (2) until the gas valve in the testing connection (3) of the accumulator is closed. After that, install connecting hose.

•

Open the valve (8) at the nitrogen bottle and check the gas pressure of the bottle. The gas pressure of the nitrogen bottle must always be higher than the specified filling pressure of the accumulator.

•

Adjust the specified filling pressure by means of setting screw (6) of the pressure reducing valve. Open the gas valve in the testing connection (3) of the accumulator ba turning in screw (4).

•

Slowly open the shut off valve (5) at the pressure reducing valve and fill the accumulator until the pressure gauge (7) of the testing and refilling device indicates the specified filling pressure. Then close the shut-off valve (5).

AH01531A

Page 9 of 9

•

Wait for temperature to be equalized (approx. 5 min) and, if necessary, reduce pressure with outlet screw (14) or let the pressure reach the specified value according to page o4.

•

Close outlet screw (14).

By means of T-handle (12) turn out screw (4) from the adapter (2) till the gas valve in the testing connection (3) is closed. • •

•

Open outlet screw (14) that the nitrogen can escape from the filling and testing device. Close the nitrogen bottle and remove the filling- and testing device, filling hose and pressure –reducing valve. Turn out completely screw (6) of the pressure-reducing valve. By doing so, the spring-reducing valve is discharged.

•

Re-install protection cap in the testing connection.

•

Re-tighten the hydraulic line.

AH01531A

COMPONENT CODE:

25

REF NO.

AH02513b


DATE

January 4, 2005 Page 1 of 4

This PARTS & SERVICE NEWS supersedes the previous issue No. AH02513a which should be discarded. SUBJECT:

Testing wear and tear of swing circle bearing

PURPOSE:

In time ordering of a new swing circle in order to prevent unexpected downtime

APPLICATION:

All types

FAILURE CODE:

2500CA

DESCRIPTION: For assessing the condition of the swing circle bearing, we recommend that its normal wear rate is determined. The first measurement must be performed when the excavator is put into operation in order to obtain a base value for subsequent repeat measurements. The following measurements have to be effected: 1. Period of the first 10.000 h: 2. Period more than 10.000 h:

every 5.000 working hours; every 2.500 working hours.

After finishing the measurements, record the values obtained in a tabular form. The diagram shows the principle of bearing wear progression. If the “increased wear” situation is reached, prepare the changing of the swing circle.

)

• We recommend to turn the swing circle (180°) after 20 000 working hours.

normal wear

increased extrem wear wear

Axial movement/wear

mm

Base value

Working hours

h AH02513b

Page 2 of 4 Measurement procedure

1. Park the machine on level ground. 2. Slew the attachment to the normal working position (idler wheel in front). 3. Remove cover as shown in the photos (Illust. 7 and 8). 4. Clean the center slew gear tooth and the contact point on the superstructure. 5. Install the dial gauge* as shown in the photos. 6. Turn the swing brake switch in the on position. 7. Straighten the attachment fully (lmax) and raise the shovel approx. A=3 m over the ground (Illust. 1, 3 or 5). 8. Set measuring instrument (dial gauge*) to zero.

ã

• Make sure the area below and around the excavator is clear of all persons before you start operating.

9. Move the attachment in the shown position (Illust. 2, 4 or 6). Lower the attachment until the track lift off the ground up to the sprocket (B).

)

• Use for all measurements the same distances “A” and “B”.

10. Move the attachment in the normal parking position. 11. Read measurement “M 1” (out of the memory) and record in the table (page 4). 12. Repeat the measuring procedure at the same point for a 2nd value (M 2). 13. Remove the dial gauge, swing the superstructure 180 degrease and repeat the measuring procedure two times. * We recommend to use a digital dial gauge with min. / max. measuring value memory (Part No. 794 537 73).

Photo only as example

AH02513b

Page 3 of 4

AH02513b

Page 4 of 4

Excavator Typ:

Planned h 0

Actual h

Date

Serial number:

Front M1

Front M2

Mfront = (M1 + M2)/2

Rear M1

Rear M2

Mrear = (M1 + M2)/2

5 000 10 000 12 500 15 000 17.500 20 000 22.500 25 000 27.500 30 000 32.500 35 000 37.500 40.000

AH02513b

COMPONENT CODE:

75

REF NO.

AH02521d


DATE

August 18, 2009 Page 1 of 10

This PARTS & SERVICE NEWS supersedes the previous issue Number AH02521c which should be discarded. SUBJECT:

Track group – wear measurement

PURPOSE:

Revision

APPLICATION:

H 185 to PC8000

FAILURE CODE:

752DCA

DESCRIPTION: 1. 2. 3. 4. 5. 6. 7.

Preconditions for the measurements Adjusting range for guide wheels Chain elongation / measured over three track pads (4 pins) Circular pitch (Sprocket / Track pad) Wear of track pads (Roller contact surface) Conditions for changing to oversize sprockets Tables

The professional and regular inspection increases the service life of the track group and can avoid early and very expensive repairs, including unforeseen standstill of the machine. It is recommended to perform the inspections every 3 month or 1500 working hours according to the description and to fill in the measured values to the table on page 10. The measurements are described in detail and illustrated on the following pages. To prevent unnecessary problems and standstills and to assure fast help when wear limits are reached, it is recommended to send the filled-in tables in the mentioned intervals to Komatsu Mining Germany, Service Department 8151.

Illustration 1

AH02521d

Page 2 of 10 1.

Preconditions for the measurements:

1.1.

Cleaning of the track group, according to the Maintenance Manual

Illustration 2 1.2

Track sag (A): On Machines without the hydraulic track - tensioning system • H 185S up to max. 230 mm • H 285 - H 285S up to max. 300 mm • H 485 - H 485S up to max. 420 mm

1.3

Track sag (A): On Machines with hydraulic track - tensioning system • No specification, since self-regulating

Illustration 3

AH02521d

Page 3 of 10 2.

Adjusting range for guide wheels

Illustration 4

Legend (1)Guide wheel (2)Slide block (3)Stop plate “X” Adjusting range for track tension The adjusting range for track tension is the distance “X” between guide wheel slide block (2) and stop plate (3). Depending on the stretching of the track the slide block (2) may come in contact with stop plate (3). In such a case, it must be ensured that the track does not become too loose. Depending on track condition; the removal of one track pad will restore the adjusting range “X”. If necessary contact our Service Department for more information.

AH02521d

Page 4 of 10

3. Chain elongation / measured over three track pads (4 pins) This wear check has to be carried out in 4 equally distributed areas of the track chain (L1 to L4 - l.h. and R1 to R4 - r.h.). • Turn superstructure 90° to the travel direction. • Retract attachment and lower bucket on the ground until the chain has no longer contact with the ground. • Block the machine against inadvertent lowering with suitable devices.

ã

• Turn sprocket until the first measuring area (L1) is located at the deepest point of sag “T“).

)

• To measure the areas L2 - L4 turn the chain always forward until point “T“ is reached.

• To obtain a comparable measuring result, stop the main drive motor/engine of short duration, so that the track tensioning system is released to pilot pressure. • Place the points of the dividers into the centre bores of pins 1 and 4 of the measuring area L1 / R1, determine the distance and record in the table on page 10. • Repeat measuring procedure at measuring areas L2 / R2 to L4 / R4.

T

Illustration 5

AH02521d

Page 5 of 10 4.

Circular pitch (Sprocket / Track pad)

For this inspection, the excavator has to be placed on an even surface and only one chain has to be moved, like turning. Diesel engine: Electric motor:

Operate at low idle. Operate joy-stick slightly.

• Move l.h. track group forward (Sprocket rotation F = forward), until the contact area of the sprocket tooth (0) and the track-pad lug (0) is in the uppermost position without loosing contact, (Refer to illustration 6 “A”, page 6 as example). • Measure gaps (X1). Measure inside and outside of the sprocket between the sprocket teeth (7) and track-pad lug (7) at 3 points, equally distributed on the chain.

)

• Sprocket tooth (7) has to be used irrespective of the numbers of teeth of the sprocket (possible 14 or 15 teeth).

• Record the values into table -circular pitch A- on page 10. • Repeat the measurements on the r.h. track group. • Move l.h. track group back (Sprocket rotation R = backwards), until the contact area of the sprocket tooth (0) and the track-pad lug (0) is in the lowest position, (Refer to illustration 6 “B”, page 6 as example). • Measure gaps (X2). Measure inside and outside of the sprocket between the sprocket teeth (7) and track-pad lug (7) at 3 points, equally distributed on the chain. • Record the values to the table -circular pitch B- on page 10. • Repeat the measurements at the r.h. track group.

5.

Wear of track pads (Roller contact surface)

• Stop the engine/motor and secure the machine against unintentional movement. • Mark 3 track pads of each track group (l.h. track group and r.h. track group) to make repeated measurements in the future comparable. • Take a ruler to measure the wear of the roller contact surface. The ruler needs an even contact surface, if not exist, prepare the track pad as necessary. (Refer to illustration 6 “C”, page 6). • Record the measuring results in the form sheet on page 10.

)

• For wear limits of individual parts please refer to P&S News “AH06507 Undercarriage – wear limit values”.

AH02521d

Page 6 of 10

) The real position of the sprocket lug (0) might deviate from these illustrations.

C

Illustration 6 AH02521d

Page 7 of 10

6.

Conditions for changing to oversize sprockets

1.

If the connection point of Roller path depth and Elongation is in the oversize sprocket area* and all X – dimension (X1 and X2) becomes zero, only then change to oversize sprocket.

2.

If the connection point of Roller path depth and Elongation is in the oversize sprocket area* but not all X – dimension (X1 and X2) becomes zero, run further with the standard sprockets as long as X1 or X2 reaches zero.

3.

If the connection point of Roller path depth and Elongation is in the standard sprocket area* run further with the standard sprockets as long as you reach the oversize sprocket area and all X – dimension (X1 and X2) becomes zero. * refer to illustrations 7 to 10 For the exchange of the oversize sprockets, refer to Service Bulletin AH00514.

AH02521d

Page 8 of 10

Minimum wear for oversize sprocket PC 3000-6 1145

Elongation over 4 pins [mm]

1144

Condition: X1 and X2 becomes zero 1143 1142 1141 1140 1139 1138 1137 1136 1135 10

11

12

13

14

15

16

17

Roller path depth [mm]

Illustration 7

Minimum wear for oversize sprocket PC 4000-6 1212 1211

Condition: X1 and X2 becomes zero


1210 1209 1208 1207 1206 1205 1204 1203 1202 1201 1200 1199 1198 1197 15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32



Page 9 of 10

Minimum wear for oversize sprocket PC 5500-6 1421 1420


1419 1418


1417 1416 1415 1414 1413 1412 1411 1410 1409 1408 1407 1406 1405 1404 1403 1402 1401 10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29


Illustration 9


Minimum wear for oversize sprocket PC 8000-6 1472 1471 1470 1469 1468 1467 1466 1465 1464 1463 1462 1461 1460 1459 1458 1457 1456 1455 1454 1453 1452 1451 1450 1449 1448 1447 1446 1445 1444 1443


15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38



Page 10 of 10

7.

Tables for measurements

Machine-Type : Customer : Oversize sprocket ? : (left hand side)

Oversize sprocket ? : (right hand side)

NO

Serial-No. : Location : Date of installation: ................... at operating hours: ..................... Date of installation: ................... at operating hours: .....................

YES

Ö

NO

YES

Ö

Chain elongation (Illustration 5): Measuring area W-dimension [mm] via 4 pins

Left hand crawler track “L“ L1

L2

Chain elongation (Illustration 5): Measuring area W-dimension [mm] via 4 pins

Operating hours : Date of measurement : Part-No. of track pad :

L3

L4

Right hand crawler track “R“

R1

R2

R3

R4

Circular pitch: Illustration 6 “A“

3 points (equally distributed on the chain) 1

Sprocket side

inside

2 outside

inside

3 outside

inside

outside

X1-dimension [mm] L.H X1-dimension [mm] R.H Illustration 6 “B“

3 points (equally distributed on the chain) 1

Sprocket side

inside

2 outside

inside

3 outside

inside

outside

X2-dimension [mm] L.H X2-dimension [mm] R.H

Wear of Track pads (Illustration 6 “C“): Track pad

Side

No.1 No.2

L.H. L.H.

No.3 No.4 No.5 No.6

L.H. R.H. R.H. R.H.

Dimension “D“ [mm]

Number of cracked track pads left hand crawler track

right hand crawler track

AH02521d

COMPONENT CODE:

03

REF NO.

AH03506b


DATE

October 25, 2003 Page 1 of 5

This PARTS & SERVICE NEWS supersedes the previous issue AH03506a which should be discarded. SUBJECT:

Hydraulic oil cooler and water cooler fan bearings

PURPOSE:

Replacement of the bearings

APPLICATION:

PC4000; PC5500; PC8000

FAILURE CODE:

0373CA

DESCRIPTION: Two types of bearing units are used for the cooler fans at the above mentioned excavator models: 1. Grease lubricated bearings

)

2. Gear oil lubricated bearings

• We recommend to replace these bearings to avoid consequential damages according to the following table: Bearing unit Replacing time after: Grease lubricated bearings 8 000 working hours Gear oil lubricated bearings 10 000 working hours * * or if damage or a leak has occurred.

)

• The hydraulic motors for the fans should be replaced preventively every 10.000 working hours.

AH03506b

Page 2 of 5

Hints for replacement: 1. Grease lubricated bearings

1 Bearing retainer 2 Shaft 3 Hydraulic motor 4 Fan 5 Bearing 6 Grease nippel 7 Circlip 8 Bolt 9 Bolt 10 Locking plate

1. Remove the hydraulic and the grease lines; the fan; and then the motor. 2. Remove the bearings and the fan shaft. 3. Clean all parts carefully. 4. Install the first bearing (5) and fill the chamber between the bearings to 50% with grease. 5. Install the shaft with the first bearing (5) and the grease into the bearing retainer. 6. Install the second bearing and fix it with the circlip (7). (Install also the sleeve between the bearings if applicable.) 7. Grease the hydraulic motor drive shaft with “Optimol paste white T” and fill the chamber in the fan shaft to 50% with normal grease according to the drawing above. 8. Reinstall the bearing hub, the fan and the motor. 9. Reconnect all lines. • Grease the bearings every 500 working hours with maximal 2 strokes with the hand greasing pump.

AH03506b

Page 3 of 5

2. Gear oil lubricated bearings 2. Gear oil lubricated bearings 1 Bearing retainer 2 Shaft 3 Circlip 4 Bearing 5 Shaft grommet 6 Shaft seal 7 Plug Fill the chamber at the lip type seal with grease.

1. Remove the hydraulic lines; the fan, then the complete unit. 2. Drain off the gear oil and remove the motor, the bearings, the fan shaft, the shaft grommet and the shaft seal. 3. Clean all parts carefully. 4. Check the dia. “d” according to drawing and table at the next page. 5. Install a new shaft grommet with the flanged end at first (press it into depth “a” see next page). 6. Do not remove the seam of the shaft grommet. 7. Install the 1st bearing and the shaft seal into the bearing retainer. 8. Grease the shaft and install it. 9. Mount the 2nd bearing(4) and the circlip. 10. Check the spline and grease the hydraulic motor drive shaft with “Optimol paste white T”. 11. Reinstall the motor by using a new O – ring and mount then the fan. 12. Fill in the bearing retainer gear oil according to the Maintenance Manual. 13. Reconnect the hydraulic lines.

AH03506b

Page 4 of 5

PC4000

PC5500

PC8000

Oil cooler

Water cooler

Oil cooler

Water cooler

Oil cooler

Water cooler*

Part no.

Part no.

Part no.

Part no.

Part no. Part no.**

Part no.

Fan mounting 89590740 90202640 91091140 90479140 90389040 93394140 90968540b (assy.) Repair kit *** Press depht "a" (mm) Shaft dia. "d" (mm)

79296573 79296673 79296573 79296673 79296773 79484873 79296873

4 -0,5

3,7 +0,2

4 -0,5

3,7 +0,2

∅80 ±0,05

∅110 ±0,05

∅80 ±0,05

∅110 ±0,05

4 -0,5

6,4 ±0,8

∅100±0,05 ∅130−0,025

4,3 ±0,8 ∅ 85 ±0,05

* Serial No. 12040 up – see drawing next page ** Serial No. 12048/12049 only *** The Repair kit includes: 2 bearings; 1 shaft seal; 1 shaft grommet; 1 O-ring

Fill the chamber at the lip type seal with grease.

AH03506b

Page 5 of 5

PC8000-6 Water cooler fan bearings

Intermediate ring

AH03506b

COMPONENT CODE:

71

REF NO.

AH03510


DATE

2nd June 2003 Page 1 of 18

SUBJECT:

ESCO bucket tooth system

PURPOSE:

Hints for handling

APPLICATION:

PC4000; PC5500 (15012 - ); PC8000

FAILURE CODE:

7168Z9

DESCRIPTION: At our excavators PC4000; PC5500 (15012-) and PC8000 the new bucket tooth system “POSILOK” is used. In the following is showed how to handle the parts of this system. Page 2

1.

Overview

1.1 1.2

Komatsu standard version Optional version

2.

The Points

3

2.1 2.2

Removing the points Installing the points

4 5

2 2

3.

The Adapters

3.1 3.2 3.2.1 3.2.2 3.2.3 3.3 3.4

Adapter removal Nose rebuild Nose end and sides rebuild Nose flats rebuild Rear corner rebuild Adapter installation Retighten Sidewinder Pin

6 8 8 9 9 10 11

6

4.

Wear Caps

11

4.1 4.1.1 4.1.2 4.2

11 11 12 13

4.2.1 4.2.2

Lock style wear caps (PC4000) Removal Installation Non lock style wear caps (Option PC4000; PC5500; PC8000) Removal Installation

5.

The Shrouds

14

5.1 5.2 5.2.1 5.2.2 5.2.3 5.3 5.4

Removal the shrouds Installing the shrouds Prepare the surface Position the bosses Welding the bosses Inspecting Worn Shrouds Installing (Shrouds and Pins)

14 15 15 16 17 17 18

13 13

AH03510

Page 2 of 18 1. 1.1

Overview Komatsu standard version

Additional wearcap for plate lips version (PC4000) Wearcap

1.2

Optional version

!

• For changing to optional version new points, new adapters and the wearcaps are required.

AH03510

Page 3 of 18 Classification of the Tooth Systems to the Excavator Types Type of Excavator PC4000 PC5500 PC8000 - ( 12030) - ( 12034)

Shovel Version S 110 S 130 S 145 S 130 S 130

Backhoe Version S 95 S 130 S 145 -

Component Preparation Prior to installing the new tooth system components: • Thoroughly clean all bearing surfaces on the tooth base, adapter and pin. • Visually inspect top and bottom of tooth base for wear, refer to following sections. • Replace all damaged components.

2.

The points

4 2

3

6

5 1 1

Point

2

Posilok Locking Pin

3

Integral rubber lock

4

Adapter

5

Mating rails between point and adapter

6

Stabilizing flats

AH03510

Page 4 of 18 2.1

Removing the points

!

• All persons performing maintenance work should wear a approved hard hat, safety glasses, steel-toed shoes and gloves. • To avoid injury to others, keep people not directly involved well out of the way.

1. Removal tool between the (PART NO. 79350273) Posilok Pin and the lock

2. Drive the Posilok Pin out using a removal tool

(Part No. 793 502 73)

Use this end to start the Posilok Pin out.

• • •

Use this end to drive it through.

Remove the vertical drive-through pin using a hammer and a pin removal tool (Part No. 79350273). Make sure to insert the tip of the removal tool between the Posilok Pin and the rubber lock. In order to loosen the point for removal from the adapter, it may be necessary to tap the sides of the point to loosen fines.

AH03510

Page 5 of 18 2.2

Installing the points

Preparation Prior to point replacement, make sure adapters are clean and free of damage. Carefully inspect adapters for excessive wear. If the nose is worn or if insufficient wear metal remains to see adapters through their work cycle, they should be replaced with new ones. Vertical locking pins: Locking pins may be reused provided they do not show signs of significant wear, damage or distortion. Points: If you are going to install new points, make sure the rubber lock is installed so the arrows embossed on the surface of the lock are pointing forward (toward the tip of the point).

Position the locking pin and drive it in.

Vertical locking pin

Point • •

Install the points onto the adapters. After positioning a point onto its adapter, drive in the vertical locking pin using an 4 kg (8lb) hammer. The rubber lock keeps the Posilok Pin securely in place.

Posilok Pin engages the lock.

Topside and forward •

Drive in the Posilok Pin until it engages the lock. When the Posilok Pin is correctly in place, the rubber lock fits into the slot of the Posilok Pin to secure it.

AH03510

Page 6 of 18 3.

The adapters

3.1

Adapter removal Prior to using an adapter tool be sure that the following safety precautions are followed at all times: • Always wear proper safety equipment including hardhat, gloves, safety glasses and steel-toed shoes. • Never exceed the lifting capacity of the tool. Lifting tool 122K (Part No. 793 503 73) rated capacity 270kg (600lb) - for the S145 tooth system. Lifting tool 112K (Part No. 793 504 73) rated capacity 230kg (500lb) - for the S130 tooth system. • Tool is intended for vertical lift only. • Always stand clear of the raised adapter. • Never allow anyone to work under the adapter until it is secured to the lip by the appropriate locking mechanism. • Always use the safety features (lock and safety pin) as indicated. Never use hand tools or other fastener to secure the sleeve. Never use anything other than the sleeve provided to support the adapter. • Replace the tool when it becomes visibly damaged or distorted. Do not attempt to repair a damaged tool.

• •

Position the bucket with the nose tilted slightly upward. Clean debris from adapter Sidewinder Pin head slot and remove cap from Sidewinder Pin head. (The fastening Sidewinder Pin may become frozen in the nose hole by cemented fines. In this event, use either a hammer and drift or a porta-power, applied directly against the end of the Sidewinder Pin sleeve, to force the Sidewinder Pin out. Use a striking plate, as needed, to avoid hammering the end of the Sidewinder Pin base. With body completely retracted, insert drift that fits inside hex recess and hammer Sidewinder Pin through nose hole. Alternately, drift can be placed against outer sleeve. Avoid hammering over hex recess and thereby peening over the edges of this recess.)

AH03510

Page 7 of 18

•

Insert Allen hex bit (14; 17 or 19 mm) into the head of Sidewinder Pin and turn counterclockwise (only for S 95 clockwise) until the Sidewinder Pin body is fully retracted. Do not continue to turn after “stop” is felt. The Sidewinder Pin is designed for operation with a ratchet wrench and should not normally require use of an air-impact wrench.

! •

• For removing the adapter the Sidewinder Pin need not to remove out off the adapter base if it is in good condition. • If the Sidewinder Pin have to be removed the end opposite the hex socket must be removed at first.

Lifting tools (refer to drawing next page): 122K (793 503 73): (for S145)

- Remove the safety pin of the adapter tool and slide the sleeve off the arm. - Guide the arm through the square hole in the nose of the adapter. - Arm must be pointed towards rear of the adapter. - Slide the sleeve onto the arm, align the holes in the arm and sleeve and install safety pin.

112K (793 504 73): (for S130)

- Guide the lug on the end of the arm through the D-shaped hole in the nose of the adapter. - Rotate the arm towards the rear of the adapter until the tool is aligned with the adapter 90° and slide the lock down through the D-shaped hole and insert the safety pin.

AH03510

Page 8 of 18

Part No. 793 503 73 (for S145) Part No. 793 504 73 (for S130) Rotate the arm 90° for fixing

Safety pin of the adapter tool Sleeve •

Using a boom rated at 270 kg (600 lb) or greater (PC5500 and PC8000) or a boom rated at 230 kg (500 lb) or greater (PC4000), hook into the shackle at the top of the arm and remove the adapter.

3.2 Nose rebuild Nose fit: This tooth system is designed to operate with movement of the adapter on the nose. However, movement may become excessive over long term service because of nose wear. In this event, the nose can be rebuilt in the indicated areas with welding and grinding.

3.2.1 Nose end and sides rebuild

AH03510

Page 9 of 18

•

Place the nose side template on the centerline of nose. Nose side template Size S 95 S 110 S 130 S 145

• •

Nose Side Template 79350573 79350773 79350973 79400373

Nose Flats Template 79350673 79350873 79351073 79400473

Weld–rebuild nose end surface and grind flat until gage ends align with front edge of pin hole. Weld stringer beads should run parallel to the nose width. Rebuild nose end radii as necessary.

3.2.2 Nose flats rebuild • •

Place the nose flats template over the nose as shown. Weld buildup nose flats and radii and grind flat until template contacts nose end. Nose flat template

3.2.3 Rear corner rebuild • • • •

Weld rebuild rear corners of nose. Chalk or paint weld buildup areas, place adapter as far as possible on nose and then remove. High spots will be indicated by missing chalk or paint. Grind weld buildup areas until a new adapter has a little or no movement up and down. Grind blend smoothly into rear shoulders.

AH03510

Page 10 of 18 3.3

Adapter installation Prior to using an adapter tool be sure that the following safety precautions are followed at all times: • Always wear proper safety equipment including hardhat, gloves, safety glasses and steel-toed shoes. • Never exceed the lifting capacity of the tool. Lifting tool 122K (Part No. 793 503 73) rated capacity 270kg (600lb) - for the S145 tooth system. Lifting tool 112K (Part No. 793 504 73) rated capacity 230kg (500lb) - for the S130 tooth system. • Tool is intended for vertical lift only. • Always stand clear of the raised adapter. • Never allow anyone to work under the adapter until it is secured to the lip by the appropriate locking mechanism. • Always use the safety features (lock and safety pin) as indicated. Never use hand tools or other fastener to secure the sleeve. Never use anything other than the sleeve provided to support the adapter. • Replace the tool when it becomes visibly damaged or distorted. Do not attempt to repair a damaged tool.

•

The Sidewinder Pin must be fully retracted in the adapter base. Sidewinder Pin can be inserted from either side of base. Recommend corner positions be installed from inside.

•

Position the bucket with the nose tilted slightly upward.

•

Use a lifting tool and a lifting boom for the movement of the adapter as described in section 3.1. Test lift the adapter to check for satisfactory adapter tilt angle.

!

• The adapter should tilt downwards at the rear for easy installation onto the nose.

•

Lower the adapter and reposition the shackle as needed to achieve appropriate tilt angle.

•

Lift the adapter and slide it onto the nose. With the lifting boom still holding the adapter, install the adapter locking pin:

!

• For applications where soil fines pack and harden, it is recommended that the outer sleeve of the pin be covered in grease.

AH03510

Page 11 of 18

•

Using hex bit and socket drive, turn hex socket end of Sidewinder Pin clockwise to extend the pin into the pin hole in the opposite side of the adapter. Tighten to the specified torque value shown below. Size S 95 S 110 S 130 S 145

•

3.4

Allen type wrench size 14 mm 17 mm 19 mm 19 mm

Recommended pin torque 160-200 Nm (120-150ft-lb) 200-260 Nm (150-190ft-lb) 260-390 Nm (190-290 ft-lb) 260-390 Nm (190-290 ft-lb)

Insert the Sidewinder Pin cap to prevent the pin hex socket from filling with soil fines. Cap should snap into place. Retighten Sidewinder Pin

Retighten the Sidewinder Pin every 600 to 1200 hours of operating service depending on the severity of application.

!

• Some loosening of pin ½ - ¾ turns is normal. It is not necessary to keep it tightened to the recommended torque.

4. Wear Caps 4.1 Lock style wear caps (PC4000) 4.1.1 Removal • •

•

Clean debris from the gaps around the wearcap lock. Do not strike corners or edges with hammer! Rotate Lock : Use a drift and a 2-4 kg/4-8 lb hammer to rotate the lock to the unlocked position.

It may be necessary to partially rotate the lock in both directions to break loose soil fines, before fully rotating it.

!

• Lock must be rotated completely (180 degrees) to release the wearcap. • Lock can rotate either way.

AH03510

Page 12 of 18

Remove Wearcap: Slide wearcap out of adapter slots. Use appropriate lifting devices to support and remove wearcap. It may be necessary to place a pry bar between the adapter and the rear inside face of the wearcap to lift and free it from soil fines.

4.1.2 Installation

!

• Wearcap tabs, adapter tab slots, and lock recesses must be thoroughly cleaned. Inspect all components for damage. Replace any damaged parts.

•

Position Wearcap Lock First place the lock flat side down against the inside of the wearcap, adjacent to the lock opening. Slide it toward the wearcap lug. One of the lock shafts will enter the hole in the lug. Push the lock up tight against the lug. Then, using a drift placed in one of the lock pockets, tap the drift with a hammer to cause the lock to rotate halfway around, until the flat side of the lock is facing you and is lined up with the inside face of the wearcap.

•

Wearcap Installation Place the wearcap on the adapter. The tabs on the inside of the wearcap fit into the tab slots in the adapter.

•

Lock Wearcap Use an suitable tool and hammer to rotate the lock to the locked position. If lock resists rotation, this indicates more cleaning of the adapter slots is required. When flat is facing out, the lock is in a locked position.

AH03510

Page 13 of 18

4.2

Non lock style wear caps (Option PC4000; PC5500; PC8000)

!

• For using of these kind of wear caps special points and special adapters are required.

4.2.1 Removal • •

Drive out the point pin and remove the point. Slide the worn wearcap off the adapter.

!

• If soil packs tightly between the wearcap and the adapter, it may be necessary to strike the flat sides of the wearcap several times with a hammer, to loosen it for removal. • Do not strike corners or edges with hammer!

4.2.2 Installation • • •

Inspect all components for damage. Replace any damaged parts. Slide wearcaps onto the adapter top and bottom surfaces, so that the wearcap rear central and two forward side tabs insert fully into the respective slots of the adapter. Install and pin the point.

AH03510

Page 14 of 18 5. 5.1

The Shrouds Removal the shrouds

The Toplok shroud system is engineered to make change-out easy. Before following these simple steps shown to the Figures, it’s important to clean fines from pin area by tapping the shroud to loosen them, then scraping them using a chisel or needle gun (if fines are heavily packed). • •

Use a small bar with flat end (19 mm wide maximum) to retract the latch and lift the pin out. Pins can be reused if not worn below the locator flange and the insert latch rubber is fully bonded to the steel tip and fully seated in the pin body.

Place a pry bar or pinch bar behind the latch as shown, as a lever to compress it.

!

Lift out and remove the lock. Slide the shroud off the lip base.

• In severe applications assist removal by inserting a pry bar under the lock from the rear of the shroud and lifting up the latch end of the pin while prying as shown.

AH03510

Page 15 of 18

5.2 Installing the shroud 5.2.1 Prepare the surface In order to provide sufficient support for the boss as well as its pin, the mounting surface must: • Be relatively smooth and free of debris, weld spatter, and other irregularities. • Have a profile that produces a gap no greater than 3 mm or 1/16" at the boss weld. Any gap greater than 3 mm or 1/16" must be shimmed. Checking the Fit Pad Areas • • • •

The fit pad surface (1) & (2) should be perpendicular to each other. Make sure 70% of the fit pad surfaces (1) & (2) are in contact with the gauge. After achieving this, the fit pad surface (3) should be checked. Use a straight edge to help check the surface consistency.

Plate lips (PC4000)

Cast lips (PC5500 and PC8000)

Templates Part numbers for checking and preparation the lips Type of Excavator PC4000 PC5500 PC8000

Shovel Version Lip Shroud Template 654 547 40 654 548 40 794 005 73 655 867 40 or 907 281 40 907 006 40

794 007 73

Backhoe Lip Shroud 654 627 40 654 628 40 654 629 40 655 867 40

Version Template

794 008 73

907 448 40 On request

794 006 73 794 007 73

AH03510

Page 16 of 18

5.2.2 Position the bosses Checking the Boss Position To insure the boss is located correctly, the gap between the gauge and the boss rails should not exceed 1mm/.04in. If the gap exceeds 1mm/.04in.,the boss has to be removed and a new boss installed (see below). The back of the boss should line up with the back of the gauge rail. If the boss does not line up with the back of the gauge rail, then two repair options are possible: • (A) If the gap does not exceed 1.5mm/.06in., build up the back of the boss; or • (B) Weld build the leading edge fit pad (2). This may result in the ramp fit pad (3) also requiring weld build up.

Weld Rebuilding Fit Pads When weld rebuilding fit pads ensure the weld surface is clean and free of any contamination that might prevent a good weld. Follow the preheat, interpass and post heat guidelines below. Summary of Welding Specifications • Electrodes: E7016 or E7018 low hydrogen (keep dry!) • Wires: E70T-5, E71T-1, or E70T-1 with CO 2 gas. • Preheat: 200°F/95°C (350-400°F/175-205°C if air temperature is 40°F/5°C or lower.) • Interpass: Maintain interpass temperature less than 500°F/260°C. • Postheat: If air temperature is 40°F or lower, postheat 350-400°F, then let air cool. • Remove slag after each pass and peen each bead. New Boss installation • Set the boss onto the gauge rails and locate the back of the boss with the back of the gauge rails. If no gauge is available, use a new shroud to locate the boss. • Move the gauge onto the lip, making sure the gauge is centered between the nose bases and the gauge is in contact with fit pad surfaces (1) & (2). • Practice has shown, that the boss will suck down 1/16" during welding. To equalize this use a 1/16" shim under the boss, even if there is no gap between the fit pad (1) and the boss. This will ensure the boss height is correct after welding. • If there is a gap between the fit pad surface (1) and the boss, use a thicker shim accordingly.

AH03510

Page 17 of 18 5.2.3 Welding the bosses The weld surface must be clean and free of any contamination that might prevent a good weld. Follow the preheat interweld and post heat guidelines below. Summary of Welding Specifications • Electrodes: E7016 or E7018 low hydrogen (keep dry!) • Wires: E70T-5, E71T-1, or E70T-1 with CO 2 gas. • Preheat: 200°F/95°C (350-400°F/175-205°C if air temperature is 40°F/5°C or lower.) • Interpass: Maintain interpass temperature less than 500°F/260°C. • Postheat: If air temperature is 40°F or lower, postheat 350-400°F, then let air cool. • Remove slag after each pass and peen each bead. Weld the boss to the lip. Make sure that the boss is shimmed, so that the height of the boss will be correct after welding. Weld area (A) completely before welding areas (B) & (C). Welding Guide Weld Location Boss TAB TBB TCB

(A) Depth of weld plug holes mm/in Plug Weld 10/.38 Plug Weld 13/.50 Plug Weld 16/.62

(B) Size of fillet weld-on ends mm/in Fillet 10/.38 Fillet 13/.50 Fillet 13/.50

(C) Size of fillet weld-on ends mm/in Fillet 3/.19 Fillet 6/.25 Fillet 6/.25

5.3 Inspecting Worn Shrouds Toplok shrouds protect the bucket lip and wings from abrasive wear. Use of ESCO 12S abrasion resistant alloy assures long life before change out. • Periodic inspection should be made to determine when to replace a shroud. • Monitor high wear surfaces of the Toplok shroud for wear. • Special “wear indicators” are special panels that will open up to alert the user of the need for changing shrouds.

AH03510

Page 18 of 18

5.4

Installing

Installing the shroud •

Slide the shroud over the lip and boss to install the pin. If installing a new shroud, the pin must have contact with the back of the boss and with the back of the shroud without losing contact at the leading edge.

Installing the pin •

Position the pin in the shroud cavity as shown.

•

A light blow with a hammer will engage the pin.

•

The shroud is now securely attached.

AH03510

COMPONENT CODE:

63

REF NO.

AH03528


DATE

Sept. 29, 2003 Page 1 of 1

SUBJECT:

Pilot control safety line

PURPOSE:

Prevention of serious injury or death through high voltage system

APPLICATION:

PC8000-6 Electric Drive

FAILURE CODE:

6300Z9

DESCRIPTION:

The pilot line of the above mentioned excavators is a vital safety equipment. This line controls the security of the following components: §

Fire suppression system (9K3);

§

Flaps at slip ring unit (OS4 and OS4B);

§

HT – switch cabinet (OS10; OS11);

§

Emergency switch at the cable drum (OS15);

§

Flaps at the cable drum (OS17; OS18);

§

Flap at the terminal box of the cable drum (OS19).

If all these components are in normal working order the pilot line is closed. If one component is not in normal working order this line will be interrupted and the power supply of the excavator will be shut off in the external transformer station.

ã

• Make sure that the pilot line is always in proper working order. A defective or missing pilot line can cause serious injury or death.

AH03528


COMPONENT CODE:

46

REF NO.

AH04518a

DATE

June 29, 2005 Page 1 of 2

This PARTS & SERVICE NEWS supersedes the previous issue AH04518 which should be discarded. SUBJECT: Welding procedure for welded counterweight PURPOSE:

Emphasize the importance of expelling the accumulate gases from the counterweight chambers before welding

APPLICATION:

H 255; PC3000; PC5500(SN15011 and up); PC4000; PC8000(SN12037 and up)

FAILURE CODE:

4621Z9

DESCRIPTION:

ã

• Avoid injury or death! • Do not perform welding operation before expelling the accumulated gases from the counterweight chambers! • The gases may explode!

The welded counterweights are filled with a mixture of iron ore and breech blocks. They are not fully filled. It is possible that in the separate chambers explosive gases have collected. There is a risk of explosion during welding, grinding, cutting and drilling without coolant.

The following outlines the proper gas expelling procedure from counterweight (Illustrations 1 and 2) 1. Counterweights with a thread connection point(1): Connect a hose to this point and blow compressed air toward the inside. At these counterweights all chambers are connected to each other. 2. Counterweights without thread connection point: Make the holes (2) larger by means of a 10 mm drill. Blow out carefully all chambers separately through the holes (2).

AH04518a

Page 2 of 2

(1)

(2)

Illustration 2 AH04518a

COMPONENT CODE:

6A

REF NO.

AH05501a


DATE

September 15, 2006 Page 1 of 1

This PARTS & SERVICE NEWS supersedes the previous issue AH05501 which should be discarded. SUBJECT:

Abnormal vibration on hydraulic pipes

PURPOSE:

Reduction of stress on the pipes

APPLICATION:

All types

FAILURE CODE:

6A00GB

DESCRIPTION: To reduce the stress on hydraulic pipes and the flange bolts install a pair* of metal half clamps (weight approx. 5 kg). Start in the middle of the line and check the effect by laying on a hand. Try to optimize the effect by shifting the clamps. Mark the optimal position. *if required two pairs of half clamps can be used Description

Pipe 50x6 (PN)

Pipe 65x8 (PN)

Modification kit (assy.)

938 578 40

938 581 40

AH05501a


COMPONENT CODE:

K1

REF NO.

AH05510

DATE


SUBJECT:

Bearing flushing of the A4VS variable displacement axial piston pump

PURPOSE:

Activate the external flushing of bearing by mounting a new pump

APPLICATION:

PC4000 (SN08151 up); PC5500 (SN15011 up); H 455S (SN15007; 15009); PC8000 (SN12037 up); H685SP (SN12020; 12030)

FAILURE CODE:

K100FA

DESCRIPTION: The installed main pumps are provided with an external cooling and lubrication system for flushing of drive shaft bearing and shaft seal. Oil supply is provided from the X4-pressure circuit. To direct the external cooling oil to the bearing and shaft seal it is necessary to turn in the throttle screw all the way. Observe also the information plate fixed at the pump.

Drawing and photos as example

AH05510

COMPONENT CODE:

30

REF NO.

AH05511


DATE

March 23, 2005 Page 1 of 4

This PARTS & SERVICE NEWS supersedes the previous issue No. 21-558 which should be discarded. SUBJECT:

Dual cone seal ring mounting

PURPOSE:

Mounting hints

APPLICATION:

all types

FAILURE CODE:

3047AA

DESCRIPTION: Leaky dual cone seal rings must be replaced, in order to prevent damages through "dry running". Dual cone seals have also to be replaced in case of component repairs. Dual cone seals are precision parts made from chilled cast iron. Therefore, sharp knocks and blows should be avoided. The correct way to install dual cone seals is as follows: • Only remove the seal (1) from its original wrapping just before installing. This protects the super - finished seal faces (2) from damage and contamination. • Seal housing (3) must be free of dirt and machining residues; all edges in the housing bore must be rounded. • The illustration shows the preloaded seal (1). • Install the face seal by means of the assembly tool (4). Pressure is applied directly via the O-ring (5). • For easier assembly, moisten the housing bore and O-rings with spirit (no oil or grease!). • Order number for assembly tool (4), refer to the table on page 2. For the machining dimensions of the assembly tool, refer to the illustration and Fig. on page 3. • The illustration shows the dual cone seal (1) before mounting it with tool (4) into housing (3).

AH05511

Page 2 of 4 • Press the seal ring (1) with the special tool like a push button into the housing (3). Take care that afterwards the housing surface (6) lies parallel to the seal face (2). The O-ring (1) must not sit wave-like in the housing bore or bulge partially looped out of the bore. C = correct W = wrong

• Before the seal rings (1) are clamped to the installation dimensions, apply a thin grease or oil film to the seal faces (2), preferably with a soaked chamois leather cloth. Fig. 1 2 3 4 5 6

Description Seal ring Seal face Seal housing Tool O – ring Housing surface

Table for selection of the assembly tool (other tools on inquiry) Part No. Dual Cone Seal 145 800 40 180 472 40 180 624 40 202 986 40 226 424 40 226 425 40 255 058 40 269 454 40 270 460 40

Order-No. Assembly tool 766 311 73 766 308 73 766 312 73 766 315 73 766 322 73 766 317 73 766 314 73 766 312 73 766 316 73

Part No. Dual Cone Seal 323 823 40 324 067 40 461 627 40 461 628 40 696 523 73 696 525 73 804 595 73 963 754

Order-No. Assembly tool 766 323 73 766 309 73 766 318 73 766 307 73 766 310 73 766 311 73 766 313 73 766 321 73

AH05511

Page 3 of 4 Assembly tool (locally made) The assembly tool consists of two half-shells that are closed around the seal ring. The two halves are joined by a hinge. Step (d) grips between the O-ring (5) and the land of the seal ring. The pressure required to insert the seal is then applied directly via the O-ring (5). Measure dimension "b" at the dual cone seal. Determine the machining dimensions "a", "b", "c" and "d" according to this measured dimension in the chart. The dimension "X" can be chosen freely.

∅b mm 95 99 104 110 111 112 121 127 126 139 142 141,5 143 146 157 162 175 159 174,5 177 169 172,5 169 171 170 176 182 194

∅a mm 100 107 118 115 118 120 128 131 134 148 150 149 150 153 163 169 182 166 181,5 185 176 180 175 177 176 183 190 201

∅c mm 89,5 92,5 98 104 105 107 115 121 120 133 135 133 137 137,7 150,5 155 169 153,5 162 168 161 166,5 165 168 165 167,5 177 182,5

d mm 1,8 3,5 3 2,5 4 3 4 3,5 3 3 4 3 4 4 4 3 4,5 3 4 4 2,8 3,5 2 2,5 4 3,5 3 4

∅b mm 191 200 202 213 217 231 229,5 242 254 270,5 282,8 295,5 326 343,5 348 377,5 397 418 458 503 536,5 563 593 611 703 626 753 890

∅a mm 198 208 209 220 225 238 236,5 249 261 279 292 302,5 334 350,5 357 384,5 407 426 468 518 545 578 608 620 710 642 768 898

∅c mm 185 192 196 201 210 220 220,5 232 242,5 258,5 269 282 321 335 342 369 385 410 446 495 528,4 555 585 603 694 618 745 878

d mm 4 4 4 4 4 4 4 4 4 4 4 4 4 4 7 4 4 5 4 7 5 7 7 5 5 7 7 10

AH05511

Page 4 of 4

Assembly tools for mounting of dual cone seal

AH05511

COMPONENT CODE:

25

REF NO.

AH05518


DATE


This PARTS & SERVICE NEWS supersedes the previous issue 21 - 503 which should be discarded. SUBJECT:

Swing circle pinion

PURPOSE:

Wear check every 5000 Operating hours

APPLICATION:

PC3000; PC4000; PC5500; PC8000

FAILURE CODE:

2518CA

DESCRIPTION: All swing pinions are surface hardened to ensure a long service life. If the depth of the wear reaches the hardening depth, the wear of the pinion will be rapid. The increased tooth back-lash and the different tooth meshing, could decrease the service life of the slew ring and the swing gear box(es). By means of regular wear check , every 5000 operating hours, the depth of the wear should be compared to the original shape.

AH05518

Page 2 of 2

The following table shows the machines with the pertaining swing gear box(es) and the corresponding hardening depth:

Type

PN Swing gear box

Hardening depth

PC3000

898 100 40 917 915 40 924 352 40 926 795 40 898 100 40 925 864 40 926 795 40 898 100 40 917 915 40 925 864 40 926 795 40 917 915 40 924 325 40 926 325 40

2.0 2.0 2.0 2.0 2.0 1.8 +0.4 2.0 2.0 2.0 1.8 +0.4 2.0 2.0 2.0 2.0

PC4000

PC5500

PC8000

)

• If the depth of the wear reaches the hardening depth, the slew pinion should be replaced, to ensure a proper function of the machine.

AH05518

COMPONENT CODE:

K1

REF NO.

AH05525


DATE

September 20, 2005 Page 1 of 3

SUBJECT:

Suction elbows of the Main Pumps

PURPOSE:

Hints for sealing

APPLICATION:

PC3000-1; PC4000-6 (to # 08156) PC5500 (to # 15019); PC8000 (to # 12042)

FAILURE CODE:

K1T3AA

DESCRIPTION:

1. 2.

PC3000-1 PC4000; PC5500; PC8000

AH05525

Page 2 of 3 1. PC3000-1 1 2 3 4

Seal Intake Remachining surface Bolt

Illustration 1 as example

• •

In case of leakiness disassemble the suction elbow (2) and remachine the sealing surface (3). Then reassemble the suction elbow (2) by using a new seal (1).

)

• • • •

Install the 4 bolts (4) crosswise and evenly. Final torque: maximum 179 Nm! Replace the intake (2) by a new one if necessary. Check the surface (3) for evenness also of the new intake (2) before installing. Even it out if necessary.

AH05525

Page 3 of 3 2. PC4000; PC5500; PC8000 •

Type PC4000-6 PC5500-6

PC8000-6

In case of leakiness replace the old suction elbow (2) by a new one with an other sealing system (1)(O-ring). Intake (old)

Intake (new)

O - ring

891 451 40

928 335 40

517 582 98

624 085 40

928 706 40

517 582 98

624 085 40

928 706 40

517 582 98

894 317 40

928 287 40

517 582 98

894 321 40

928 285 40

517 582 98

894 322 40

928 288 40

517 582 98

894 323 40

928 289 40

517 582 98

624 085 40

928 706 40

517 582 98

• Screw in the 4 bolts (4) crosswise and evenly. • Final torque: maximum 179 Nm!

Illustration 2 as example AH05525


COMPONENT CODE:

26

REF NO.

AH05535f

DATE

December 15, 2008 Page 1 of 24

This PARTS & SERVICE NEWS supersedes the previous issue AH05535e which should be discarded. SUBJECT:

Hints for replacing the slew gear of a different manufacturer

PURPOSE:

Revision

APPLICATION:

PC3000 (#06193 and up); PC4000 (#08152 and up); PC5500 (#15018 and up); PC8000 (#12041 and up)

FAILURE CODE:

2600CA

DESCRIPTION: • New swing gears will be delivered without gear oil. • After replacing the swing gear, fill in oil according to the Maintenance Manual. REMARK The machines can be equipped either with a swing machinery of manufacturer "L&S" Part No. 926 795 40 or of manufacturer "Siebenhaar" Part No. 925 864 40; 936 560 40 or 944 872 40. Refer to the data plate on each swing machinery housing to find out the manufacturer of the swing machinery. Both swing gears are replaceable by using of a special modification kit. Lubricants

Filling Capacities (liters)

AH05535f

Page 2 of 24

1.

Description (general)

2.

Overview 2.1 Swing Machinery manufactured by "L&S" 2.2 Swing machinery manufactured by “Siebenhaaar” 2.3 Overview lubrication lines

3.

Modification kits 3.1 Modification kit PC3000-6 3.1.1

Replacing “L+S” gear by “Siebenhaar” gear

3.1.2

Replacing “Siebenhaar” gear by “L+S” gear

3.2 Modification kit PC4000-6 3.2.1


3.2.2




3.3.2




3.4.2


AH05535f

Page 3 of 24 1.

Description (general)

1. Remove the bolts at the hydraulic motor. 2. Remove the motor with connected hoses and place it beside or if this it not possible, disconnect the hydraulic lines and block the ports. 3. Disconnect the lubrication lines below the gearbox. 4. Remove all fastening bolts from the gearbox. 5. Install 2 eye bolts to lift the gearbox assy. 6. Remove the gearbox from the superstructure frame. 7. Clean the flange area at the superstructure free of grease, oil, dust and paint. 8. Insert the new gearbox and mount it with the new bolts and the washers to the superstructure. 9. Cover the bolt heads with plugs. 10. Swap the drain valves and the breather filters from the old to the new gearbox and install the dip sticks. 11. Remove the cover below the gearbox and connect the lubrication lines. 12. Reinstall the cover with bolts. 13. Reinstall the motor with bolts. 14. Reconnect all hydraulic lines. 15. Fill in oil to the max. oil level markings*. 16. Install the cover plates (PC3000; PC4000*). * If the slew gear PN 944 872 40 (Siebenhaar) will be delivered for first installation in a PC4000-6, the pinion cover PN 939 460 40 (right) or the pinion cover PN 939 455 40 (left) has to be installed also or these covers have to be modified according to the PSN AH08518a.

* "L&S" gear (Part No. 926 795 40) 2 oil chambers: (gear housing; motor adapter housing); "Siebenhaar" (Part No. 925 864 40; 936 560 40 or 944 872 40) Three oil chambers: (gear housing; motor adapter housing, brake housing)

AH05535f

Page 4 of 24 2.

Overview

2.1

Swing Machinery manufactured by "L&S"

Legend for illustration 1 Swing gears (1) Oil level gauge (2) Oil filler plug (3) Breather filter (10) Drain couplings or evacuation nozzles for Wiggins system Motor Adapter Housing (4) Oil level gauge and filler opening. (5) Breather filter (6) Oil drain plug

Illustration 1

AH05535f

Page 5 of 24 2.2

Swing machinery manufactured by “Siebenhaaar”

Legend for illustration 2 (1) Swing machinery (2) Brake housing (3) Compensator oil tank for swing machinery (4) Oil level gauge for swing machinery (5) Oil drain plug for motor adapter housing (6) Oil level gauge for motor adapter housing (7) Breather filter for brake housing (8) Oil level gauge for brake housing (9) Oil drain plug for brake housing (10) Breather filter (11) Drain coupling or evacuation nozzle for Wiggins system

For avoiding overheating of the disks inside the brake a correct adjustment of the brake oil level (8) is necessary.

)

• Too high oil level reduces the life time of the brake.

AH05535f

Page 6 of 24 Swing machinery manufactured by “Siebenhaaar”

Illustration 2

AH05535f

Page 7 of 24 2.3

Overview lubrication lines

AH05535f

Page 8 of 24 3. 3.1

Modification kits Modification kit PC3000-6

3.1.1 Replacing “L+S” gear by “Siebenhaar” gear (PC3000-6; illustration 3) Modification Kit: PN 794 853 73 Pos.

Part No.

Qty.

Description

10

323 460 40

1

Bleeder valve

11

517 676 98

34

Bolt

12

516 920 98

34

Washer

15

507 037 98

2

Nut

16

340 465 99

2

Washer

22

907 142 40

34

Plug

30

307 824 99

2

Bolt

31

374 428 99

1

Union

32

517 905 98

1

Hose assy.

33

500 141 98

2

Union

34

372 174 99

1

Union

35

334 601 99

2

Nut

36

340 469 99

2

Washer

37

0443452511

1

Clip

38

340 467 99

2

Washer

934 351 40

1

Thread tube

0443451810

1

Clip

0443451910

1

Clip

307 777 99

1

Bolt

AH05535f

Page 9 of 24

Illustration 3 AH05535f

Page 10 of 24 3.1.2 Replacing “Siebenhaar” gear by “L+S” gear (PC3000-6; illustration 4) Modification Kit: PN 794 867 73 Pos.

Part No.

Qty.

Description

10

323 460 40

2

Bleeder valve

11

517 013 98

34

Bolt

20

872 200 40

1

Union

30

925 833 40

1

Pipe 157 mm

31

517 489 98

1

Socket

32

906 868 40

1

Olive

33

371 264 99

1

Union nut

34

517 490 98

1

Union

35

907 568 40

1

Dipstick

36

921 815 40

1

Cover

37

319 159 99

7

Bolt

38

504 149 98

7

Washer

39

517 073 98

2

Union

40

371 273 99

2

Union nut

41

906 346 40

4

Olive

42

215 627 99

1

Pipe

43

517 074 98

1

Union

44

371 258 99

2

Union nut

45

907 228 40

1

Union

AH05535f

Page 11 of 24


Page 12 of 24 3.2

Modification kit PC4000-6

3.2.1 Replacing “L+S” gear by “Siebenhaar” gear (PC4000-6) Modification Kit: PN 797 345 73 (l.h.) (Illustration 5) Pos.

Part No.

Qty.

Description

11

517 612 98

34

Bolt

12

516 920 98

34

Washer

15

374 428 99

1

Union

16

507 037 98

10

Nut

17

512 545 98

10

Washer

18

507 488 98

10

Pin bolt

19

506 129 98

10

Washer

22

904 614 40

1

Cover plate rear l.h.

23

904 617 40

1

Cover plate front r.h.

24

307 827 99

2

Bolt

26

907 142 40

34

Plug

27

939 455 40

1

Pinion cover l.h.

29

510 213 98

2

Thread pin

30

340 112 99

2

Washer

31

512 545 98

2

Washer

32

334 600 99

2

Nut

308 639 99

2

Bolt

510 730 98

2

Resilient sleeve

AH05535f

Page 13 of 24

Modification Kit: PN 797 349 73 (r.h.) (Illustration 5) Pos.

Part No.

Qty.

Description

11

517 612 98

34

Bolt

12

516 920 98

34

Washer

15

374 428 99

1

Union

16

507 037 98

10

Nut

17

512 545 98

10

Washer

18

507 488 98

10

Pin bolt

19

506 129 98

10

Washer

20

945 988 40

1

Cover plate rear r.h.

21

938 534 40

1


24

307 827 99

2

Bolt

26

907 142 40

34

Plug

28

939 460 40

1

Pinion cover r.h.

29

510 213 98

2

Thread pin

30

340 112 99

2

Washer

31

512 545 98

2

Washer

32

334 600 99

2

Nut

308 639 99

2

Bolt

510 730 98

2

Resilient sleeve

AH05535f

Page 14 of 24


Page 15 of 24 3.2.2 Replacing “Siebenhaar” gear by “L+S” gear (PC4000-6; illustration 6) Modification Kit: 794 869 73 Pos.

Part No.

Qty.

Description

15

872 200 40

1

Union

20

922 584 40

1

Cover plate rear l.h.

21

922 583 40

1

Cover plate front l.h.

22

922 586 40

1


23

922 587 40

1

Cover plate rear r.h.

25

516 919 98

34

Bolt

28

921 815 40

1

Cover

29

319 159 99

7

Bolt

30

517 073 98

2

Union

31

371 273 99

2

Union nut

32

906 346 40

2

Olive

33

215 627 99

1

Pipe 400 mm

34

517 074 98

1

Union

35

371 258 99

2

Union nut

36

906 346 40

2

Olive

37

907 228 40

1

Union

38

371 257 99

1

Union nut

39

907 080 40

1

Olive

40

922 580 40

1

Cover pinion l.h.

41

922 578 40

1

Cover pinion r.h.

42

517 489 98

1

Socket

43

517 490 98

1

Union

44

906 868 40

1

Olive

45

371 264 99

1

Union nut

46

925 833 40

1

Pipe 157 mm

47

907 568 40

1

Dipstick

49

339 907 99

1

Seal ring

AH05535f

Page 16 of 24

Illustration 6

AH05535f

Page 17 of 24 3.3

Modification kit PC5500-6

3.3.1 Replacing “L+S” gear by “Siebenhaar” gear (PC5500-6; illustration 7) Modification Kit: PN 794 870 73 Pos.

Part No.

Qty.

Description

10

323 460 40

2

Bleeder valve

12

308 639 99

2

Screw

15

339 907 99

2

Seal ring

24

516 920 98

34

Washer

25

517 612 98

34

Bolt

26

907 142 40

34

Plug

510 730 98

2

Resilient sleeve

516 159 98

2

Union

515 362 40

2

Oil drain coupling

AH05535f

Page 18 of 24


Page 19 of 24 3.3.2 Replacing “Siebenhaar” gear by “L+S” gear (PC5500-6; Illustration 8) Modification Kit: PN 794 871 73 Pos.

Part No.

Qty.

Description

17

921 815 40

1

Cover

18

907 131 40

1

Union

19

214 140 99

1

Pipe 85 mm

20

374 460 99

1

Socket

21

872 200 40

1

Union

22

371 279 99

2

Union nut

23

906 979 40

2

Olive

24

516 920 98

34

Washer

25

517 889 98

34

Bolt

26

907 142 40

34

Plug

27

907 228 40

1

Union

28

517 074 98

1

Union

29

371 258 99

2

Union nut

30

906 346 40

4

Olive

31

517 073 98

2

Union

32

371 273 99

2

Union nut

33

906 346 40

2

Olive

34

215 627 99

1

Pipe 200mm

35

319 159 99

7

Bolt

36

504 149 98

7

Washer

50

517 489 98

1

Socket

51

517 490 98

1

Union

52

906 868 40

1

Olive

53

371 264 99

1

Union nut

54

925 830 40

1

Pipe 350 mm

55

907 569 40

1

Dipstick

AH05535f

Page 20 of 24


Page 21 of 24 3.4 Modification kit PC8000-6 3.4.1 Replacing “L+S” gear by “Siebenhaar” gear (PC8000-6; illustration 9) Modification Kit: PN 794 872 73 Pos.

Part No.

Qty.

2

904 613 40

1

Cover plate r.h.

3

904 618 40

1

Cover plate l.h.

7

517 612 98

34

Bolt

8

516 920 98

34

Washer

9

907 142 40

34

Plug

10

323 460 40

3

Bleeder valve

12

308 636 99

2

Bolt

510 730 98

2

Resilient sleeve

374 428 99

1

Union

13

Description

AH05535f

Page 22 of 24


Page 23 of 24 3.4.2 Replacing “Siebenhaar” gear by “L+S” gear (PC8000-6, illustration 10) Modification Kit: PN 794 873 73 Pos.

Part No.

Qty.

Description

11

516 919 40

34

Bolt

13

898 288 40

1

Cover plate

14

914 737 40

1

Cover plate

20

872 200 40

1

Union

21

374 460 99

1

Screwed socket

22

371 279 99

2

Union nut

23

906 979 40

2

Olive

24

914 736 40

1

Pipe 85 mm

25

907 131 40

1

Union

26

517 489 98

1

Socket

27

906 868 40

1

Olive

28

371 264 99

1

Union nut

29

925 830 40

1

Pipe 350 mm

31

517 490 98

1

Union

32

907 569 40

1

Dipstick

33

921 815 40

1

Cover

34

319 159 99

7

Bolt

35

517 073 98

2

Union

36

371 273 99

2

Union nut

37

906 346 40

4

Olive

38

215 627 99

1

Pipe 200 mm

39

371 258 99

2

Union nut

40

517 074 98

1

Union

41

907 228 40

1

Union

AH05535f

Page 24 of 24


COMPONENT CODE:

8D

REF NO.

AH05546


DATE

December 6, 2005 Page 1 of 2

SUBJECT:

Automatic lubrication system - Vent valve (PN 769 879 73)

PURPOSE:

Hints for trouble shooting

APPLICATION:

All types with “Lincoln” Lubrication System

FAILURE CODE:

8D00ME

DESCRIPTION:

Manual actuation (Vent valve: PN 769 879 73)

FUNCTION: The solenoid gets energized when the lubrication starts. The connection from A to B gets closed, thus a pressure build-up is possible. The solenoid gets de-energized, as soon as the lubrication cycle is finished. This causes opening of the connection A to B, thus the supply line to the lubricant barrel is open. The lubricant flows from A to B. TASK (Refer to illustration next page): By the function of the vent valve (7) the lubricant supply line gets pressure released, after the lubrication cycle is finished. The injector pistons can move into their initial position.

AH05546

Page 2 of 2

Troubleshooting: The solenoid valve (7) sometimes is blocked by dirt and causing that the pumping pressure will be not built correctly due to bypassed pressure back to grease barrel. On the monitor in the operators cab any failure in lubrication system will be indicated.

Manual actuation

To make easy troubleshooting the 2/2 – Directional valve (7) is equipped with the possibility of manual actuation. The valve had a push button on the top to verify whether the electric problem or the vent valve itself causing the lubrication pressure bypassed. For manual actuating of the valve (7) push down the pin on top of the valve e.g. with a screwdriver.

AH05546

COMPONENT CODE:

2C

REF NO.

AH06512


DATE


SUBJECT:

Travel gears – Brake and motor adapter housings – Oil Change

PURPOSE:

Improvement of the oil change – Avoiding of overfill the brake housings

APPLICATION:

H 485S; H 655S; PC8000

FAILURE CODE:

2C4LZ9

DESCRIPTION:

Regular oil level checking of the brake housings is carried out with the engine at standstill, brakes applied. For draining the oil at the 3000 h maintenance the brakes must be released in order to remove the oil between the brake disks, this requires the engine running. However, filling of the brake housings has to be done with the engine stopped and the brakes applied to prevent overfilling. Attached you will find new pages of the Maintenance Manual. Please replace them in the existing machine Service Literature.

COMPONENT CODE:


REF NO. DATE

AH06524 September 6, 2006 Page 1 of 2

This PARTS & SERVICE NEWS supersedes the previous issue 21 – 199b which should be discarded. SUBJET:

Hydraulic cylinder

PURPOSE:

Hints for bleeding

APPLICATION:

All types

FAILURE CODE:

H100BJ

DESCRIPTION: To avoid damages to the hydraulic system caused by air in the cylinders, a bleeding procedure has to be carried out after each opening or cylinder exchange. • Read the safety instruction in the Operation and Maintenance Manual carefully, before starting any work on the excavator.

1. Standard procedure for bleeding of hydraulic cylinder 1. Run the engine at low idle. PC5500 and PC8000: Start for the bleeding procedure only one engine. Electric driven excavators: Set the service switch S155 (X2 – main board) to position “2” for “QMIN” control of the main pumps. 2. Extend and retract each cylinder 4 or 5 times without going to the end of its stroke (stop approx. 100 mm before the end of the stroke). At first there can be a large amount of air inside the cylinders, so the cylinder may not move for the first ten seconds. In such cases, do not operate the joy stick to the end of its travel. Be carefully! 3. Keep the engine running at low idle/or QMIN* and operate each cylinder from a point 100 mm from the end of its stroke slowly (take at least 10 seconds) to the end of its stroke (fully extended) and hold the work equipment joy stick at the full stroke position for 3 minutes.

AH06524

Page 2 of 2 4. Next run the engine at high idle/or QMAX* and operate each cylinder from a point 100 mm from the end of its stroke slowly (take at least 10 seconds) to the end of its stroke (fully extended) and hold the work equipment joy stick at the full stroke position for 1 minutes. 5. Repeat steps 2 – 4 if necessary. 6. Make sure that the switch S155 is set to the “0” position as soon as the bleeding procedure of the hydraulic cylinders is finished.* * Electric driven excavator

• After bleeding the cylinders check oil level in the hydraulic tank according to the Maintenance Manual and add oil if necessary.

AH06524

COMPONENT CODE:

32

REF NO.

AH06530


DATE


SUBJET:

Relieving of the track chain tension

PURPOSE:

Hints for working at the crawler unit

APPLICATION:

PC3000; PC4000; PC5500; PC8000

FAILURE CODE:

3200FA

DESCRIPTION:

)

• Read the safety instruction in the Operation and Maintenance Manual carefully, before starting repair works.

For avoiding damages at the travel brakes (4) the following procedure should be used: • Turn the superstructure (90°) and lift the machine. • Shut off the engine. • Open cock (2) for releasing the pressure. • Close cocks (1) and cock (3) if installed. • Close cock (2) (important!). • Now the engine can be started and the sprocket can be turned to the working position. The travel brake is released by pilot pressure.

Illustration as example

AH06530

Page 2 of 2

AH06530

COMPONENT CODE:

3

REF NO.

AH06544 November 23, 2006


DATE

Page 1 of 11 This PARTS & SERVICE NEWS supersedes the previous issue 21 – 435a which should be discarded. SUBJECT:

Hydraulic track tensioning system –Pressure increasing valve

PURPOSE:

Revision

APPLICATION:

All types with hydraulic track tension system

FAILURE CODE:

3000PB

DESCRIPTION: 1. Overview (as example for PC8000)

2

** Not available at all excavators.

3

2. Purpose of the pressure increasing valve

3

3. Function of the Pressure increasing valve

5

4. Adjustments / Checks

7

4.1 Pre-conditions

7

4.2 Basic Adjustments

7

4.3 Setting procedure, high pressure stage

10

4.4 Setting procedure, low pressure stage

10

4.5 Final works

10

5. Functional Test

11

AH06544

Page 2 of 11

1. Overview (as example for PC8000)

AH06544

Page 3 of 11

Legend for illustration (Z 21398a): (59) Rotary distributor (joint). (ST) Supply line, pilot pressure from travel parking brake circuit (118.1) Supply line shut-off cock**. (118.2 + 118.3) Service shut-off cocks. (118.4) Main shut-off cock. (119.1 + 119.2) Membrane accumulator, 1.3 liter (pre-charge pressure 31bar) (120.1 – 120.4) Bladder accumulator, 5 liter (pre-charge pressure 150bar) (121.1 + 121.2) Check valves (prevents feedback pressure to pilot pressure) (124.1 – 124.4) Track tensioning cylinders (125.1 + 125.2) Check valves (prevents a cross-over flow) (141) Pressure increasing valve.

*

"O" = open "C" = closed

** Not available at all excavators.

2. Purpose of the pressure increasing valve The two system pressures • 35 bar with engine stopped • 310 bar with engine running are controlled by the pressure increasing valve as follows. With stopped motor and switched off ignition there is no pilot pressure at pressure increasing valve (141) and only the lowest adjusted pressure of 35 bar remains in the system. As soon as the motor has been started, the pilot pressure acts on the pressureincreasing valve. As a result, the system pressure can rise to the adjusted pressure of 310 bar.

AH06544

Page 4 of 11

AH06544

Page 5 of 11 Legend for illustration (Z 21846): (1) Pilot valve with valve seat (2) Valve poppet (3) Compression spring (4) Main valve with sleeve (5) Main piston (6) Closing spring (7) Set screw - low pressure (8) Set screw - high pressure (9) Piston (10) Pin (11+12) Jet bore (13+14) Lock nut

35 bar 310bar

3. Function of the Pressure increasing valve The valve poppet (2) is connected via the jet bores (11) and (12) with the P port. If static pressure increases above the set pressure value, the valve poppet (2) opens and allows oil to flow freely to tank (T1). This oil generates a pressure drop in the spring chamber of the main spool, the closing force of the spring (6) is cancelled, and the main piston (5) opens to allow the pump flow to flow to tank (T2). Damped opening and closing is obtained by the throttled volumetric change. By applying external pressure of Pst max = 60 bar to the main spool (9) via port X, the pre-tensioning of the pressure spring (3) is increased by the amount of the piston stroke "S" and system pressure is increased correspondingly. The setting is fixed by means of the setting screw (7) and lock nut (13); 1 turn of the screw ~ 150 bar.

AH06544

Page 6 of 11

AH06544

Page 7 of 11

4. Adjustments / Checks Legend for illustration (Z 22759a): (1) Piston (2) Lock nut (3) Set screw - high pressure (4) Lock nut (5) Set screw - low pressure (P) Plug (X) Pilot pressure port (141) (118.1) (118.3) (118.4) (119.2) (120.3 / .4) (124.3 / .4) (M11.1) (M29.2) (M29.4) (MRV)

310bar 35 bar

Pressure increasing valve Service shut-off cock – supply line* Service shut-off cock in the side frame Main shut-off cock Membrane accumulator 31 bar Bladder accumulators 150 bar Track tensioning cylinders Pressure check point (Main control block II) Pressure check point at the track tensioning cylinders L.H.-side Pressure check point at the bladder accumulators L.H.-side Main relief valve – Operating pressure of main control block

* Not available at all excavators. 4.1 Pre-conditions • •

Correct MRV (Main Relief Valves), SRV (Secondary Relief Valves) and pilot pressure setting and the system must be free of air. The description is only for the R.H. track. The same procedure applies also for the L.H. side.

4.2 Basic Adjustments 1. 2. 3. 4.

Connect a pressure gauge to check point M 11.1 Start the motors. Increase the concerning MRV-setting, to ~ 330 to 340 bar. Switch OFF the motors, open cock valve (118.4) to allow pressure relieves of track cylinders, and close it again.

AH06544

Page 8 of 11

Hydraulic circuit diagram (partly) for the right hand track tensioning system

AH06544

Page 9 of 11

5. 6.

Move the pressure gauge from M11.1 to M29.4 For the adjustment, two pressure check unions have to be modified as follows and exchanged against the pressure checkpoints M11.1 and M29.2. - Remove cap. - Drill, until the ball and spring are removable.

7.

Connect pressure checkpoint M11.1 with pressure checkpoint M29.2, using a long pressure gauge hose (required for the oil supply). 8. Disconnect the pilot pressure line at port X of the pressure-increasing valve (141) and close the hose with a plug (P). 9. Loosen lock nut (4) of the pressure-increasing valve and screw in set sleeve (5) until piston (1) comes to stop (substitution of 35bar pilot pressure). 10. Start the motors. 11. Stall the hydraulic with the clam opening function (clam cylinders completely retracted) and observe pressure at checkpoint M29.4. A pressure of 310 + 5 bar has to be reached within a time of 10 – 15 minutes and must remain at this value.

W

•

The maximum pressure will be shown only after the accumulators are completely filled with oil.

•

When the pressure reaches the pre-charge gas pressure (31 bar and 150 bar), the gauge pointer moves slower depending on the gas compression.

If the gauge shows a lower or higher value, the pressure-increasing valve must be adjusted.

AH06544

Page 10 of 11

4.3 Setting procedure, high pressure stage a) b) c) d)

Loosen lock nut (2). Adjust pressure with setscrew (3). Secure adjustment by tightening lock nut (2). Re-check pressure setting.

The low-pressure setting of the pressure-increasing valve must now be reset (with the pilot pressure line at port X still disconnected):

4.4 Setting procedure, low pressure stage a) b) c) d)

Stall the hydraulic with the clam opening function (clam cylinders completely retracted) and observe pressure at checkpoint M29.4. Loosen lock nut (4) and turn setscrew (5) ccw until gauge at checkpoint M29.4 shows 35 bar. Tighten lock nut (4). Re-check pressure setting.

4.5 Final works a) b) c) d) e)

Switch OFF the motors and open cock (118.4) to allow pressure relieve. Re-connect the pilot pressure line to port X of the pressureincreasing valve (141). Remove the pressure gauge hose between pressure checkpoint M11.1 and pressure check point M29.2. Close the cock (118.4). Re-set MRV (Block IV) to 310 + 5 bar after the check / adjustment is finished.

AH06544

Page 11 of 11

5. Functional Test After all adjustments are finished, do the following: a) b)

Bleed all air from the system Place shutoff and pressure relief cocks into correct operating position. Connect pressure gauge to check point (M29.4). Start motors. Travel approx. 10 m with the shovel. Stop the motors. The pressure must drop to 35 bar.

c) d) e) f) g)

If the pressure remains at a higher or lower pressure*, re-adjust the low pressure setting at the pressure increasing valve (141).

)

*

The pressure may drop below 35 bar after a longer time. This is O.K. because of internal leakage.

AH06544

COMPONENT CODE:

H2

REF NO.

AH06545


DATE

November 22, 2006 Page 1 of 3

SUBJECT:

Hydraulic cylinder bushings

PURPOSE:

Installation hints

APPLICATION:

All types

FAILURE CODE:

H2Z6CA

DESCRIPTION:

)

• Pay attention to the position of the lubricating holes and the lubrication grooves when installing new bushes to ensure good lubrication and maximum lifetime. • Install the bushes as shown at the next pages.

AH06545

Page 2 of 3

AH06545

Page 3 of 3

AH06545

COMPONENT CODE:

55

REF NO.

AH08504


DATE

August 7, 2008 Page 1 of 2

SUBJECT:

Windscreen

PURPOSE:

Mounting hints

APPLICATION:

PC4000; PC5500; PC8000

FAILURE CODE:

5532PB

DESCRIPTION:

W

• Before carrying out any repairs, read all the safety instructions of the Operation and Maintenance manual of your shovel. • The local safety rules must also be observed.

A different holes pattern is used since January 2007 for the frame of the windscreen. We offer two types of windscreens for replacement of a damaged one: 1. Windscreen with mounting holes in the frame and 2. Windscreen without mounting holes. We recommend using windscreen with new holes pattern in the frame, also for shovels, delivered before 2007. Advantages: • Only one fitting of new bore holes in the cab. • In case of a next windscreen exchange the same holes can be used.

AH08504

Page 2 of 2

Pos. 01

Pos.

Part No.

769 528 73 12 mm; green; drilled 12 mm; green; 797 251 73 undrilled

Part No. 793 739 73 797 253 73

01

Description

796 564 73

797 254 73

Description 12 mm; green; drilled 12 mm; green; undrilled 19 mm, with splinter shield foil coating; drilled 19 mm, with splinter shield foil coating; undrilled

AH08504

COMPONENT CODE:

71

REF NO.

AH08507


DATE

April 9, 2008 Page 1 of 9

SUBJECT:

Steel structure

PURPOSE:

Repair welding procedure

APPLICATION:

PC3000-6; PC4000-6; PC5500-6; PC8000-6

FAILURE CODE:

7100FE

DESCRIPTION:

W Content 1. 2. 3. 4. 4.1 4.2 5. 6. 7. 8.


Introduction General Protective Measures Steps of the weld repair procedure Selection of appropriate electrodes and welding rods Selection of appropriate electrodes Selection of appropriate welding rods Preparation of the defective Part Carrying out the Weld Repair Post heating Inspection of Repair

AH08507

Page 2 of 9

1. Introduction Weld repairs can cause severe damage to an entire structure if performed incorrectly. Therefore we recommend consulting your Komatsu Service Organization in order to avoid improper welding procedures. If cracks are found in the steel construction of your excavator, please inform our service department as soon as possible. Attach suitable information material (photos, catalogue drawings etc.) showing the location and nature of the crack. 2. General Protective Measures Welding operations can cause damage to electronic components (Computers, Control Units, Sensors etc.) in case the welding current goes through these units. Therefore protective measures are necessary before any weld repair is started. 1. Observe the prevailing safety and fire prevention regulations. Get advice from authorized Electricians for all medium and high voltage systems related questions. 2. Before any weld repair is started, a survey should be made of the area and all safety considerations satisfied such as fuel tanks, hydraulic oil reservoirs, oil lines, electrical cables and synthetic materials. 3. Remove the battery main switch keys and switch off all circuit breakers, refer to the Operation Manual of the Excavator for more information. 4. Attach the welding ground directly to the part that is being repaired. Do not allow welding current to go through bearings. Welding current could arc the bearings, resulting in severe damage to the bearing. 3. Steps of the weld repair procedure 1. Clean the damaged part or area to be repaired. 2. Inspect the worn or fractured area by visual inspection and/or non-destructive testing. 3. Determine the type of material to be repaired. 4. Determine the welding electrode or the welding wire and process to be used. 5. Preheat before welding. 6. Weld by using appropriate welding techniques. 7. Post heat. 8. Make a survey of the repair welding.

AH08507

Page 3 of 9

4. Selection of appropriate welding electrodes and welding wires Table 1: The components shown in illustrations 3 and 4 are made of six different materials (a, b, c, d, e or f) as shown in the table below. Material designation

former

present

international

a

St52-3N

S355J2G3

1.0570 (17G1S)

b

GS24Mn6V

GS24Mn6V

1.1118

c

StE690

S690Q

1.8931

d

GS18NiMoCr36

GS18NiMoCr36

1.6759

e

TStE355

P355NL1

1.0566

f

Hardox 400

4.1 Selection of appropriate welding electrodes Table 2: The following welding electrodes are required for the weld repairs: Key number

Welding Electrode (AWS)

4 5* 7* 9*

E 7016 E 7018-G E 8018-G E 100 18-G

* Hydrogen content less than 5mg per 100ml

Table 3: Types of welding electrodes to be used for the different materials (a to f) Material a b c d e f

a 4 4 4 4 4 7

b 4 4 7 5 7

c 4 7 9 9 7

d 4 5 9 9 7

f 7 7 7 7 7 7

AH08507

Page 4 of 9

Example: Selection of the correct welding electrode for weld repair a crack in the welded joint between material (a) and (c). The table 4 shows the correct electrode with key number 4 in the red shaded field. Table 4 Material a b c d e f

a 4 4 4 4 4 7

b 4 4 7 5 7

c 4 7 9 9 7

d 4 5 9 9 7

f 7 7 7 7 7 7

4.2. Selection of appropriate welding wires Table 5: The following welding wires are required for the weld repairs Key number

Welding wire (AWS)

21 25/25a 30 32

ER70 S6 ER100 S1 E70 T5 E90 T5-G

Table 6: Types of welding wires to be used for the different materials (a to f) Welding wires a b c d e f

a 21; 30 21; 30 21; 30 21; 30 21; 30 25; 32

b 21; 30 21; 30 21; 30 21; 30 21; 30 ---

c 21; 30 21; 30 25; 25a; 32 32 21; 30 25; 25a; 32

d 21; 30 21; 30 25; 25a; 32 32 21; 30 ---

f 25; 25a; 32 --25; 25a; 32 --25; 25a; 32 25; 25a; 32

AH08507

Page 5 of 9

5. Preparation of the defective Part • Clean the fractured area or worn part of all oil, grease, paint, moisture, dirt, rust, spalled material or any other materials, which may be detrimental to a weld. • Inspect the fractured areas carefully by non-destructive testing such as magnetic particle or dye penetrant inspection. • When removing cracks, a V groove should be made with a 30° to 45° angle. Remove defective material up to the bottom of the crack.

Illustration 1 Use electrodes out of a freshly opened can or from an electrode holding oven. Dry the electrodes according to the instructions of the electrode manufacturer. Preheating of the part before preparing it for weld repair is essential to reduce the thermal shock. The preheat temperature depends on the composition of the material, see table 7 for the required temperature. Measure the temperature beside the joint at a distance equal to the sheet metal thickness using suitable temperature indicating devices. Table 7 Material S355J2G3 P355NL1

S690Q

GS24Mn6V GS18NiMoCr3 Hardox 400

Groove depth (mm) <10

Preheat temperature (°C) 20

Interpass temperature (°C) 220

10 - 20 20 - 50 10 10 - 20 >20 <10 10 - 20 >20

50 100 50 100 150 50 100 150

220 220 150 180 220 150 180 180

>10

150

200

Post heat temperature (drop per hour)

50 degree. max.

AH08507

Page 6 of 9

6. Carrying out the Weld Repair

) • •

•

• •

• All weld repairs should be carried out by qualified and experienced welders. • Provide the necessary equipment such as the correct clothing, head gear, exhausts systems or respirators and if required platforms for safe access to the repair area. It is important to maintain the preheat temperature according to table 7 throughout the repair. The interpass temperature should never exceed the maximum permissible value shown in table 3. Measure the temperature beside the joint at a distance equal to the sheet metal thickness using suitable temperature indicating devices. All cracks through the parent material will require a welding from both sides, see illustration 1. The Service Bulletin No. 21-594 contains instructions for making a “Man Hole” which is necessary for weld repairs from inside the boom or stick. When welding in a vertical position always weld using the vertical up technique. Properly applied multiple pass welding is the required procedure, illustration 2. Use a blunt-nosed chisel (C) to calk the weld beads (A and B) with the groove wall before welding the space between the beads (A and B). Repeat the calking of beads (A and B) at each weld layer.

Illustration 2 • •

Once a repair has been started by preheating and welding, the part should be worked on until completed. A recommended technique for repair is to butter the groove with weld metal. Buttering is the addition of one or more layers of weld metal to the face of the joint or surfaces to be welded.

AH08507

Page 7 of 9 •

•

After the welding has been completed, check the repair for any undercuts, overlaps or any other notch type discontinuity while the preheat is still up to temperature. Make any repair necessary at this time. After the repair cools, grind all butt-welded repairs smooth using 36 or finer grit grinding material. All grinding marks should be parallel to the direction of primary stress if possible. Make sure there is a smooth transition between the weld metal and the parent plate.

7. Post heating •

Maintain the preheat temperature according to table 7 for at least 15 minutes after the weld repair is finished and then cool the repair area slowly, refer to table 3 for maximum allowable temperature drop per hour.

8. Inspection of Repair •

• •

)

Inspect the completed weld after it has cooled to the ambient temperature by non-destructive procedures as dye penetrant, or magnetic particle inspection and ultrasonic inspection, if possible. A final inspection of the weld repair should be made after 24 hours in order to detect hydrogen induced cracks. If surface defects are found, remove all defects by grinding to a maximum depth of 1.5 mm. Larger defects have to be removed according to the repair procedures described on the preceding pages. Grind welds so they blend in with the parent material. All spot welding also require preheating and post heating. • It is not recommended to weld on reinforcement plates as the main stress will remain ~float~ through the steel structure regardless how many additional plates would be applied to the structure.

AH08507

Page 8 of 9

Illustration 3 AH08507

Page 9 of 9


COMPONENT CODE:

71

REF NO.

AH08508


DATE


SUBJECT:

Bushings of the attachment and at the undercarriage

PURPOSE:

Wear checking procedure

APPLICATION:

PC3000-1; PC3000-6; PC4000-6; PC5500-1; PC5500-6; PC8000-1; PC8000-6

FAILURE CODE:

7100CA

DESCRIPTION:

W


)

• For installation of bushes please refer also to Parts & Service news AH06545.

1. Bushings of the attachment 2. Bushings between bolted track frame and undercarriage (depends on the execution)

AH08508

Page 2 of 3 1. Bushings of the attachment

Illustration 1 Example for determining the clearance of the boom cylinder bushes (The procedure for the other attachment bushes is analogues.) 1. Place the attachment on the ground as shown on illustration 1. 2. Raise the attachment a little bit from the ground. 3. Make a line with a felt pen from boom bearing to the boom cylinder barrel (a = 30 cm). 4. Make a 2nd line with a felt pen from boom bearing to the boom cylinder piston rod (b = 30 cm). 5. Press the attachment on the ground so far that the chains at “c” just remove from the ground. 6. Measure the distances at “a” and “b”.

)

• We recommend to renew the bushes if the clearance reaches a value of about 3 mm.

AH08508

Page 3 of 3 2. Bushings between bolted track frame and undercarriage 1. Position the machine in a position so that the track frame can be lifted of the ground.

2. Install a dial gauge so that the dial gauge magnetic portion is on the side frame. 3. Set the pointer on to the car body and set to zero.

4. Raise the track frame slowly off the ground until the dial gouge stops moving. Record the measurement.

)

• We recommend to renew the bushes if the clearance reaches a value of about 3 mm.

AH08508

COMPONENT CODE:


REF NO. DATE

6B AH08516 September 17, 2008

Page 1 of 7 This PARTS & SERVICE NEWS supersedes the previous issue AH07519a which should be discarded. SUBJECT:


PURPOSE:

Hose standardization and routing improvement

APPLICATION:

H 485 (#12001 to 12019; 12021 to 12024)), H 685 (#12020); H 655 (#12025 to 12027; 12030 to 12032); PC8000-1 (#12033; 12035; 12036); PC8000-6 (#12038 to 12053 without 12041; 12045 to 12047)

FAILURE CODE:

6B00FA

DESCRIPTION:

W


We recommend replacing the hydraulic lines on the stick and the boom according to the description at the following pages and the hydraulic hoses between stick and boom. Advantages: • All 6 new hydraulic hoses with the same Part no. • The hoses are shorter and therefore less lateral movement.

AH08516

Page 2 of 7 Description 1. Remove the 6 pipes on the boom (36; 37), all hydraulic hoses between stick and boom (1), and all pipes on the stick (16 to 21) (Illustration 1). 2. Remove the lubrication line / hose (34; 35) (Illustration 5). 3. Cut off the old plates (32) (Illustration 1 + 6). 4. Weld on the two new plates (32) to the mounting rail (shift the mounting rail 400 mm) (Illustration 6). 5. Install the six new pipes (36; 37) to the boom (Illustration 1). 6. Install the new blocks (3) (Illustration 2). 7. Install the new lubrication pipe (35) and the new lubrication hose (34) (Illustration 5). 8. Install additional and new clamps to the stick for the pipes according to Illustrations 3 and 4. 9. Install the new pipes (16 to 21) to the stick (Illustration 1). 10. Install the 6 new hoses (1) and the distributer block (2). 11. Bleed the new lubrication line. 12. Bleed the new hydraulic hoses /lines refer to Parts & Service News AH06524.

AH08516

Page 3 of 7 Required parts PN 797 356 73 (Refer to drawings below) (Required parts for cold weather design* PN 797 357 73) Pos.

Part No.

Qty.

1* 2 3 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 34* 35 36 37 38 39 40

940 328 40 948 197 40 952 701 40 319 313 99 504 662 98 319 305 99 319 323 99 502 960 98 534 004 99 504 818 98 308 581 99 948 191 40 952 702 40 952 703 40 952 704 40 952 705 40 952 706 40 952 707 40 504 445 98 308 612 99 509 310 98 504 446 98 510 151 98 332 334 99 561 548 40 946 809 40 946 807 40 905 235 40 502 965 98 512 724 98 946 814 40 796 451 73 796 452 73 534 008 99 534 009 99 504 445 98

6 1 2 48 48 8 8 2 2 2 4 2 1 1 1 1 1 1 6 20 10 6 4 4 2 4 2 2 8 1 1 3 3 4 4 4

Description Hose NW 50 x 3200 Clamp rail assy. SAE-L-Block 2” Bolt M 20 x 120 Nut M 20 Bolt M 20 x 60 Bolt M 20 x 90 Plate Plate Clamp set Bolt M 10 x 70 Pipe 38 x 240 Pipe assy. right Pipe assy. left Pipe assy. right Pipe assy. left Pipe assy. right Pipe assy. left Pair of clamps Bolt M12 x 100 Locking plate Pair of clamps Bolt M12 x 120 Nut M12 Angel Weld on plate (10x70x60) Pipe bracket weld on Plate Plate Hose for Lube system Pipe for lube system Pipe Pipe Cover Plate Weld on plate Pair of clamps

* Different Parts for cold weather design (- 50°C) included in PN 797 357 73 1 940 765 40 6 Hose NW 50 x 3200 34 Hose for Lube system 907 078 40 1

AH08516

Page 4 of 7 Overview 1



Illustration 2

AH08516

Page 6 of 7 New Pipe retaining clamps

Illustration 3

Illustration 4

AH08516

Page 7 of 7 New lubrication line

Illustration 5 Shifting of the mounting rail (400 mm)

Illustration 6

AH08516

COMPONENT CODE:


6B

REF NO. DATE

AH08532 October 2, 2008 Page 1 of 4

SUBJECT:


PURPOSE:

Hose standardization and routing improvement

APPLICATION:

PC8000-6 (SN12028; 12029; 12046; 12054 to 12060)

FAILURE CODE:

6B00FA

DESCRIPTION:

W


We recommend replacing the hydraulic lines on the stick according to the description at the following pages and the hydraulic hoses between stick and boom. Advantages: • All 6 hydraulic hoses with the same length and straight hose connectors. • Only one clamp rail for the hoses necessary. • Routing improvement.

AH08532

Page 2 of 4 Description 1. Remove the both outer hydraulic hoses between stick and boom (1) and all pipes on the stick (16 to 21) (Illustration 1). 2. Install the new blocks (3) (Illustration 2). 3. Install the new pipes (16 to 21) to the stick (Illustration 1). 4. Install the 2 new hoses (1) and the new clamp rail (2). 5. Bleed the new hydraulic hoses /lines refer to Parts & Service News AH06524.

Required parts PN 948 190 40 (Refer to drawings below) Pos. 1* 2 3 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21

Part No. 940 328 40 948 197 40 952 701 40 319 313 99 504 662 98 319 305 99 319 323 99 502 960 98 534 004 99 504 818 98 308 581 99 948 191 40 952 702 40 952 703 40 952 704 40 952 705 40 952 706 40 952 707 40

Qty. 2 1 2 48 48 8 8 2 2 2 4 2 1 1 1 1 1 1

Description Hose NW 50 x 3200 Clamp rail assy. SAE-L-Block 2” Bolt M 20 x 120 Nut M 20 Bolt M 20 x 60 Bolt M 20 x 90 Plate Plate Clamp set Bolt M 10 x 70 Pipe 38 x 240 Pipe assy. right Pipe assy. left Pipe assy. right Pipe assy. left Pipe assy. right Pipe assy. left

* Different Parts for cold weather design (- 50°C) 1 940 765 40 2 Hose NW 50 x 3200

AH08532




Illustration 2

AH08532

Supplier’s documentation

9 SUPPLIER’S DOCUMENTATION

Version 2010/1

PC8000-6

9 -1

Supplier’s documentation

Contents of this chapter: AVANTI HYTORQUE

9 -2

PC8000-6

Version 2010/1

XXI/Avanti/Stealth SERIES Operational Manual

July 2004

Table of Contents XXI/Avanti/Stealth SERIES Operational Manual

SECTION I IMPORTANT SAFETY INSTRUCTIONS SECTION II BEFORE USE

2-1 Working Pressure 2-2 Hydraulic Connections 2-3 Electrical Connections 2-4 Air Connections

SECTION III OPERATION

3-1 General 3-2 Connecting the System 3-3 Drive Direction Change 3-4 Reaction Arm XXI/Avanti 3-5 Setting Torque 3-6 Setting Pump Pressure 3-7 Tightening Procedures 3-8 Operating the XXI, Avanti & Stealth Systems 3-9 Loosening Procedures

SECTTION IV 4-1 Tool set up and operation USE WITH LoaDISC 4-2 LoaDISC Tensioning WASHER & CLAMP-NUT 4-3 LoaDISC De-tensioning 4-4 LoaDISC Lubrication 4-5 CLAMP-NUT Tensioning 4-6 Clamp-nut De-tensioning 4-7 Clamp Lubrication SECTTION V 5-1 General Information OPERATION 5-2 Hydraulic Connections HYTORC POWER PACKS 5-3 Prior to Use 5-4 Operation –Electric Pump-5-5 Operation –Air Pump-5-6 Automatic Pump 5-7 Starting with Automatic System SECTION VI HELPFUL INFORMATION

Tool Dimensions & Parts List Field-proven Torquing Procedure Pressure/Torque & Pressure/Load Conversion Chart Recommended Torque For ASTM A193 Grade B7 Studs

INTRODUCING THE NEW GENERATION HYTORC

Thank you for buying the NEW HYTORC FREEDOM-LINE! This manual is designed to provide you with the basic knowledge required to operate and maintain your HYTORC bolting equipment. Please read this manual carefully and follow the instructions provided. If you have any questions regarding HYTORC bolting equipment, please call us at 201-512-9500 or contact us at [email protected]. Your purchase of HYTORC bolting equipment entitles you to the following services at no extra cost to you. Free on-site training in the application and operation of your HYTORC bolting equipment * Free semi-annual training * Free annual tool inspection. * Free loner tools in case of failure under warranty * Free engineering assistance by calling 1-800-FOR-HYTORC or our international office. Your local HYTORC bolting specialist is available around the clock for your convenience. Should you require any assistance, please contact us to obtain our local specialist’s information. World-wide Warranty HYTORC bolting equipment is engineered to the latest technological standards and is accompanied by our exclusive 12 word, 12-month warranty: “YOU BREAK IT UNDER NORMAL USE, WE FIX IT FREE OF CHARGE!” If your HYTORC equipment cannot be repaired on site, FREE loaner equipment will be made available to you upon request, while under warranty.

INTRODUCTION

HYTORC tools are uniquely multi-purpose. They can be used as accurate bolting equipment on conventional nuts in open or confined spaces. They also can be used as reaction arm free tensioning equipments, when used with HYTORC LoaDISC washer or HYTORC-Clamp, Hydraulically Actuated Mechanical Tensioner. SECTION I IMPORTANT SAFETY INSTRUCTIONS HYTORC tools are designed for the safety of operators. However, they are powerful tools and certain safety precautions should be observed to avoid accidents or personal injury. The following tips will assist you. READ ALL INSTRUCTIONS KEEP WORK AREA CLEAN AND WELL LIT CONSIDER WORK AREA ENVIRONMENT

Electric pumps should never be used in any atmosphere which can be considered potentially volatile. If there is any doubt, use an air pump.

Also note: Metal to metal contact can cause sparks. Precautions must be taken. AVOID PREMATURE TOOL STARTING

The pump remote control should be operated by a designated operator and ensure “ALL CLEAR” prior to starting and to avoid premature tool starting.

STAY CLEAR DURING OPERATION

In most cases, the tool will allow “hands free” operation. If the tool must be reset on bolt during operation, make sure the remote control operator is aware of turning the pump off.

IMPORTANT NOTE: NEVER HOLD THE TOOL DURING OPERATION! GUARD AGAINST ELECTRIC SHOCK

Ensure the pump is properly grounded and the proper voltage is used.

STORE EQUIPMENT PROPERLY

When not in use, tools and accessories should be properly stored to avoid deterioration.

USE THE RIGHT TOOL Do use tools or attachments suitable for the applications. *refer to our recommended torque/load chart PROPER SAFETY ATTIRE

When handling/operating hydraulic equipment, wear work gloves, hard hats, safety shoes, safety glasses and other applicable clothing.

MOVING EQUIPMENT

Do not use hydraulic hoses, uniswivels, pump power or remote cords as means of moving the equipment.

SECTION I IMPORTANT SAFETY INSTRUCTIONS -continued from the previous pageHOSES

Do not kink hoses. Inspect and replace if damaged.

SHROUDS AND COVER PLATES

All tools are equipped with shrouds and/or cover plates to prevent contact with the moving internal parts. Do not use tools without these safety covers. If the covers are missing or damaged, replace immediately.

MAINTAIN TOOLS

For the best results, inspect tools, power packs, hoses, connectors, electric lines and accessories for visual damage before each usage. Always follow instructions for proper tool and pump maintenance.

SAFETY ALERT

Do not use power equipment under the influence of any mood altering substance.

PRIOR TO OPERATION

Ensure that all hydraulic connectors are securely connected. Verify that the hydraulic hoses are not kinked. Insure the square drive and its retainer are fully and securely engaged.

PRIOR TO USE (if use with reaction arm)

Before placing your tool on the application, cycle it to ensure proper function. If using the torque mode, locate a solid and secure reacting point. Be sure the reaction arm is retained firmly and positioned to face the same direction as the square drive. Be sure the hydraulic hoses are free of the reacting point. Pressurize the system momentarily; if the tool tends to “ride up” or to “creep”, stop and adjust the reaction arm to a solid and secure position.

NOTE: Remain clear of the reaction arm during operation and never put body parts between reaction arm and reaction surface. ALWAYS USE QUALITY ACCESSORIES

Use genuine HYTORC accessories. Use correct size accessories and engage them fully. Stay clear of all moving accessories during operation.

DO NOT USE FORCE

Do not apply any impact by using hard objects on bolting equipment or accessories. This may cause malfunction or breakage.

ALWAYS CONSULT

Please contact HYTORC for any questions related to our equipment or your bolting needs. Safety is always the number one priority.

SECTION II INSTRUCTIONS BEFORE USING YOUR NEW HYTORC READ CAREFULLY: Most malfunctions, in new equipment, are the result of improper operation and/or set-up. PREPARATION: Remove HYTORC equipment from shipping container. INSPECTION: Visually inspect all components for any damage during transportation. If damages are found, notify HYTORC immediately. 2-1 Working Pressure The tool’s maximum working pressure is 10,000 PSI (700kg/cm2, 690 Bar) Make sure that all hydraulic equipment used is rated for 10,000 PSI operating pressure. To set pump pressure for XXI models to 10,000 PSI for both advance & retract, locate selector valve underneath the couplers. Turn the pump off and loosen the lock nut. Turn the center screw counter-clockwise until it stops. Tighten the lock-nut. For Avanti & Stealth models, turn the center screw clockwise until it stops. Tighten the lock-nut to set the pump pressure to 1,500 PSI for retract. 2-2 Hydraulic Connections With older style pumps, (SST-10, SST-20), the retract side of the system may remain pressurized after the pump has been switched “off”. This trapped pressure makes it impossible to loosen the retract-side fittings by hand. To release the pressure, find the 5/16 manual override holes in the end of the black solenoids on the pump. With a welding rod, Allen-key or similar device, push in on the ends of both solenoids, each in turn, and the residual pressure will be released. All fittings will, then, be hand tightened again. Hoses and couplers must be free and unobstructed before and during the operation of the tool. External impact on the couplers may break off the fittings. Current pump models are equipped with an auto-pressure relief. Never disconnect or connect any hydraulic hoses or fittings without first unloading wrench and the pump. Double check the gauge reading to assure pressure has been released. When making connections with quick disconnect couplings, make sure the couplings are fully engaged. Threaded connections such as fittings and gauges must be clean and securely tightened and leak free. CAUTION: Loose or improper threaded fittings can be potentially dangerous if pressurized. Severe over tightening can cause premature thread failure. Never grab, touch or in any way come in contact with a hydraulic pressure leak. Escaping oil can penetrate the skin and cause injury.

SECTION II INSTRUCTIONS BEFORE USING YOUR NEW HYTORC -continued from the previous page2-3 ELECTRICAL CONNECTIONS Ensure proper power availability to prevent motor failure or dangerous electrical overloading. Compare the motor nameplate for required amperage. Do not use electric pump, if three prong electrical plug is not whole. Minimize the length of extension cords and be sure they are of adequate wire size, with ground connectors. Extension cord up to 50 feet should be #10 AWG gauge. CAUTION: Electric motors may spark. Do not operate in an explosive atmosphere or in the presence of conductive liquids. Use an air pump instead. 2-4 AIR CONNECTIONS Ensure that you have sufficient air flow of 80 psi ( 50 cfm) to operate your pneumatic pump. If in doubt, compare the pump manufacturer’s recommended air flow rating prior to pressurizing pump. Improper air flow may damage the pump motor. For best results, use air hose larger than 3/4 “ diameter. Use of a filter regulator lubricator (FRL) is highly recommended. (diagram below) AIR ADJUSTMENT KNOB AIR FLOW ON/OFF LEVER

OIL LUBRICATOR ADJUSTMENT KNOB FILTER CAP

AIR PRESSURE GAUGE CONDENSATION BOWL

DRIER 1. 2.

Adjust flow to 1-2 drops per minute. Fill half way with grade 46 hydraulic oil supplied.

AUTO WATER DRAIN PORT

SECTION III OPERATION – Torquing Conventional Nuts 3-1 General All HYTORC tools are supplied completely assembled and are ready to use. A HYTORC Hydraulic Power Pack, for use with your HYTORC tools, is recommended to provide the speed, pressure and portability that makes your HYTORC SYSTEM more efficient and accurate. The SYSTEM accuracy of your HYTORC tool is +-3% based upon manufacturer’s specifications. This accuracy maybe certified through calibration by HYTORC or any other qualified calibration facility whose program is traceable to the National Institute of Standards and Technology (N.I.S.T.) Using a calibrated gauge enhances the accuracy of your HYTORC SYSTEM. 3-2 Connecting the SYSTEM The wrench head and power pack are connected by a 10,000 PSI operating pressure (40,000 PSI burst) twin line hose assembly. Each end of the hose have one male and one female connector to assure proper interconnection between pump and wrench head. IMPORTANT:

To avoid tool malfunction, do not reverse connectors.

Connect the twin line hose to the uniswivel as shown below. Make sure male couplers are connected to female couplers. During the operation, check the connection to ensure the couplers are not loose. Insure the connectors are fully engaged and screwed snugly and completely together.

Connect to tool

Connect to pump

*Connect male end of hose to female end of both tool and pump & female end of hose to male end on both tool and pump

From hose

From hose

SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-3 Drive Direction Change Avanti tools To remove the square drive, disengage the drive retainer assembly by depressing the retaining round button and gently pulling on the square end of the square drive. The square drive will slide out. To insert the drive in the tool, place the drive in the desired direction, engage drive spline and ratchet spline, then twist bushing until engage to the housing spline. Push drive through ratchet. Depress drive retainer button, engage retainer with drive and release button to lock.

Button Drive Retainer

Square Drive

The diagram on the right illustrates the direction that the square drive should face for tightening and loosening of a standard right hand fastener.

Loosening

Tightening

Stealth tools The Stealth tools use interchangeable ratcheting links. For tightening, simply engage the nut with the right side of the link facing down. For loosening, the left side of the link faces down. Ratcheting link can be detached from the Stealth power head by pulling the power head out while pressing the button shown below.

STEALTH MADE IN U.S.A.

STEALTH

MADEIN USA

Loosening

Link release button

3-4 Reaction Arm

Please read operating instructions prior to use, and use common sense.

Tightening

KEEP HANDS OFF DURING OPERATION!

The Avanti can be used with a 360 degree adjustable universal reaction arm.

Make sure the reaction arm spline is fully engaged on the square drive spline. Secure the position by tightening the set screw on the reaction arm. *ALWAYS USE A SAFETY HANDLE

SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-5 Setting Torque Once the SYSTEM is fully connected and the proper power supply is available, it is time to adjust the pump pressure to the level needed on your job. When tightening, use the manufacturer’s specifications to determine the torque value ultimately required. Appendix I – which is presented as a guideline for comparison only – gives typical torque values specified for the most commonly encountered fasteners. Torque sequence varies from plant to plant and even within the same plant may vary depending on the gasket material and other factors. Always abide by on-site-procedures. Always refer to the pressure-torque conversion table that came with the tool. 3-6 Setting the Pressure on the Pump

T Handle

To set the pressure on the pump, follow this procedure. 1. Loosen the knurled locking ring below the “T” handle on the pump’s external pressure regulator. Then turn the “T” handle counterclockwise until it turns freely and easily. 2. Turn the pump “ON”. Using the pump’s remote control pendant, push down the advance switch (or button on air pump) and hold it.

Locking Ring

3. While holding the pump in the advance mode, slowly turn the “T” handle clockwise and observe the pump pressure gauge rise. NOTE: Always adjust the regulator pressure up – never down. 4. Once the desired pressure is reached. Turn off the pump and “LOCK IN” the pressure by tightening the knurled lock nut. Turn on the pump once more and pressurize to verify the pressure is maintained. 3-7 Applying the Avanti – the Tightening Process 1. Once your target pressure is set, cycle the tool three or four times to full pressure. Cycling the tool ensures that the system is operating properly and removes trapped air, if any. 2. Place the proper size driving unit on the square drive and secure properly. 3. Place the tool on the bolt, making sure that everything is fully engaged. Further ensure that the drive retainer is engaged. 4. Make sure the reaction arm is firmly abutted against a stationary object. 5. When positioning the wrench, make sure that the hose connections are well clear of any obstructions. 6. After all the above are confirmed, apply momentary pressure to the SYSTEM to ensure proper tool placement.

SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-7 Applying the Stealth – the Tightening Process 1. Once the target pressure is set (refer to 3-6) Cycle the tool several times to full pressure to assure proper operation. 2. Place the right side of the ratchet link directly over the nut. Ensuring the hex is fully engaged and the reaction pad portion of the link abuts solidly against an adjacent nut or other stationary object. (see 3-3 for proper tool placement) 3. Ensure hose connections are clear of any obstacles. 4. After all the above are confirmed, apply momentary pressure to the SYSTEM to assure the reaction point is stable. 3-8 Operating the Avanti and Stealth SYSTEMS 1. By pushing down on the remote control button in the advance position, the rear of the tool will be pushed back until the reaction surface will contact its reaction point. 2. Continue to hold down the advance button as the socket turns until you hear a “CLICK” which will signify the hydraulic cylinder inside the tool is fully extended and will not turn the socket further. 3. Continuing to hold down the remote control button will result in a rapid buildup of pressure to the point of where the gauge reads what was preset prior to applying the wrench. IMPORTANT: The reading of full preset pressure after the cylinder is extended DOES NOT INDICATE that this pressure (torque) is applied to the bolt. It only indicates that the cylinder is fully extended and cannot turn the nut further until the tool automatically resets itself. Releasing the remote control button will retract the cylinder. The tool will automatically reset itself and the operator will hear a “CLICK” indicating he can again push the remote control button and the socket will turn. Each time the cylinder is extended and retracted, it is called a cycle. Successive cycles are made until the tool “STALLS” at the preset Torque/PSI with an accuracy of +-3%. Repeatability is +-1%. IMPORTANT: ALWAYS ATTEMPT ONE FINAL CYCLE TO INSURE THE “STALL” POINT HAS BEEN REACHED. NEVER HOLD THE TOOL DURING OPERATION. Use safety handle to set and remove tools.

GZEBM12037-0

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